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input #3 at www.controleng.com/information

APRIL 2017 Vol. 64 Number 4

Features 32 System integration of mobile controls and monitoring: Questions and answers Cover Story: Reliable wireless capabilities are facilitating mobile monitoring and control. Experts explain why and how mobility helps automation and control applications.

32 COVER: Garvey Corp. uses tablets to save time, above. In a separate application, right, my Mobile mobility software from mySCADA, shows a hydropower plant implementation. Images courtesy of each company.

38 Artificial intelligence and its impact on machine vision Artificial intelligence (AI) for machine vision will allow AI to think more like humans by employing deep learning techniques and other functions that humans use to develop their brains.

40 Building an ICS cybersecurity ecosystem Companies, governments, and vendors need to develop a cyber ecosystem that encompasses more than just the four walls of their organization to help mitigate a threat that becomes more sophisticated every day.

42 Connecting controls helps manage assets Asset management: A winning Industrial Internet strategy starts with connected controls to help systems use more asset data, dynamically adapt in real-time to changing business conditions, and automatically upgrade as needed for better cybersecurity. Advantages include productivity gains of 22% and a maintenance cost reduction of 40%.

40 42

â&#x20AC;&#x2DC;

This new era of controls brings an emergence of the industrial app economy. Because Industrial Internetenabled controllers can run multiple apps simultaneously,

44 Motion controllers can adapt themselves Tutorial: Adaptive motion controllers can be modified to a controlled process behavior, among other controlled process benefits.

57 Digital Edition Exclusives Achieve proper motor alignment by detecting and correcting soft foot. Understand upstream and downstream pipe diameters for flow measurement.

APRIL 2017

CONTROL ENGINEERING

â&#x20AC;&#x2122;

benefits are increased.

CONTROL ENGINEERING (ISSN 0010-8049, Vol. 64, No. 4, 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 2017 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.

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Are you ready for Smart Factory?

Connected. Reliable. Secure. These are the essential features that put the power of Smart Factory at your fingertips - devices that are interconnected, networks that stand up to tough data and environmental challenges, and platforms that protect against cyber attacks. Whether youâ&#x20AC;&#x2122;re just getting started, managing a complex network, or anywhere in-between, Moxa has the tools to guide your transition every step of the way. Learn more at www.moxa.com/smartfactory.

input #4 at www.controleng.com/information

Keep Your Instrument Processes Locked Down Tight.

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Put a fortress of protection around your process with FS Functional Safety Series instrumentation from Moore Industries. You can be conďŹ dent that it will safeguard your processes when you need it the most. Our STA, SSX, SST, SRM, STZ and the NEW SFY Functional Safety Frequency-to-DC Transmitter have been designed and built to strict IEC 61508 standards, ensuring safe and reliable function â&#x20AC;&#x201C; particularly in environments where hazardous or emergency situations are likely to occur.

Demand Moore Reliability To learn more about our Functional Safetyy Series,, call (800) 999-2900, or go to: www.miinet.com/safetyseries input #5 at www.controleng.com/information

APRIL 2017 Vol. 64 Number 4

Inside Machines Appears after page 45; Also, see the Digital Edition: www.controleng.com/DigitalEdition

M1 Matrix drives reduce energy consumption for transporter system

Industrial matrix drives were used for a transporter system retrofit to reduce energy consumption and costs by creating a more maintenance-free mechanically integral distribution system. Regeneration capabilities save an estimated $1,500 per year.

M8 Customizing electrical enclosures Enclosure cutouts can be made after a purchase. However, cutouts made by the manufacturer may help save time and reduce costs.

M11 Proof of concept, testing for integrated vision applications A control system integrator and automation vendor developed a vision lab for testing, advice, proof-of-concept work and validation.

Departments 8 Think Again Ethernet cuts automation hardware, labor costs, errors

10 Product Exclusive Power monitoring input module for single-phase applications

Products

60 RIGHT: Six-axis collaborative robot; below, mobile robots. Also see robot monitoring system; laser profiler; process control system

12 Research Integration trends in instrumentation, control systems

14 Integrator Update Creating a buy-out agreement with multiple business owners

Control Engineering International 16 Network integration enables Industrial Internet of Things. 17 Easier automation helps food production.

64 Back to Basics Sensors 101: Control system inputs

News 22

Michigan governor touts manufacturing professionals; Automation company acquisition

23 24

Automate 2017 highlights

Electrical code revisions; automation anniversary; headlines online

Four manufacturing automation benefits, Bell joins Editorial Advisory Board.

www.controleng.com

61 RIGHT: Controller with servo amplifier. Also see: Motion controller; compact limit switch line; automated checkweigher system; carrier system

62 LEFT: Motors for robots, medical applications. Also see an angle ring encoder.

CONTROL ENGINEERING

APRIL 2017

| 5

More resources posted daily at:

APRIL

IIoT

www.controleng.com

New Products

Control Systems

Process Manufacturing Discrete Manufacturing

System Integration

Determine insurance’s role for cybersecurity incidents There’s a lot more to read online. Go to www.controleng.com/news to read Control Engineering’s exclusive web content. Protect senstive systems by taking them offline Researchers developing 3-D printed skin for robots A tale of system integration success Three steps for securing your IoT system.

Control Engineering provided unique automation research in 2016: Industrial Internet of Things (IIoT) and Industrie 4.0, system integration, cybersecurity, and on career and salary trends for engineers. Read summaries and sign up to download the full reports at www.controleng.com/ce-research.

NEWSLETTER: II OT: OPERATIONS & IT

How an IIoT-enabled maintenance maturity model works Keep up with the latest industry news by subscribing to Control Engineering’s 16 newsletters at www.controleng.com/newsletters: The IIoT assembly line: Getting a head start Predictive analytics enable open connectivity, collaboration

Networking & Security

Info Management

Education & Training

Upcoming Webcast Series: The Industrial Internet of Things (IIoT) is a transforWebcasts mational strategy that is revolutionizing manufacturing operations across the world. CFE Media publications take an in-depth look at IIoT-related issues, strategies, and opportunities. Building on the past IIoT webcasts, the 2017 four-part series will examine concepts, technologies, applications, and case uses for IIoT and of interest to engineers, managers, and technicians across the production industries. Couldn’t catch a recent webcast? See it on-demand at www.controleng.com/webcasts.

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

Striving to achieve a reliable state for improved productivity.

Point, click, watch

CONTROL ENGINEERING

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APRIL 2017

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www.youtube.com/user/controlengineeringtv.

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Plant Engineering content manager Bob Vavra (left) talks with Jeff Miller, director of project management, Interstates Control Systems and Jack Woelber (right), the president of Interstates Control Systems, about the present and future for system integrators.

The tablet and digital editions of this publication have unique content for our digital subscribers. This month has digital exclusives on: How piping affects flow measurements and proper motor alignment.

ed at gr te In

System Integrator of the Year: Interstates Control Systems

Read this on your tablet

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An Electrocomponents Company.

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

Ethernet cuts automation hardware, labor costs, errors A redesigned automated industrial process to improve safety and efficiency saved $106,654 in hardware, design, and installation costs by using an industrial Ethernet protocol instead of hard wiring.

Using an

industrial Ethernet protocol saved money for industrial system project design, installation, and hardware costs, according to Mike Prokop, CMSE, LSO (certified machinery safety expert via TUV NORD, laser safety officer) and chief electrical engineer at Taylor Winfield Technologies Inc. Among those Prokop worked with on the project was Nick Maillis, electrical engineer, programmer, and co-worker on an industrial process redesign that included 2,700 hazards to mitigate. Prokop described the effort and quantified benefits associated with saving $106,654 in hardware, design, and installation costs by using an industrial Ethernet protocol compared to hardwiring, as described in a presentation at the 2016 General Assembly Meeting for PI North America in September 2016. The savings quantified excludes a two-thirds reduction in potential errors. Automated system design

Taylor Winfield Technologies is an original equipment manufacturer (OEM) of large capital equipment including steel processing, automated assembly, induction heating, material handling, and resistance, laser, arc, and plasma welding systems. With about 100 employees, the company’s markets include agriculture, appliance, automotive, electronics, nuclear energy, hardware, lighting, mining, pharmaceutical, and steel processing industries. The project redesigned and automated a manual industrial process to handle and store 5,000 lb rolls of plastic film that depended on paper-based processing and forklift handling for 720 rolls per day in a

ADVICE GO ONLINE See photos and project component details with this article online; www.taylor-winfield.com showed its capabilities at Automate 2017, Chicago, April 3-6.

APRIL 2017

CONTROL ENGINEERING

20,600 ft2 area. Rolls are entered in the system, processed, and stored before being palletized and shipped. The rolls are pushed in on a conveyor rail, the barcode is read with wireless barcode scanners, and a vision system centers the crane to lift each roll for weighing and placement at the orbital wrapper. The roll is rejected if the weight is incorrect. According to Maillis, a robot lifts end boards for the roll, inspects them using a vision system, applies glue, assembles, and places them for pickup by another robot. At the banding station, the robot places the end boards onto a gantry for placement on the roll. The center of the rolls and end boards are located using another vision system. Pressure and heat help apply the bands. The system stores about 400 rolls. Orbital wrapping is applied with labeling. Along the way, 87 configurations and nominal measurements are possible with five conveyors and 10 doors. Automated system components

The system uses a failsafe PLC, six enclosures, input/output (I/O) modules, light curtains, non-contact coded magnet safety switches, and safety input modules for zone isolation. Detailed savings analysis and tables were produced comparing hard-wired costs to use of industrial Ethernet, looking at wiring, safety relays, I/O connections, hardware, and labor, producing more than $106,000 in savings, not counting the cost of potential errors avoided with 1,146 connections with a digital network versus 3,795 with hardwiring. Twenty-eight people were trained for other, less risky functions. 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 senior contributing Kevin Parker, Senior Contributingeditor, Editor,IIoT, IIoT,O&GE OGE 630-890-9682, KParker@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 978-302-3463, 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. Marketing Reprintsconsultants: See ad index.

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

Editorial Advisory Board www.controleng.com/EAB Publication Sales: See ad index

Doug Bell, president, InterConnecting Automation, www.interconnectingautomation.com Editorial Advisory Board David Bishop, president and a founder www.controleng.com/EAB Matrix Technologies, www.matrixti.com David president and Diversified a founder Technical Services Inc. DanielBishop, E. Capano, president, Matrix Technologies, www.matrixti.com of Stamford, CT, www.linkedin.com/in/daniel-capano-7b886bb0 Joe Martin, president and founder Joe Martin, president and founder Martin Control Control Systems, Systems, www.martincsi.com www.martincsi.com Martin Rick Pierro, Pierro, president president and and co-founder co-founder Rick Superior Controls, Controls, www.superiorcontrols.com www.superiorcontrols.com Superior Mark Voigtmann, Voigtmann, partner, partner, automation automation practice practice lead lead Mark Faegre Baker Baker Daniels, Daniels, www.FaegreBD.com\ www.controleng.com Faegre www.FaegreBD.com

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PRODUCT EXCLUSIVE power quality

Power monitoring input module for single-phase applications Spectrum Controlsâ&#x20AC;&#x2122; 1756-RMS-SC ControlLogix Power Monitoring input module is intended for any single-phase application requiring precise power monitoring. It also calculates power factor using real, reactive, and apparent power measurements by sampling voltage and current.

Spectrum Controlsâ&#x20AC;&#x2122;

1756-RMS-SC ControlLogix Power Monitoring input module is intended for any singlephase application requiring precise power monitoring that integrates into a Rockwell Automation ControlLogix installation. The 1756-RMS-SC module offers eight current and voltage input channel pairs with 250 V ac isolation, 16-bit resolution, fully linearized data and over/under range indication. The module calculates power factor using real, reactive, and apparent power measurements by sampling voltage and current. These power measurements are useful for glass furnaces, motor drives, pump systems, compressor systems, and conveyor belts. Other applications include building services, wind turbines, battery monitoring, solar power generation systems, and material processing. The 1756-RMS-SC module allows the user to monitor power use at high update rates. The module also gives the programmable logic controller (PLC) control to maximize power usage without running the risk of damaging expensive equipment. With a full-featured add-on-

profile, the module automatically populates information into the data table of the ControlLogix controller. This module is programmed using existing Studio 5000 programming software. ce Spectrum Controls www.spectrumcontrols.com Input #200 at www.controleng.com/information

ADVICE GO ONLINE See more new products in the new Products for Engineers Database: www.controleng.com/NP4E. Also see the product section in the April 2017 print/digital edition of Control Engineering. Interested in introducing a product to the world here? Contact Mark T. Hoske, mhoske@cfemedia.com.

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X2 series. Strong. Stylish. Smart. Learn more at beijerelectronics.com/x2pro input #8 at www.controleng.com/information

Cabinet Confidence Network security means increased productivity Phoenix Contactâ&#x20AC;&#x2122;s expertise and commitment to innovation across a wide range of industries enable you to build your control cabinet with confidence. In a single network, everything is vulnerable. Protect your systems against unauthorized access by people or malware. Industrial routers from Phoenix Contact protect your network with a powerful, flexible, and fast firewall. Call 1-800-322-3225 or visit: www.phoenixcontact.com/confidence_mguard

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input #9 at www.controleng.com/information

Ethernet products, software, services spending Don't know

25%

research

36% 20%

2016 IIoT & INDUSTRIE 4.0 STUDY:

19%

Integration trends in instrumentation, controls

One-third of respondents to the 2016 Industrial Internet of Things & Industrie 4.0 study are involved in the instrumentation, measurement, and controls systems or devices industry—82% of whom reported to be investing more in advanced technologies to support IIoT, Industrie 4.0, or digital manufacturing initiatives. Below are four additional findings from this report segment: 1. Perspective: Thirty-seven percent of instrumentation/controls engineers do believe that IIoT and Industrie 4.0 are helpful to their existing initiatives, and 45% would describe them as “different words for what we’ve been trying to do all along.” 2. Useful attributes: Respondents involved with instrumentation, measurement, and controls systems or devices have found the interoperability (53%), security (42%), and analytics attributes (38%) of the IIoT framework to be the most useful. Regarding the Industrie 4.0

About the same

platform, respondents most value the real-time capabilities (44%) and interoperability functions (40%). 3. Technologies, services: The most useful groups of technologies and services in supporting IIoT/Industrie 4.0/ digital manufacturing in the instrumentation/controls industry are wired or wireless networking, device bus, Fieldbus networks, I/O modules and systems (53%) and HMIs, SCADA, historian, alarm management or data acquisition systems (48%). 4. Annual budget: Companies involved in the instrumentation, measurement, and controls systems or devices industry estimate a $1.2 million annual investment in IIoT, Industrie 4.0, and/or digital manufacturing areas; 39% estimate $100,000 or less. ce View more information at www.controleng.com/2016IIoTStudy. Amanda Pelliccione is the research director at CFE Media, apelliccione@cfemedia.com.

Top 5 expected benefits of IIoT, Industrie 4.0 implementation Connect people, data, machines Increase innovation Increase information flow

Spend more on products/ software

64% 49% 46%

Improve data analysis

44%

Ease system integration

44%

More than half of instrumentation/controls engineers expect their company’s implementation of IIoT and/or Industrie 4.0 to better connect people, data, and their machines. Source: Control Engineering

Spend more on services

Thirty-six percent of end users report spending more on Ethernet products and software than on services. Source: Control Engineering 2016 Mobility, Ethernet & Wireless Study

30%

of end users are seriously concerned about the cybersecurity of wireless communications devices and protocols within their facilities. Source: Control Engineering 2016 Cybersecurity Study

of engineering firms has integrated—or has plans to integrate—process sensors and transmitters. Source: Control Engineering 2016 System Integration Study

59%

of end users are currently using or planning to use elements of both IIoT and Industrie 4.0 in their facilities. Source: Control Engineering 2016 IIoT & Industrie 4.0 Study

More research Control Engineering covers several research topics each year. All reports are available at www.controleng.com/ce-research.

www.controleng.com/ce-research FOR MORE RESEARCH INFORMATION

APRIL 2017

CONTROL ENGINEERING

www.controleng.com

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INTEGRATOR UPDATE business value

Creating a buy-out agreement with multiple business owners Co-owning a business requires careful planning in the event a buy-out of one of the owners occurs.

provisions is

Starting a business with someone else is like a marriage. At the beginning, everyone is positive, excited for the future, and sure of its success. However, if one or more owners leave the business, motivations have a way of changing. Defining “fair” and “reasonable” ways to undo the relationship becomes difficult, and too often ends up in the courtroom. As business owners are coached, “Don’t get into business together without first defining how you’ll get out of business with each other.”

to consider all

Creating a buy-sell agreement

‘

The key to well-defined valuation

the possible triggering events to one of the business owners leaving, and then define the owner’s intent under each

’

event.

ADVICE KEY CONCEPTS Defining a buy-sell agreement for multiple business owners. What to include in the valuation provisions of a buy-sell agreement. How to simplify a buy-out scenario between multiple business owners. GO ONLINE For more about business valuations and links to parts 1 through 8 of this series, 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 buy-sell agreement be revised or reviewed?

APRIL 2017

The way to define and document how to handle the buy-out of one (or more) of the owners is by creating a buy-sell agreement. The buy-sell agreement outlines what happens to the shares of an owner who leaves the business, for any number of reasons. It is a legally binding agreement that is typically drafted by an attorney. When an owner leaves the business, the most critical paragraphs (referred to as the valuation provisions) of the buy-sell agreement define how the departing owner’s shares are to be valued. Unfortunately, the valuation provisions are too often ill-defined or non-existent. The key to well-defined valuation provisions is to consider all the possible triggering events to one of the business owners leaving, and then define the owner’s intent under each event. What if an owner quits? Is fired? Retires? Gets divorced? It is typically stressful, emotional, and unfortunate when a business owner leaves the business. This is not the time to come to an agreement on what is a reasonable approach to valuing the departing owner’s shares. Too often, business owners in this situation reach for their buy-sell agreement only to realize it is silent under the triggering event that has occurred, or is ambiguous as to how the shares should be valued. Terminology such as “book value,” “fair market value,” and other such language does not give sufficient or clear instruction to a business appraiser who will be hired to do a valuation of the business. More information and direction regarding the owners’ intent is needed. Some important clauses that should be discussed and included in the valuation provisions of a buysell agreement include: Who is able to buy out an owner’s shares in the business?

CONTROL ENGINEERING

What events will trigger a buy-out? How will the value be determined? Does this differ under various triggering events? Do discounts and/or premiums apply relating to control or minority? Should there be an additional discount if someone decides to quit? Once the value has been determined, what are the terms of payment? What date should be used for the valuation? While an attorney can help create or update a buy-sell agreement, it is wise to work with a business valuation expert on the sections pertaining to these valuation issues. Unfortunately, templates or boilerplate language do not work because it is critical that the owners define their intent—what do they consider fair or reasonable under each circumstance, before they know who will be the one to trigger the event. If a death occurs, it is outside of their control and the buy-out can be funded with life insurance. If a business owner quits, it may leave other owners in a lurch. If a business owner is fired because of a particular reason or because of an internal disagreement, owners typically would agree to have that situation treated differently. To guarantee an agreement that will truly help the owners separate, they need to go through numerous “what if ” scenarios and answer questions so there are no surprises. At a minimum, have an independent business appraiser review the valuation provisions and give feedback to the existing language. The goal is to have an unambiguous agreement that defines how the owners will act under any possible triggering event. An appraiser can provide questions that need to be answered to define the valuation provisions of such an agreement. Business owners will spend far less time and money with these best practices than in litigation later when one of the triggering events occurs and the owners begin to fight for their own best interest. ce Catherine J. Durham is 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

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input #11 at www.controleng.com/information

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CONTROL ENGINEERING international

Network integration enables Industrial Internet of Things It’s easier to implement Industrial Internet of Things applications with network integration, data collection, visualization, and analysis, according to a Control Engineering China interview.

For Industrial Internet of Things (IIoT) and intelligent manufacturing, enterprises should lay a firm foundation before integrating higher levels. All plant-level equipment should be connected, and all data from connected equipment should be transmitted to a database, said Daniel Gao, vice president of sales of Red Lion Controls Asia Pacific. The automation company can help enterprises with interconnections in the supply chain, interaction with the web and mobile phones, and with writing data to a data center for thing-to-thing connections. Without such foundations, Gao said, it would make no sense to talk about intelligent manufacturing, IIoT, or Industrie 4.0. U.S.-based Red Lion Controls Inc. participated in the 2016 China International Industry Fair, which was held Nov. 1-5, 2016, in Shanghai with the theme of “Industrial IoT (IIoT).” During the exhibition, Gao was interviewed by Control Engineering China. Gao noted that Red Lion Controls may solve some difficult challenges by matching customized products and solutions, in swift mode of operation among larger automation companies.

Aileen Jin is editor in chief, Control Engineering China. Courtesy: Control Engineering China

Industrial networking, automation

ADVICE KEY CONCEPTS Manufacturing needs to begin Industrial Internet of Things applications with interconnected plant networks. Connected equipment should transmit data to a database for analysis. Intelligent manufacturing: Visualization of results can improve performance. GO ONLINE www.controleng.com/international www.cechina.cn CONSIDER THIS Is your equipment interconnected and transmitting data for analysis?

APRIL 2017

Red Lion Controls’ main business consists of two major parts: industrial networking and industrial automation. After the purchasing of N-Tron in 2010 and SixNet in 2011, related sales have been satisfying. For industrial networking, Red Lion Controls has a traditional advantage, Gao said. As early as the 1990s, the company introduced the protocol converter, which included more than 300 types of industrial interface protocols and enabled seamless communication among different manufacturers’ equipment. Compared with ordinary industrial converters, products offered by Red Lion Controls allow secondary development and are provided with functions such as storage, collection, programming and control. Intuitive user interface screens may be created by a virtual human-machine interface (HMI), and processes may be controlled by remote access of data files by embedded web services. Using the industrial interface protocols, the company developed a series of industrial automation products, including an HMI that eases infor-

CONTROL ENGINEERING

The Red Lion Controls PTV (ProducTVity Station) visualization management system can put real-time information where decisions are needed. Courtesy: Red Lion Controls

mation integration and data capture. In product development, Red Lion Controls has been attaching great importance to product modularization. Globally, the industrial automation and industrial networking businesses of Red Lion Controls represent about half the company. Gao said in the Asia Pacific region including China, the proportion of industrial automation business is relatively low and remains an opportunity for growth. He hopes that both sectors may be balanced in future. “The market is huge, and our products are quite welcomed by the customers.” Gao is confident in the further development of Red Lion Controls in China. Accelerating expansion

Gao, who joined Red Lion Controls in February 2016, said Red Lion Controls has made some achievements in fields such as water treatment, traffic, power, and oil and gas, with recent annual growth estimated at 20%. “Overall market share is relatively low, and we can even do better,” Gao said. To accelerate the development pace in China, Gao expects “significant” merger and acquisition (M&A) activity, as the company seeks complementary positions in industrial automation and industrial networking in China. ce

Aileen Jin is editor-in-chief, Control Engineering China. Edited by Mark T. Hoske, content manager, Control Engineering, mhoske@cfemedia.com. www.controleng.com

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Easier automation for food production What will future food manufacturing look like? Control Engineering Europe spoke to some key industry vendors about the future of food production. As the need for skilled labor increases, and regulations require track and trace records, advanced automation is getting easier to apply and use.

Food manufacturers

need to become more agile and flexible to satisfy the changing and increasingly demanding requirements of retailers and consumers in a market where consumer purchasing intelligence is becoming increasingly powerful, internet ordering is growing rapidly, and logistics are becoming highly dynamic. The U.K. ranks as the second worst country for productivity among the industrialized nations; if productivity could increase to U.S. levels, each household would be $25,669 (£21,000) per year better off. “For the machine designer it is simply not possible to adapt many existing solutions to achieve the step change in productivity that manufacturers are looking for,” said Martin Leeming, CEO at Trakrap. “The whole system architecture needs to change from the bottom up, and you quite literally have to go back to the drawing board and start again.” Speed to market, asset utilization

Leeming, like others, said the answer is in the digitization of machines and processes and in the acquisition and proper use of big data. “A big step change in productivity improvement does not lie in simply undertaking the same process with less people. It requires companies to rethink other things like speed to market, asset utilization, energy reduction, reduced changeover times and making to order, not to stock,” Leeming said. He said many barriers remain: only 48% of manufacturers claim to be ready for Industrie 4.0, and it is thought that 40% to 50% of existing machinery will need to be replaced to make the step change that the U.K. needs. Keith Thornhill, business manager, food and beverage at Siemens U.K. and Ireland, said the current rate of technological change within the industrial environment shows no sign of slowing, so food industry prediction is not an exact science. Even so, “With competitiveness and changing consumer demands increasingly being seen as industry drivers, it is clear that automated processes, whether ... physical or digital, will assist food manufacturers to deliver cost-effective, repeatable and safe products,” he said. However, to achieve this, there is a need to focus on critical areas of productivity, efficiency, and agility. By looking to maximize effectiveness www.controleng.com

it is possible to take significant steps toward creating the technological-driven solutions necessary for the competitive years ahead. Some identifiable areas require particular attention, Thornhill said. He advises food manufacturers to set a clear mid- to long-term vision of digital integration so factories can adopt maximum transparency across all areas of product development and production. “This includes a need for closed-loop data integration from the enterprise resource planning (ERP) level right through to production, individual asset performance, and back,” Thornhill said. “Detailed machinery and automation specifications also need to be agreed [upon], so data transparency can underpin strategic decision making and productivity targets can be addressed.” Thornhill also advises that companies seek to reduce obsolescence to reduce costs and to future proof available assets. Automation investment drivers

Andrew Macpherson, food and beverage manager at Festo, agrees that the pressure from retailers and consumers to safely produce more food, of greater variety, at sustainable prices and high quality, is driving investment in automation. He predicts that the level of automation in the food sector in 10 years will completely change the food production environment. “In the future, food production machines from different manufacturers will need to share data and communicate with each other, using open communication protocols, and will be able to

Software, drives, and controllers from Siemens operated the Hacos MDECO 3D Chocolate Decorating Machine at Pack Expo 2015 in Chicago, producing the diverse customized confections shown. Courtesy: Mark T. Hoske, Control Engineering, CFE Media

ADVICE Key concepts Automation increases productivity, quality, and food safety. Food processors and equipment manufacturers have opportunity with Industrie 4.0. Digital integration helps with transparency and flexibility. GO ONLINE See more international coverage at www.controleng.com/international and more from Control Engineering Europe at www.controlengeurope.com. CONSIDER THIS Are you updating your machines or applying retrofits rapidly enough to keep pace with competitive needs?

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CONTROL ENGINEERING international

Hacos ChocoCAD software on a Siemens Simatic HMI showed measurements for volume, speed, acceleration, height, and product name, among other information, to help with custom chocolate manufacturing at Pack Expo 2015 in Chicago. Courtesy: Mark T. Hoske, Control Engineering, CFE Media

make necessary adjustments automatically. These machines also will be able to tell the operator if a problem is developing, whether performance is dropping or energy consumption is rising, and more importantly what needs to happen to fix it,” said Macpherson. Food manufacturers, suppliers and customers will be linked more closely. Data relating to consumer demands and trends will be shared to ensure that production adjusts with real-time demands. “Available data will bring new challenges, relating to security and how to interpret it. Engineers will have to work more closely with their IT colleagues to get the maximum benefit for their business,” he said, adding: “As the link between the consumer and the food manufacturer gets closer, production machinery will need to become more flexible and able to change to smaller batch quantities, quickly.” Macpherson believes that the materials used in the production machines of the future also may be completely different from what is being used as standard today. An example is the development of nano-coating technologies such as plasma coating. “This could allow standard materials to be coated to provide increased bacterial resistance, potentially replacing stainless steel in the food sector,” he said. New technologies will emerge that help extend the shelf life of food products, involving new processes or the use of different gases, for example, ozone. “This will raise further challenges for food machinery producers, such as how to handle these new processes while ensuring it is a safe working environment for staff,” concluded Macpherson. Flexible track and trace

“The requirement for efficiency monitoring, product tracking and traceability, faster, safer, lower-cost processing and packaging solutions, and

APRIL 2017

CONTROL ENGINEERING

plant flexibility are growing across all sectors of the food industry,” said Chris Evans, marketing and operations group manager at Mitsubishi Electric– Automation Systems Division UK. This has resulted in rapid advances in automation technology. One of the biggest is the increasing use of small articulated arm and SCARA-style robots to perform repetitive tasks. [SCARA stands for selective compliance articulated robot arm.] “Mitsubishi hosts regular seminars on the use of robotics in the food industry and attendees are usually surprised by the low package cost, combined with ease of use and simple integration,” said Evans. “Platform integration is a major theme when it comes to delivering multiple benefits. Users expect an incremental improvement when replacing individual automation components such as drives, servo systems and PLCs [programmable logic controllers],” Evans said. “If you take a holistic view of your automation system, then you can make some really significant gains.” A powerful PLC used to manage a production line can coordinate guided-operator pick, light systems that improve quality and throughput for manual workers, conveyor systems, process plant ovens and chillers, high-speed packaging machines, robot cutting, and packing and stacking lines. “The future for automation in the food industry is most certainly going to be centered around increased plant and automation platform integration, simply because the universal advances that producers require cannot be delivered without it,” concluded Evans. Automation helps personalization

Mass production is changing as consumers demand more highly personalized products. In the automotive industry, it is possible to choose a car’s details, prior to manufacturing on a flexible production line. Similar choices are coming to the food market. It is already possible to design your own chocolates and have them made on a 3D chocolate printing machine (see related photos). In the U.K., Boomf, a personalized confectionery producer, has seen business increase by 600% in its second year. Consumer choice is great for the customer, but “often represents a challenge to the traditional business model which is built on high volume, mass production. If you want to survive then you need to differentiate, and do something different,” said Steve Arnold, business manager food and packaging at SMC. New technologies are emerging to help businesses meet the need for more flexible, agile, smart manufacturing. Data appears to be the key, first collecting it and then being able to interpret it, to allow www.controleng.com

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CONTROL ENGINEERING International

‘

Far more could be achieved with robotics and vision;

Keeping pace with competitors

ensure that the best is made of what is already available while keeping a close eye on emerging

’

technologies.

businesses to make more informed decisions. “New buzzwords like ‘cyber-physical systems’ are already allowing machine builders to transform a humble electric drive or process valve into a smart sensor, allowing manufacturers to purchase standard production lines but with the capability to run many different product formats in large and small batches and still turn a profit,” continued Arnold. “The automotive sector has been doing this for many years and the challenge for the food sector is to embrace this new technology too, allowing for greater flexibility and agility to meet changing consumer demands.” According to Mike Wilson, sales and marketing manager at ABB Robotics U.K., robotic automation will become a more attractive solution for production and packaging applications in the food and beverage industry. Robots allow producers to keep pace with the demand for greater variety, quality, and faster delivery. Producers need to find new ways to keep pace. “The U.K. food and beverage sector has been investing more in automation in recent years to help it survive the supermarket price war. However, further investment in automation is needed to ensure continued competitiveness,” said Wilson. “Other countries are automating at a much faster rate, with the most productive country in the food and beverage sector being Finland.” International Federation of Robotics (IFR) data said Finland adopted 55 more robots per 10,000 employees than the U.K. in 2014. As factories globally start to increase use of smart technology, U.K. food manufacturing needs to focus on that subject too. “As the tools which perform the various processes involved in smart manufacturing, robots are the primary technology that should be considered before implementing a full Industrie 4.0 strategy,” Wilson said. “As cyber-physical systems that use data to operate and communicate with other elements in the factory, robots are one of the most prevalently featured automated machines in any Industrie 4.0 model. They also are beneficial to anyone wishing to overcome the typical challenges facing food producers, such as inconsistent product quality, flexibility and reliability problems. Robots can also perform processes which have been identified as high risk by the health and safety executive (HSE),” Wilson said. Labor costs, AIVs

“The U.K. food industry is a high labor economy; I don’t really see that changing any time soon,” said Robert Brooks, European industry marketing manager, food and beverage for Omron Europe. “We are seeing a continuing move towards ‘redeployment’ of the workforce for better resource efficiency, and this is being driven by cost and need.”

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Brooks said the industry is short of skills and at the same time there’s a greater need for automation driven by productivity and flexibility demands. “This means that any automation solutions, such as robotics, will need to be easy to use,” he said. Brooks said there is an increasing appetite within the food industry for robotic solutions. Around-the-process robotics, such as autonomous intelligent vehicles (AIVs) also will form a fundamental part of the future food manufacturing plant. Initially applications for such solutions, which are designed to dynamically move materials around a plant without the need for facility modifications, might include raw stock material replacement and replenishment, and bringing spares and repairs to the line. “Moving people away from repetitive tasks, and with the potential to link these robots into the production and maintenance processes or ERP systems, the food industry could find a host of applications for this new breed of robots,” Brooks said. “There are so many opportunities for their adoption within the food manufacturing environment and again, this will be driven by the need for greater efficiency.” Brooks also expects to see increasing adoption of simulation technologies to provide a low-cost solution to visualize the total cost of ownership and proof of concept of any potential new automation solutions before purchase. “Artificial intelligence (AI) is another technology that is knocking on the door of the food factory,” continued Brooks. “We should expect to see these cognitive thinking systems being employed to make sense of the increasing amounts of data being made available from smart systems. “AI technology could be used, for example, to help manufacturers link consumer buying patterns to the weather and environment. There are many areas where cognitive thinking solutions could find applications in the food industry,” Brooks said. For now, though, Brooks advises that engineers need to look more closely at the tools they have available. “I believe that there is far more that could be achieved with today’s robotic and vision solutions. It is important to ensure that the best is made of what is already available while also keeping a close eye on emerging technologies. It also is important to take time out to find out how these technologies might fit into your organization, now and in the future, because you can be sure that some of your competitors will be doing just that.” ce Suzanne Gill is editor, Control Engineering Europe; Edited by Mark T. Hoske, content manager, Control Engineering, mhoske@cfemedia.com, from a Feb. 6 post on the Control Engineering Europe site, “Taking a glimpse into the future of the food production process.” www.controleng.com

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INDUSTRY NEWS and events

What’s Next? RMC75 1 or 2-Axis

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input #14 at www.controleng.com/information

Michigan governor touts manufacturing professionals While touting the job and technology growth in his state, Michigan Governor Rick Snyder told the audience at the recent Manufacturing in America event in Detroit that the challenge of creating and growing jobs in his state and others was creating the right environment for job growth. “As governor, I don’t create jobs; you do,” Snyder told more than 250 manufacturing leaders on March 22 at the annual event sponsored by Siemens and Electro-Matic. “What we can do is create the ecosystem.” Snyder said the state reversed economic decline over the last decade by reimagining the tax system, but also by building the talent around the high-tech manufacturing growth. Snyder noted that Michigan created a job website (MITalent.org) a decade ago at a time when the state’s unemployment rate was 11%, and there were 80,000 open jobs on the site. Today the state’s unemployment rate is 5% and there are 100,000 job openings on the site. “We want to create an environment to fill those needs. Michigan

Michigan Governor Rick Snyder told the audience at the Manufacturing in America event in Detroit the challenge of creating and growing jobs in his state and creating the right environment for job growth. Courtesy: Bob Vavra, CFE Media

leads the nation in creating manufacturing jobs.” Snyder noted the changes already underway in manufacturing require a fresh look at manufacturing jobs. “We said everyone should get a 4-year degree, and we stopped telling everyone there was an equally noble career in skilled trades-to become a professional. We need to promote that.” “We also need to remind people that manufacturing is about making something better to improve people’s lives. It’s not just about making a product; it’s about innovating.” Bob Vavra, content manager, Plant Engineering, CFE Media, bvavra@cfemedia.com.

Machine, factory automation provider to be acquired by ABB ABB announced, on April 4, plans to acquire B&R, a provider focused on product- and software-based, open-architecture solutions for machine and factory automation worldwide. B&R, founded in 1979 by Erwin Bernecker and Josef Rainer is headquartered in Eggelsberg, Austria, employs more than 3,000 people, including about 1,000 R&D and application engineers and operates across 70 countries. The combination is expected to expand ABB’s offering of industrial automation, by adding B&R’s products, software and solutions for machine and factory automation with ABB’s robotics, process automation, digitalization and electrification. Through the acquisition, ABB looks to expand in industrial automation and position itself for potential growth opportunities resulting from the Fourth Industrial Revolution. It expands “technology and software solutions around measurement, control, actuation, robotics, digitalization and electrification,” said ABB CEO Ulrich Spiesshofer. Josef Rainer, co-founder of B&R, cited “ABB’s global presence, digital offering and complementary portfolio” as means to “further accelerate our pace of innovation and growth.” Edited by CFE Media from an ABB press release.

APRIL 2017

CONTROL ENGINEERING

www.controleng.com

Digital edition? Click on headlines for more details. See news daily at www.controleng.com/news

Automate 2017 highlights While the deadline for this issue was prior to the Automate show, April 3-6, these companies were among those offering a preview of what they expected to show. Motors for robotic, medical applications

TQ Systems’ RoboDrive motors are compact and feature strong dynamics and precision which can be used for medical, robotic and aerospace applications. The variable concept offers solutions for a variety of demanding drive applications. Alternative voltage levels, increased speeds and customized torque adaptations also are available on special order. RoboDrives are available in sizes with different stator lengths, and outer diameters from 25 to 115 mm and a wide torque range from 0.024 to 11.2 Nm.

Flexible gantry system

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Robot grippers for collaborative robots

On Robot’s two-finger RG2 grippers—available in single and dual versions—are designed to mount on the arms of cobots without external wires. The RG2 grippers easily can be programmed directly from the same interface as the robot, and the gripper can be modified without previous programming experience, making them ideal for collaborative robot users.

Signal Integrity, Compact Design 2 Software Packages for DAQ or T&M • $17 per Channel Possible – Lowest Cost in Industry • Up to 384 Channels in 19” Instrumentation Rack • Application Software from $250 • ±0.035% Accuracy • 1500Vrms Channel-to-Bus Isolation Güdel’s type ZP Gantry System enables flexible positioning of the legs of the gantry beam, which is designed to provide a substantial advantage in the production line. Courtesy: Güdel CONTROL ENGINEERING

APRIL 2017

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input #15 at www.controleng.com/information

INDUSTRY NEWS and events

Four benefits of manufacturing automation U.S. manufacturing accounts for $2.17 trillion in annual economic activity and more than 98% of U.S. manufacturers qualify as small businesses. Manufacturers must leverage every advantage to remain effective as they face global competition. Manufacturing automation has been an essential part of this. Automation empowers small American businesses to stand toe-to-toe with entrenched rivals around the globe. But how does automation facilitate that? Start by focusing on these four benefits.

1. Automation means higher productivity

End-to-end factory automation can increase production compared to plants that use only a few automation systems. Equipment can often be kept running for longer periods of time with comparatively little impact on the maintenance outlook.

2. Automation means lower overall costs

Through automation, the complex process of fabricating a product can be simplified to its most basic components. Automation systems can be upgraded until they are as efficient as possible: generating little waste heat, using the minimum power and focusing on controlled and precise movements. All this makes manufacturing cheaper, which cuts cost and raises profits.

3. Automation means workplace safety

Even the most sophisticated robotic system is useless without human insight to guide it. When automation is deployed in a factory, it can mean team members no longer have to worry about the most dangerous and dirty tasks, as lifethreatening processes are often the first to be delegated to robots. That reduces

Han® ES Press Simple Connection with a Click.

accidents and helps workers maintain their health over time.

4. Automation means high-level focus

Tedious manual labor simply can be left to the machines and allows manufacturing personnel to focus on the best way to improve efficiency on the floor, expand their products’ capabilities, and many other engaging tasks. There’s a good reason why manufacturing automation is being adopted from coast to coast: it benefits everyone. Today we’re in the midst of a new automation boom that promises to fundamentally transform how manufacturing is done. This article originally appeared on the Robotics Industries’ Association (RIA) Robotics Online Blog. The RIA is a part of the Association for Advancing Automation (A3), a CFE Media content partner. Edited by Chris Vavra, production editor, Control Engineering, CFE Media, cvavra@cfemedia.com.

Bell joins Editorial Advisory Board Doug Bell joined the Con-

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trol Engineering editorial advisory board on March 28 to provide input to editorial staff on editorial content, relevancy, automation market, and audience; to serve as a first-level sounding board for new initiatives and ideas; and to participate in events and contribute editorially. Bell worked as a control electrician for Crown & Cork Seal for 17 years in Milwaukee, Wis. and then took a corporate job installing controls on production lines, putting up plants, troubleshooting controls and performing every facet of control work. After working for Eaton Cutler-Hammer, he started InterConnecting Automation Inc., which focuses on training people in the AutomationDirect line of automation products. Bell lives in Milwaukee, Wis. www.controleng.com/EAB

HARTING-usa.com/customized-solutions input #16 at www.controleng.com/information

APRIL 2017

CONTROL ENGINEERING

Electrical code revisions for product condition made

cover story

Digital edition? Click on headlines for more details. See news daily at www.controleng.com/news

Two code revisions recommended by the Professional Electrical Apparatus Recyclers League (PEARL) were adopted for inclusion into the latest version of the National Electrical Code, 2017 Edition (NEC). These revisions represent the first time since its inception in 1897 that the NEC makes reference to product condition, specifically allowing for reconditioned, remanufactured, and refurbished electrical product. The NEC 2017 Edition includes proposed changes to NEC rules 110.3 and 110.21. NEC 110.3—Examination, Identification, and Use of Equipment— ensures that reconditioned equipment is acknowledged and considered for use in installations. The revision to NEC 110.21— Equipment Markings-Reconditioned Equipment—requires reconditioned equipment to be marked with the name, trademark or other descriptive marking that identifies the organization responsible for reconditioning the electrical equipment. The date of reconditioning is also required to be marked on the equipment. - Edited by CFE Media from a PEARL press release.

Automation group selects board of directors, celebrates 25th anniversary

APRIL 2017

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: Hannover Messe, Hannover, Germany, April 24-28 www.hannovermesse.de/home Offshore Technology Conference & Exhibition, Houston, May 1-4 www.otcnet.org CSIA Executive Conference, Fort Lauderdale, May 2-5 www.controlsys.org/events/ executive-conference Sensors Expo, San Jose, Calif., June 27-29 www.sensorsexpo.com

Top five Control Engineering articles March 6-12: The most visited articles included PID learning, standardized control system programming, the Engineers’ Choice winners, multi-platform fluency and ladder logic. PMI continues strong growth trend in February The Institute for Supply Management’s purchasing manufacturers’ index (PMI)

rose to 57.7% in February, which marks the sixth straight month of growth. Tough market projected for gas, steam and hydro turbine suppliers IHS Markit reported that sales for the gas, steam and hydro turbine industries are projected to struggle through 2020 due to a lack of market opportunities for suppliers and high price erosion. Trust in IIoT data declines, according to survey According to a survey by Experian Data Quality, just over a quarter of organizations don’t trust their data, and more than half rely on educated guesses or gut feelings to make decisions based on their data. Aerospace company looking to transition to digital factory Airbus is making plans to transition to a digital factory that will bring skilled workers into the fold, but it is a challenging feat in an industry that hasn’t changed production very much in the last several decades.

Keep Hazardous Operations Separate from People, Equipment, and Materials

CAN in Automation (CiA) elected the board of directors at its annual general assembly. Business director Christian Schlegel (HMS); technical director, Uwe Koppe (Microcontrol); and CiA managing director, Holger Zeltwanger, were re-elected. The following member companies are a part of the group’s business committee: Emtas, ESD, Janz Tec, Microcontrol, and Vector. The technical committee group is Bosch Automotive Electronics, ESD, HMS, Infineon, and Vector. The international users’ and manufacturers’ group has 615 members. This year, the association celebrates its 25th anniversary. The birthday party was held during the 16th international CAN Conference (iCC) in March. Edited by CFE Media from a CAN in Automation (CiA) press release. CiA is a CFE Media content partner. CONTROL ENGINEERING

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DIGITAL REPORTS 2017 DIGITAL REPORT

MOTION CONTROL

Motion control advances and solutions can help with machine control, automated control on assembly lines, integration of robotics and automation, and machine safety. Intelligent motion control helps manufacturing end users, machine builders, and system integrators who work on these project. To view and download this digital report visit: www.controleng.com/DigitalReport/MotionControl

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How to Select a DC Motor: Coreless and Iron Core Brushed DC Motors George Hunt | Application Engineer at MICROMO

DC Motors Overview DC motors possess linear relationships that allow for very predictable operation. For instance, if enough voltage is applied across the terminals of a DC motor, the output shaft will spin at a rate proportional to that applied voltage. You can take the ratio of the applied voltage over the rated voltage and multiply that number by the no load speed and get the running speed. In addition, if you decide to measure and plot the current and torque, you will have a simple straight line indicating yet another directly proportional relationship. When torque demands increase, so does the current.

However, despite their simplicity, selecting a DC motor for an application can still be a daunting task. Many other variables must be taken into account including dimensions, load, duty cycle, environment, feedback considerations, etc. Perhaps decoding some of the mysteries of motor operation will shed some light on the selection process.

Going for Simplicity with Brushed motors If your application demands a reliable, time-tested, low cost motor, then brushed DC motor technology may be what you are looking for. The key here is simplicity. A brushed motor is designed to run off of straight-line DC voltage and can even be connected directly to a properly sized battery.

Plotting the torque and speed together, you will find that only two points of data are needed. Those are the no load speed and the stall torque. The entire motion control world, including manufacturers and designers, depend greatly on the premise that all these linear relationships will hold true â&#x20AC;&#x201C; and they do, because the laws of physics do not change!

When a DC voltage is applied across the terminals of a brushed motor, a potential difference is achieved and current is induced into the windings on the rotor. The brushes allow this current to flow through a rotating mechanical switch called a commutator. Download the paper: https://goo.gl/aYPUe1

www.micromo.com â&#x20AC;˘ marketing@micromo.com

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Turn Machine Data into Revenue with Digital Manufacturing Joe Lin | General Manager, NEXCOM’s IoT Automation Solutions Business Group

Machine markers are exploring new ways of utilizing digital manufacturing to better serve manufacturing clients. Using machine data, digital manufacturing can increase energy savings, production efficiency, and productivity for manufacturers while raising the value of industrial machines and creating revenue-generating services for machine makers. To expedite the digital adoption, the role of industrial machines must expand from machine control to machine-to-machine communication and real-time data integration.

This article considers a complete Industry 4.0 solution based on NEXCOM’s PC-based controller NIFE 105 featuring Intel® Atom® processor x5-E3930. The solution can equip the next generation of industrial machines with computing, control, and connectivity functions. The solution can interoperate with legacy standalone industrial machines by breaking information silos imposed by industrial communication protocols and connect industrial machines across the factory floors and all the way up to the cloud to allow for machine-to-machine communication and real-time data integration, catalyzing the convergence of operational technology (OT) and information technology (IT).

In a predictive maintenance scenario, the NIFE 105 solution can maintain a log to track the health of industrial machines, email or text client service engineers a summary report through web services at regular intervals, and notify the engineers when a monitored parameter falls outside a specific range. Machine makers can further incorporate 3rd-party machine learning tools to refine predictive maintenance models, or using data visualization service platforms to create a virtual war room in which data is plotted as comprehensible charts and diagrams. Standalone industrial machines can also benefit from the NIFE 105 solution. With a broad support for fieldbus and proprietary protocols, the solution can harvest machine data encapsulated in fieldbus frames and convert the data into TCP/IP packets so the machine data can be recognized by cloud service platforms for further analysis and archive. As Industry 4.0 illuminates the direction for future industrial transformation and innovations, machine data can help machine makers elevate customer satisfaction and generate recurring revenues with value-added after-sales services and push production growth for manufacturers. Register to download the paper at: http://www.controleng.com/index.php?id=17119

input #21 at www.controleng.com/information

liyinlin@nexcom.com.tw www.nexcom.com

How to Modernize Your Factory on Your Terms Jim Wilmot | Controls Product Manager, Siemens Underperforming automation systems can compromise productivity and profits Downtime is a plantâ&#x20AC;&#x2122;s #1 enemy. Thus, many manufacturers are contending with outdated or insufficient automation systems and components that are compromising productivity. The time to modernize is now! But manufacturers may still hesitate to invest in their automation systems because they fear downtime during changeover, the need for more staff training, having to convert existing code or taking a hit to their budgets.

To avoid these challenges, manufacturers should seek automation solutions that have integrated functionality and are engineered to migrate seamlessly into future technologies to lower their total cost of ownership. These solutions should be based on a single engineering framework that seamlessly integrates controllers, distributed I/O, HMI, drives, motion control and motor management using a common database as well as integrated security, safety and diagnostics. Is staying with your current vendor the best choice? While it may seem like the least painful route is to upgrade components from a current vendor, it may not be the best option for manufacturers. Many vendors have dead-ended or are phasing out legacy hardware, and no spare parts are available.

Some vendors may offer more advanced versions of obsolete parts, but manufacturers may still need to convert their code to new programming software. A total systems approach or individual component replacement? Manufacturers have two options when deciding to modernize their production: a total systems approach or individual component replacement. A total systems approach is best for manufacturers that want the full benefits of totally integrated automation â&#x20AC;&#x201D; a necessary step to integrating your entire value chain, from design and engineering, to sales, production and service. When total replacement is not feasible, manufacturers should seek advanced automation components that can easily integrate with existing systems while providing additional functionality. Doing nothing can compromise your competitiveness When it comes to modernizing, manufacturers have installation options to match their production and budget requirements â&#x20AC;&#x201C; enabling more informed decisions for greater flexibility and competitiveness.

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

www.industry.usa.siemens.com/topics/us/en/modernization/resources/Pages/Modernize-White-Paper.aspx input #22 at www.controleng.com/information

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Webcasts

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12/9/2016 4:25:01 PM

Control Engineering Webcasts help you obtain educational information on specific topics and learn about the latest industry trends. Check out some of our Webcasts on topics like: • Choosing sensors for the application • lloT series: OT/IT convergence, collaboration • lloT series: Edge, cloud, fog computing • lloT series: Maintenance optimization • System Integration case studies • lloT series: Network integration, cyber security • Motors and drives • Human-machine interface hardware, software

COVER STORY mobility answers

System integration of mobile controls and monitoring: Questions and answers Reliable wireless capabilities are facilitating mobile monitoring and control. Experts explain why and how mobility helps automation and control applications.

obile monitoring and control capabilities are being integrated with automation, controls, and other plant-floor systems. Below, a panel of experts answered questions about wireless automation and control. The experts are: Daniel E. Capano, CWSP, CWNA, GROL, Diversified Technical Services Inc., of Stamford, Conn. Capano also is a Control Engineering Editorial Advisory Board member. Robert Jardel, controls engineer, and John G. Neil, assembly and service foreman, Garvey Corp. Travis Cox, co-director of sales engineering, Inductive Automation Barbora Plaminkova, marketing director, mySCADA Technologies, whose myMobile software won a 2017 Engineers’ Choice Award in the Software—Mobile apps for controls, automation, instrumentation category.

ADVICE KEY CONCEPTS Mobile monitoring and controls can be integrated with others systems. Such mobile integration requires attention to security. Benefits include greater access to data so it can be used as information. GO ONLINE See the wireless and mobility pages at www.controleng.com under networking and information management pull-down tabs. Link to a prior cover story: Integrating wireless with wastewater. CONSIDER THIS How could mobile control, monitoring, or data entry help your processes?

APRIL 2017

CONTROL ENGINEERING

Control Engineering (CE): Please give at least one application example where mobile technologies (mobile industrial computers, tablets, smartphones) are used or being considered for monitoring or control. Capano: The Stamford Water Pollution Control Authority (SWPCA) of Stamford, Conn., is considering the use of tablets to facilitate mobile monitoring of plant operations. This obviously will happen wirelessly and after the wireless infrastructure expansion, following the supervisory control and data acquisition (SCADA) upgrade. Jardel: Garvey is using mobile technology throughout its facility. I was brought on almost a year ago to help bring Garvey’s controls work inhouse. In addition to the need to support Garvey customers, other things needed attention. Historically, assemblers and technicians would manually collect data while testing product performance. This information then would change hands and travel through multiple departments, sometimes this information is time-sensitive, further complicating the process. Garvey employees would have to walk back and forth to the Mobility software, such as myMobile from mySCADA, can be used in many ways. The best example is the visualization of the hydropower plant as shown. Courtesy: mySCADA www.controleng.com

Showing tablet use at Garvey Corp., from left to right in the photo: Craig Thompson, technician; John Clark, technician; John Neil, assembly manager; Robert Jardel, controls engineer; and Bill Chatterton, engineering manager. Courtesy: Garvey Corp.

main panel to adjust variable frequency drive (VFD) speeds and then would have to return to the machine to monitor the product. If the speed didnâ&#x20AC;&#x2122;t work they would have to return to the panel. The solution was simple: reprogram the programmable logic controller (PLC) and give employees an Apple iPad. Now, employees can change speeds on the fly while standing at the machine; what was traditionally a two-person job can now be performed by one technician in one-tenth the time. In addition to ease of use; when they finally dial in the correct speeds, with a click of a button that information is made available on the Garvey network to everyone, including engineering, proposals, and sales. Neil: With such a repeatable and user friendly system in place at Garvey, the documentation needed to improve the accuracy of machine designs is now readily available. Cox: The best example of mobility is an application that provides a service to golf courses, sports stadiums, resorts, public parks, and more, with the ability to monitor and control their irrigation systems and pump stations. In this case the data is all remote, and no one is close to the PLCs. The PLCs communicate over a cellular network to a centralized system and the only access operators have is a mobile phone. With this application, they can monitor the current status, alarms, trend www.controleng.com

historical data, and more. We see a lot of customers use mobility to monitor remote devices and provide a service. Another example has to do with troubleshooting problems on a factory floor. We have seen customers use their smartphones to not only get important machine information but can communicate with others and share video footage of the process. Usually these applications deal with monitoring data and not so much control (since security is a big concern). Plaminkova: Mobility software can be used in many ways. Visualization of hydropower plant (photo) gives the possibility to control production from anywhere, and that saves money. (No one has to be there personally. If anything happens, the system automatically sends an SMS/email to a mobile tablet and the operator, manager, or owner immediately knows that something is going on). It also saves time because no regular controls are needed. The owner of this hydropower plant used to drive to the location to check if the plant was working correctly. CE: What are (or were) the achieved or expected benefits?

â&#x20AC;&#x2DC;

With a tablet, employees can change speeds on the fly while standing at the machine; what was traditionally a two-person job can now be performed by one technician in one-tenth the

â&#x20AC;&#x2122;

time.

Capano: It is believed that the use of mobile devices will result in savings from the elimination of lost time by at least half. The ability to find operations and maintenance (O&M) CONTROL ENGINEERING

APRIL 2017

| 33

COVER STORY mobility answers

‘

Return on mobility investment on a more up-to-date control system is weeks to months, for a web-enabled HMI and some engineering time to set it

’

up.

data on an internal server from the field, and then locate a part in inventory, would be one of the ways this would be accomplished. This is also expected to give the operators the ability to monitor and eventually control plant processes in real time, allowing faster response to anomalies or emergencies from practically anywhere. Security and access control will be accessible from the mobile device. Jardel: John Neil worked on this mobility project with me day in and day out. As you might imagine, presenting it to upper management and sales didn’t go over well at first. Why? The obvious reasons: “Don’t fix something that isn’t broken,” “We have always done it this way,” and “It’s going to cost how much!?” We finally got everything approved, and within minutes Garvey technicians were on board. Within days the rest of the engineering staff had subscribed, and within weeks, the sales team was trying to offer this to customers as part of a standard package.

tion from anywhere, which brings a valuable advantage. Example: When a solar plant is overloaded, it automatically shuts down. If that happened, there was no production of the plant until someone went to the location and checked it. That delay could never happen with mobility software because the system notifies if there is an accident. CE: Should these assets be integrated into existing automation and controls, or communicate data or information in other ways and why? Capano: These devices would be integrated into the existing system using a new or existing wireless infrastructure based on open standards, inside the fence line. Outside the fence line the only option would be cellular, though any WiFi connection would allow a VPN connection back to the plant.

Cox: The biggest benefit is the BYOD (bring your own device) mentality. Everyone has a smartphone and wants access to the data. It also allows people who need the data to view it quickly.

Jardel: Absolutely, as mentioned, mobile capabilities make any process that involves an operator seamless. The panel isn’t always located in the most user-friendly area, which makes this technology extremely useful. Return on investment (ROI) for something like this is weeks to months. The end user is essentially looking at the cost of a web-enabled HMI and some engineering time to set it up. (That estimate is based on use of more up-to-date control systems; legacy systems would take a bit more work.)

Plaminkova: As mentioned, the most important benefits are the time and cost savings, and the possibility to control the produc-

Cox: For security reasons these assets should communicate information using middleware (like MQTT, which is message queueing teleme-

Neil: In the long run we expect the use of the mobility system to increase the efficiency of our customers’ daily operations as well as the repeatability and accuracy of packaging machine lines.

Table: Cost comparison: Wired and wireless links for SWPCA 330 ft wired link in trench

330 ft wireless link

Excavation 140 yds

$6,500

Design/site surveys

$2,500

Saw cut 300 ft pavement

$3,000

Access points: 2 @ $800

$1,600

Stone base

$1,000

Electricians: 1 day @ $1,120/day

$1,120

IT configuration

$1,200

WIRELESS GRAND TOTAL

$5,420

Backfill

$4,500

Patching

$3,500

Conduit and cable

$500

Router and accessories

$600

Electricians (5 days @ $1,120/day)

$5,600

Design, management, IT, misc.

$5,000

WIRED GRAND TOTAL

$30,200

Setting up a wireless infrastructure may be less hassle than imagined, and wireless access points are more economical than running wires, as previously shown in this SWPCA table. Courtesy: Stamford Water Pollution Control Authority

APRIL 2017

CONTROL ENGINEERING

www.controleng.com

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COVER STORY mobility answers try transport). They shouldn’t talk directly to the automation or controls systems, especially if we want to get this data from anywhere (not just on the plant floor).

from being able to see your data. However, control brings up a lot of security concerns especially when leveraging the cloud. Companies also have to provide the infrastructure to enable mobility.

Plaminkova: This application is already integrated into the industrial and home automation industries. There is the possibility to monitor and control the production, see the trends, and adapt with them to get ahead of competitors.

Plaminkova: Mobile and tablet usage is very common in everyday life. We believe that controlling power plants and production lines or anything else could be part of everyday life for anyone who wants to spend less time in the office or factories but still needs a general overview of the technology.

‘

Mobility software is expected to give the operators the ability to monitor and eventually control plant processes in real time, allowing faster response to anomalies or emergencies from practically anywhere, with security and

’

access control, from a mobile device.

CE: To what degree should mobile monitoring and control be integrated with other systems and how? Capano: Mobile monitoring and control should be implemented in addition to a conventional control system, not as a replacement. Wireless is the obvious medium for integration. Jardel: Security is always a concern; however, remote monitoring at these levels pose little risk to the end-user. Security clearance levels can be implemented, restricting certain information to management. Most HMI software offers radio buttons that with a click can configure these settings. Additionally, access can be restricted to a local network, further reducing security risks. Maintenance also will benefit from mobile monitoring; operators can have access in real time to their equipment. Any business owner knows that when a machine is running it’s making money; if the machine is not running it’s costing money. Imagine if an operator would get an alert to their mobile phone saying sensor-100 has lost communication, then walks over to find it had been hit by a fork-lift, and within minutes the sensor is swapped out, and the machinery is back up and running. Cox: Data collection and monitoring is a perfect application for mobility. The risk is lower since the information is read-only. There is a huge benefit

APRIL 2017

CONTROL ENGINEERING

CE: What other advice would you offer subscribers about system integration of mobile monitoring and controls? Capano: Do your homework. Use only open standard devices and systems; avoid proprietary systems unless you are going to install a complete vendor solution throughout. Otherwise, stick to open standards to allow for future expansion and greatly reduced costs. Proprietary equals excessive cost/complexity. Jardel: I would say to any controls engineer thinking about implementing this technology to dive in with both feet. We are part of a generation that wants information immediately. With that mentality in our next wave of managers, we need to be ready to meet their needs. This technology is going to be the rule and not the exception in the years to come. If sales representatives spend time learning about the added benefits to remote monitoring and control, and are on the front line, they can speak intelligently on the subject, and the end user may be more inclined to use mobility technologies in the plant. Most customers aren’t even aware that this technology exists let alone that they could potentially put it to use in their facilities. Cox: The best advice I can give is “think security first.” Make sure you are not exposing yourself to risk in attempting to get data to more people. Use middleware such as MQTT that provides transport layer security (TLS) and access control lists. Make sure the data is being sent up and is read-only in most cases. You don’t want devices talking to the plant floor directly. Plaminkova: Do not be afraid to use this modern way of monitoring and controlling. The technology (applications and so on) is ready for that, so take advantage of it, and be one of the pioneers. ce Mark T. Hoske is content manager, Control Engineering, CFE Media, mhoske@cfemedia.com. www.controleng.com

Cole Warner Automation Systems Integrator Gettle Incorporated

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MACHINE VISION artificial intelligence

Artificial intelligence and its impact on machine vision Artificial intelligence (AI) for machine vision will allow AI to think more like humans by employing deep learning techniques and other functions that humans use to develop their brains.

hen the concept of “thinking machines” emerged in the 1950s, alarmist warnings about this new field of artificial intelligence (AI) soon followed. The fear of the rise of the machines has played out in pop culture ever since, from the iconic 1968 film “2001: A Space Odyssey” to “Ex Machina.” While AI still hasn’t taken over society, improvements in data storage and processing power Artificial intelligence and have enabled the development of a lot of samples can define cognitive systems like IBM Watson that are designed to take the what is a good part and guesswork out of decision-making human. Most current iterawhat isn’t. tions of AI tackle more modest tasks like object recognition. The promise of AI looks to enable machine vision to take on challenging applications beyond the capabilities of today’s solutions. But is the technology ready for use in industrial applications?

‘

’

Testing the AI waters

ADVICE KEY CONCEPTS Artificial intelligence’s (AI’s) applicability in machine vision relies on the affiliated branches of machine learning and deep learning, AI’s development will help the technology move beyond machine vision and industrial automation, and be used for new tasks that haven’t yet been considered. The largest manufacturers need to lead the way for AI to become common across the industry. GO ONLINE Read this story online at www.controleng.com for additional stories from the AIA and other groups affiliated with A3. CONSIDER THIS What other benefits can AI provide manufacturing, and what will that mean for productivity and labor?

APRIL 2017

AI’s applicability in machine vision relies on the affiliated branches of machine learning and, more so, deep learning. At its broadest level, AI is a computer’s ability to simulate human intelligence. Diving deeper, machine learning gives computers the ability to act without being explicitly programmed. Deep learning, a subfield of machine learning, enables computers to learn from experience. Several developments over the past decade have made deep learning a reality, not just a possibility, for machine vision. “Based on new techniques in neural networks, sufficient computational power in GPUs [graphics processing unit], and an abundance of data, only now can we use artificial intelligence for image processing,” said Olivier Despont, business development at ViDi Systems, a Swiss maker of deep learning-based vision software. Deep learning holds promise over traditional machine vision because, unlike traditional image processing software that uses a rules-based approach. “AI is the next step where we take things that are not easily characterized or non-linear and

CONTROL ENGINEERING

give them to the machines to create that next level of repeatability,” said Wallace Latimer, sales director, customized optical systems at FISBA LLC. “Whereas linear algorithms create a very narrow bucket, AI/deep learning creates bigger buckets that can accept more variation,” Latimer continues. “It’s widening the acceptance band of what is good or bad, and why it’s good or bad. By having the bigger bucket, you can focus on what offers the biggest bang and reduces changes to inputs.” At least one deep learning system is on the market for machine vision users today. ViDi Suite from ViDi Systems is the first commercially available deep learning-based industrial image analysis software. The software, which integrates with standard image processing libraries, learns like a child does. “You don’t teach a child using a rules-based approach by explaining what a house is,” Despont said. “Based on few examples, our brains, even at a young age, are able to extract what makes a house. Our system works the same as the human brain.” ViDi Suite is comprised of three different tools. ViDi Blue finds and detects single or multiple features within an image. The tool localizes and identifies complex features and objects by learning from annotated images. ViDi Red detects anomalies by learning the normal appearance of an object, including its variations. The Red tool also segments specific regions in images. ViDi Green learns to separate different classes based on a collection of labeled images to classify an object. Another advantage of deep learning over traditional machine vision solutions is that it can reduce the time necessary to develop a machine vision program. “With the classic vision approach, many applications need 60-plus days of software development and feasibility,” Despont said. “ViDi can complete development in half a day.” Unlike AI systems that use server farms to power their software, such as ones that have been developed by Facebook, Google, and IBM, ViDi uses a single high-end NVIDIA GPU to train the system in a matter of minutes, rather than the days or months it takes to program and parameterize with IBM Watson, according to Despont. “And instead of using millions or billions of www.controleng.com

images, we recommend starting with 30 to 50 representative good images to teach the system,” Despont said. “We’re not sending images to a cloud-based server farm to do the processing or training. Customers are happy they can run everything on a single PC with one GPU and keep ownership of their images.” Opportunities and challenges

Deep learning shows particular promise in applications that present challenges to traditional vision systems. “AI is really suitable in food inspection among others where you want to inspect donuts or a piece of meat that shows significant difference from one instance to another,” said Bruno Ménard, software program manager at Teledyne Dalsa. But it’s not just organic inspection applications that will benefit. Ménard cites traditional defect detection applications as another example. “It’s difficult to program a computer with traditional algorithms to define the defect without having to redo the settings every time there is a new defect,” he said. “But by using artificial intelligence with a lot of samples, you can end up with a really good definition of what is a good part and what isn’t.” As AI emerges in machine vision, the technology will find a place in additional inspection tasks and eventually extend beyond the realm of industrial automation. According to Latimer, deep learning will be advantageous in markets such as medical, life sciences, food, counterfeit inspection, and lumber grading. “These are areas that all have very gray decision points,” said Latimer. “Is that apple good enough or not? That’s hard to make a linear rule to say it is. Deep learning should enable a lot of applications to become much more efficient and repeatable.” For his part, ViDi Systems’ Despont foresees that deep learning will include medical diagnostics, surveillance, autonomous vehicles, and smart agriculture for inspection or map analysis. “AI is the future and will be helping people solve some complex tasks very quickly as computational capabilities are doubling almost every one-and-a-half years,” Despont said. Many machine vision professionals recognize the promise that AI and deep learning offer to the vision industry, but they say AI’s full potential won’t be realized for at least another three to five years. What’s more, AI isn’t necessarily the solution for everything that ails traditional vision and image processing. Ménard noted two major drawbacks in AI systems. “First, you need a lot of training ... and you need to create the expert to reach the next level of classification,” he said. “The second drawback is once it’s trained and the classification fails, it’s difficult to fix the problem. You have no choice of retraining with a new sample.” Before artificial intelligence becomes commonplace in machine vision, industry experts believe the industry will have to let much bigger players do the heavy lifting. “From our niche segment, we’re getting to watch the Googles of the world drive this technology to incredible levels of investment and refinement,” Latimer said. “Our industry cannot invest the time and money at the necessary scale. We’re going to have to leverage it.” ce Winn Hardin is contributing editor, AIA. The AIA is a part of the Association for Advancing Automation (A3), a CFE Media content partner. Edited by Chris Vavra, production editor, Control Engineering, CFE Media, cvavra@cfemedia.com. CONTROL ENGINEERING

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CYBERSECURITY control systems

Building an ICS cybersecurity ecosystem Companies, governments, and vendors need to develop a cyber ecosystem that encompasses more than the four walls of an organization to help mitigate threats that become more sophisticated daily.

ADVICE KEY CONCEPTS Cybersecurity attacks against industrial control systems (ICSs) are growing in volume and nature. Corporations and government organizations must collaborate to develop critical infrastructure protection solutions that do more than meet the minimum requirements. Cybersecurity solutions must enable organizations to understand and provide awareness of how people interact with their systems. GO ONLINE Read this story online at www.controleng.com for additional stories about cybersecurity and ICSs. CONSIDER THIS What else can be done to improve the cybersecurity ecosystem for ICSs?

APRIL 2017

overnment organizations, private companies, and public-private partnerships that operate critical infrastructure are facing significant security risks as attacks against industrial control systems (ICSs) grow in volume. Control systems are becoming more interconnected and Ethernet-based architectures are more common for companies, despite their increased potential security risks. ICSs are an integral part of critical infrastructure that facilitates operations in vital industries that people rely on every day. Developing a cyber ecosystem that encompasses more than just the four walls of a company is critical in mitigating a threat that grows daily. Threats and cyber incidents—malicious or accidental—occur every day on industrial control networks. It is easier than ever to exploit vulnerabilities in industrial protocols, networks, and equipment. The past six years should have been a wakeup call to the industrial automation industry. ICSs became the primary target for these cyberattacks such as Stuxnet, Night Dragon, and Shamoon. The increased volume of attacks demands more effective operational cyber solutions that aggregate, analyze, and correlate data across multiple platforms into a near real-time visualization that depicts any potential threats that are emerging. Organizations have to look beyond their own perimeter and collaborate with their corporate partners, suppliers, and vendors on the potential impact of a cyberattack. However, these complex systems of interacting devices, networks, organizations, and people make it a potential threat as well as a benefit. Corporations and government organizations must collaborate to further develop critical infrastructure protection solutions that do more than meet the minimum requirements. Solutions must be targeted to the professionals tasked to keep critical infrastructure operating as well as make the business case that risk is mitigated. In the past, communication protocols and an isolated environment made ICSs largely immune to the malicious

CONTROL ENGINEERING

attacks that targeted corporate information technology (IT) networks. As systems become more interconnected, though, achieving end-to-end security has to be a multi-vendor, organizational effort that creates cyber ecosystem. Fashioned and specialized threats developed by skilled cybercriminals, hacktivists, and governments are turning their focus toward critical infrastructure and their ancillary systems more than ever before. The effects of these attacks go far beyond the perimeter of the intended targets, which makes security more important than ever. The U.S. Department of Homeland Security (DHS) has identified three core principles for developing cyber ecosystems: Automation, interoperability, and authentication. Automation – enabling rapid incident detection and response. Automation is a strategy that incorporates making decisions with specified actions as a response to cyber situations at machine speed instead of human response speed. Interoperability – enabling distributed threat detection across devices. Interoperability must remove the technical constraints from organizations, so that they collaborate seamlessly in cyber defense automation. Authentication – enabling trusted communication for automated collaboration in a secure manner. As automated decisions are made, authentication provides the assurance that the partners involved are authentic. Maintaining ICS integrity requires a thorough understanding of the communication standards used for various ICS components to maintain safe and efficient operations. In this cyber-physical layer, it can be difficult to spot communications errors, cybersecurity threats, and poor network health problems. Symptoms are obvious: sluggish human-machine interface (HMI) updates, unexplained shutdowns, and precarious failures of ICS components. A robust and healthy operational technology (OT) network is key to preventing these failures. www.controleng.com

There is a growing demand for many ICSs and sensory data to communicate with other commercial and enterprise level systems across the corporate network. This brings new risks and challenges that owners must face and mitigate against. There is so much data for them to sift through and there is a lack of skilled labor to help them process it, which means workers who are not qualified become an inadvertent cybersecurity risk. Initial reports of cyber attacks to the ICS go back more than 15 years. Since then the total volume has been exponential in growth and is much higher than the news reports ascertain. Widespread doubts and loss of public confidence towards these private and public entities results in deliberate suppression of information about attacks. Poorly disseminated public information would cause knee-jerk responses and solutions that may not be best. Reporting cyberattacks to regulators and support organizations is a more sensible option. This helps create solutions, mitigate the risk of future attacks, and develop stronger defense strategies. Security designed from inception

Historically, with security as an inconsequential concern, cybersecurity wasn’t designed and implemented into an ICS. It has to be integral to any project. The critical infrastructure sector must work closely with owners, industry, integrators, regulators, and vendors so effective cybersecurity measures can be integrated into the ICS from the start. The industrial sector needs to stop thinking of security as something to implement after the systems are installed. Security needs to be designed at the outset and managed at all layers across the enterprise. The most critical cyber component in ICSs are the devices and ICS cybersecurity should be focused on ensuring that the devices are safe. Cyber threats targeting the ICS are changing and growing as cyberattackers are always looking for new targets and criminal extortion is increasing. ICS security is no longer about preventing hackers or having a strong physical perimeter. An underground digital economy provides a multibillion dollar incentive for potential corporate rivals or adversaries to exploit ICS vulnerabilities. More companies will be required to detail the approach they take to cybersecurity and detail what analysis and assessment they undertook for their technology vendors and service providers. Governments are realizing that cybersecurity is one of the most serious economic and national security challenges they face and are escalating their efforts to protect critical infrastructure vulnerabilities. Initiatives by ICS vendors to reduce security risks to control systems is resulting in automation www.controleng.com

professionals being more effective in securing their industrial processes through a combination of control system design and best practices, technologies, and professional services. As the ICS represents the core of production, the cybersecurity processes must address both internal and external threats via multiple layers of defense that mitigate against various types of risk. ICS vendors and automation professionals must be committed to providing an evolving set of products and services that help mitigate risks and improve security of the production assets. The solution also must include risk analytics that assemble and correlate data in a platform that provides actionable visibility into cybersecurity blind spots.This drives effective cyber risk management and creates a stronger cybersecurity posture. Solutions must enable organizations to understand their current business environment and provide contextual awareness of how their employees, supply chain, customers and attackers interact with their control systems, data, facilities and applications. In a globally intertwined world, the threat can and does come from everywhere.

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The need for performing vulnerability assessments periodically must be understood by organizations for the value

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they provide.

Cybersecurity, part of the culture

Traditional cybersecurity approaches are necessary but not sufficient to properly protect organizations. Organizations must be pushed to invest in best in class technologies, understand their ecosystem and work with trusted partners to protect the ecosystem together. The need for performing vulnerability assessments periodically must be understood by organizations for the value they provide. This allows a company’s staff to see the business process—and the applications and data that support it—as well as map the infrastructure that connect the hardware. ce

Anil Gosine is global program manager at MG Strategy+ is a CFE Media content partner. Edited by Chris Vavra, production editor, Control Engineering, cvavra@cfemedia.com. CONTROL ENGINEERING

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ASSET MANAGEMENT industrial internet

Connecting controls helps manage assets A winning industrial internet strategy starts with connected controls to help systems use more asset data, dynamically adapt in real-time to changing business conditions, and automatically upgrade as needed for better cybersecurity. Advantages include productivity gains of 22% and a maintenance cost reduction of 40%.

W MORE

ADVICE KEY CONCEPTS Traditional control systems unable to dynamically adapt in real-time to changing business conditions. New internet-based control systems enhance connections, ease upgrades, and ensure the latest cybersecurity updates are in place. Applications bring added capabilities like smartphone apps.

ith the rise of the industrial internet, the pace of technological advancements has accelerated significantly, and initial tests of more interconnected controls show productivity gains of 22% and a maintenance cost reduction of 40%, among other benefits. Why the hesitation? Advancements are outpacing control system upgrade cycles. Today, the average traditional control system only can use about 3% of data from industrial assets and is unable to dynamically adapt in real-time to changing business conditions. Out-of-date systems also often cannot automatically upgrade internal software and security patches. Risks include productivity loss, security, and system integrity. To gain and maintain a competitive edge in this new era of software-defined machines, it is no longer enough for a control system to keep a machine running reliably. Machine-level controls need to be smart enough to collect and process data locally and be connected. Connected controllers, like connected people, can take more intelligent actions. Predictive models, optimization

GO ONLINE See the IIoT page at www.controleng.com. Find more information with this article online.

The good news is that the industry is beginning to see a new era in controls, where instead of

one application running on a controller, dozens of apps all can run simultaneously. These could be machine apps like digital twins, that embed detailed engineering knowledge into predictive models, and real-time optimizers that determine the optimal way to run assets. Such apps require more horsepower, more flexibility, and more connectivity than traditional control systems can provide. To enable these advanced capabilities, control systems are being developed for the age of the industrial internet. Piloting internet-based controls

For instance, a recent pilot program for the new internet-based control system connected machines such as gas turbines and MRI machines to cloud-computing capabilities. This has dramatically increased the amount of data captured and can deliver 1,000 times more computing power than standard control systems. By combining the power of data analytics and real-time control at scale, IICS helped improve assetsâ&#x20AC;&#x2122; performance by 7% and productivity by 22%, reduce maintenance costs by 40%, and increase network and asset security.

Connectivity apps

For instance, a secure health cloud platform uses advanced controls technology from an automation and controls company. The platform collects

GEâ&#x20AC;&#x2122;s Field Agent Technology is being deployed by GE Healthcare to boost operating room efficiency. In a recent pilot program for the new GE Industrial Internet Control System (IICS) connected machines, such as gas turbines

CONSIDER THIS Would a 1000x increase in control system computing power with more connected systems increase your productivity more than 20%?

and MRI machines to GE Predix Edge and Cloud computing capabilities. GE Healthcare developed a secure health cloud platform using advanced controls technology from GE Automation and Controls. The platform, named Carestation Insights, collects data from anesthesia machines, analyzes trends, and uncovers insights that improve patient care and boost operating room efficiency. Courtesy: GE Automation & Controls

APRIL 2017

CONTROL ENGINEERING

www.controleng.com

data from anesthesia machines, analyzes trends, and uncovers insights that improve patient care and boost operating room efficiency. Among customers using the system is the Department of Anesthesia at the Canterbury District Health Board in New Zealand. Benefits include reduction of fresh gas flow rates, which has a myriad of positive benefits including financial, ecological, and clinical. This new era of controls brings an emergence of the industrial app economy. Because industrial internet-enabled controllers can run multiple apps simultaneously, benefits are increased. The industrial app economy will spur innovation by enabling a more seamless environment for people and machines to work smarter and more efficiently together. As machines and people become more interconnected, machines will begin to use apps the same way as consumers do, to improve health, boost productivity, learn from each other, and more. Existing apps: Allow wind turbines to talk to each other and coordinate the way they change blade pitch as the wind changes to maximize wind farm power output.

Tell jet engines how to reduce fuel consumption. Check the health of gas turbines and predict when a fault is likely to happen to allow intervention with preventive maintenance. Allow doctors and nurses to schedule medical procedures more efficiently and collaborate in real-time on patientsâ&#x20AC;&#x2122; diagnoses, curing people better and faster.

â&#x20AC;&#x2DC;

With industrial internet-enabled controllers, intelligence can interface safely and securely with the brains of industrial equipment, control systems, enabling equipment and processes to act more intelligently and dynamically in response to changing conditions. Unlocking the value of the industrial internet begins at the machine level with a connected control system. ce Rob McKeel is CEO of GE Automation & Controls. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media, mhoske@cfemedia.com.

input #27 at www.controleng.com/information

This new era of controls brings an emergence of the industrial app economy. Because Industrial Internet-enabled controllers can run multiple apps simultaneously, benefits are

â&#x20AC;&#x2122;

increased.

PROCESS CONTROL adaptive motion controllers

Motion controllers can adapt themselves Adaptive motion controllers can be modified to a controlled process’ behavior, among other controlled process benefits.

very feedback controller is adaptive since it can change its control effort in response to a change in the error between the measured process variable and the desired setpoint. A true adaptive controller, however, also can adjust its individual control efforts, and its underlying control strategy. It can tune its own parameters or otherwise modify its own control algorithm to accommodate changes in the behavior of the controlled process.

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An adaptive motion controller can maintain tighter control over a process that experiences variable sensitivity like a robot with variable load weights.

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ADVICE KEY CONCEPTS The abilities of adaptive motion controllers. How adaptive motion controllers detect motion control behavior. How controllers detect performance. GO ONLINE For related links about motion controllers, read this article online. In the digital edition, click on the headline or search for the headline on www.controleng.com CONSIDER THIS What kind of applications would benefit most from using adaptive controllers?

APRIL 2017

An adaptive proportional controller, for example, might adjust its gain when it observes that the process started to respond to its control efforts too quickly or too slowly. This could help maintain tighter control over a process that experiences variable sensitivity like a robot with variable load weights. For example, if a particularly heavy load were to slow the robot’s movements, an adaptive, proportional-only controller could compensate by increasing its gain. Conversely, it could decrease its gain if its control efforts became too aggressive after the load was lightened. Either way, the controller has to be able to measure its performance to determine which course to take, if any. It could weigh the load directly, time how long it takes to move the load from point A to point B, or measure how far the arm overshoots along the way. Unfortunately, adaptive controllers are generally slow about detecting changes in the behavior of the controlled process since long-

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term changes easily can be masked by, or confused, with short-term disturbances. A long history of control efforts and process variable measurements is generally required to distinguish between short-term and long-term effects. And even when a bonafide change in the process’s behavior is finally detected, it’s not always obvious how the control algorithm should be altered to compensate. Other objectives for adaptive motion controllers

Despite these challenges, adaptive motion controllers also can optimize the trajectory that the controlled process follows to reach its destination. This is especially useful in applications where overshoot is undesirable, as explained in the previous robot control example. Once the controller has learned how the robot responds to control efforts, it can compute the final command required to move the arm to the desired position, as well as the sequence of commands required to get it there without having to reverse course. The mathematics required to accomplish this artificial learning can be extremely complicated, and no single algorithm has emerged as the superior choice. However, some variation of online modeling usually is employed where the controller calculates a mathematical equation that relates recent changes in the process variable to the control efforts that caused them. Once the process model is in hand, the controller then can adjust its control algorithm to produce the desired closed-loop behavior under the assumption that the recent behavior embodied in the mathematical model will adequately predict future process behavior as well. ce

Vance VanDoren, PhD, PE, is a Control Engineering contributing content specialist. Edited by Emily Guenther, content manager, Control Engineering, CFE Media, eguenther@cfemedia.com. www.controleng.com

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INSIDE MACHINES regeneration

Matrix drives reduce energy consumption for transporter system Inside Machines: Industrial matrix drives were used for a transporter system retrofit to reduce energy consumption and costs by creating a more maintenance-free mechanically integral distribution system. New system regeneration capabilities for two motors saves an estimated $1,500 per year.

material handling application will be regenerating about $1,500 per year in electrical savings rather than dissipating braking energy as heat. Other savings are expected with a simpler design expected to require less maintenance. In spring 2016, Maxam Inc. and Yaskawa America Inc. developed an asphalt transporter system for Gallagher Asphalt in Thornton, Ill. The transporter system is a fully integrated asphalt distribution product that is designed to load and evenly distribute asphalt into individual load out silos. The Gallagher Asphalt systemâ&#x20AC;&#x2122;s motor-driven transporter featured an eight-ton high-speed material transfer vessel and recharging storage vessel. The existing 200-ton asphalt storage silos were retrofitted with the asphalt transported system, replacing a complex system of asphalt material conveyors. Five 40 hp conveyor systems and their inefficient motors were removed The 40 HP U1000 direct ac to ac drive controls the two motor vessel axis. All images courtesy: Yaskawa America Inc.

ADVICE KEY CONCEPTS Matrix drives were used for a transporter system retrofit for Gallagher Asphalt to reduce energy and maintenance costs. The industrial matrix drives operated a multi-motor powered carriage and the transfer vessel power train. The matrix drives reduced energy and maintenance costs for Gallagher Asphalt. GO ONLINE Read this story online at www.controleng.com for more information about the project. CONSIDER THIS How could your motion control applications reduce the energy costs?

APRIL 2017

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INSIDE MACHINES regeneration

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The system is designed to be more energy efficient and provide a more maintenancefree, mechanically integral distribution system.

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and eliminated for the transporter system. The old drag slat—the steel floor in the conveyor—used chains, which required more power in conveyor plate heating than the retrofitted system. The transporter system used two matrix drives. One drive operates the 60 hp, multimotor powered carriage and another 30 hp drive operates the transfer vessel power train. The main carriage has four drive motors and the moving vessel (batcher) has two additional motors. The main carriage and the vessel need to be driven at exactly the same speed. The system is designed to be more energy efficient and provide a more maintenance-free, mechanically integral distribution system. This transporter has been operating since February 2016. The duty cycle requires the motors ramp to full speed in about 1.5 seconds. They will run at speed for about 4 seconds, then ramp down in about 3.5 seconds to stop mode. In about 10 seconds, the system repeats the process. During the fast stop time, the transporter motor’s regenerative load energy normally would be channeled into the The asphalt system distributes asphalt to the six truck load-out silos. The old drag slat used chains, which required more power in conveyor plate heating than the retrofitted system.

APRIL 2017

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INSIDE MACHINES regeneration

The Maxam transporter asphalt mass transfer system is designed for silo loading and used two Yaskawa U1000 industrial matrix drives.

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ac drives’ system braking resistors and dissipated as heat energy. Since the regenerative cycle would occur in about 20% of the total duty cycle time, significant amounts of energy would be lost as heat. The matrix ac drive works for this application because of its control technology. It employs a system of nine bi-directional switches arranged in a matrix to convert the three-phase ac input voltage directly into a three-phase ac output voltage. The ac drive topology eliminates the need for a rectifying circuit, dc smooth circuit, and the optional dynamic braking components usually required for this type of application. The converter uses all three input phases in pulse width modulation (PWM) switching to control output voltage and input current, and it provides regenerative motor control operation. This control is required when the carriage and vessel motors decelerate. This allows the drive to save energy by regenerating the motor’s overhauling energy directly back into Gallagher Asphalt’s power distribution system. This is much more efficient than releasing the motor’s regenerative energy as heat via a traditional ac drive’s dynamic braking option.

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Considerations for the limited MCC panel space, dirty, and wet weather environments along with wide ambient temperature fluctuations are important design criteria for this motor control solution.

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The motor control centers (MCC) for the transporter systems are installed in outdoorrated enclosures. Considerations for the limited MCC panel space, dirty, and wet weather environments along with wide ambient temperature fluctuations are important design criteria for this motor control solution. MCC wiring complexity is simple with the direct ac to ac matrix drive topology. Wiring requires little panel or field installation labor. The drive provides a three-phase power supply input and three-phase output main power supply wiring. The main motor power circuit component count is reduced from several components to one. Using the drive selected allows control panels to be about 70% smaller than the

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INSIDE MACHINES regeneration

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Gallagher Asphalt applied for a Commonwealth Edison utility grant because of the energy savings offered by the

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matrix drive.

The travelling batcher drive is designed for unloading the batch into each loadout silo.

traditional drive with dynamic brake module(s) and resistor(s) solution or a traditional ac drive regenerative power supply. Gallagher Asphalt applied for a Commonwealth Edison utility grant because of the energy savings offered by the matrix drive. Gallagher’s kWh costs are 0.076 cents/kWh. Operation cycle time is 8.5 hours per work day, five work days per week average with 40 weeks a

year of operational time. Approximately 20% of the total run time is spent in regenerative mode. This is 340 hours/year. Assuming each motor is at 100% braking torque during regeneration, the 30 hp drive’s total motor load will yield approximately $500/ year and the 60 hp drive’s total motor load will yield approximately $1,000/year of savings (based on $0.076/kWh) versus the standard and typical solution of using a conventional ac drive solution with the dynamic braking resistor option. ce Mike Grant is a regional drive specialist, Yaskawa America Inc. Edited by Chris Vavra, production editor, Control Engineering, CFE Media, cvavra@cfemedia.com.

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INSIDE MACHINES protecting automation

Customizing electrical enclosures Enclosure cutouts can be made after a purchase. However cutouts made by the manufacturer may help save time and reduce costs.

hen designing control systems for machines, standard or custom electrical enclosures are needed to house automation hardware. The development of these electrical enclosures grew with the use of electricity in the early 20th century. Today’s electrical enclosures support the commercial and industrial markets by protecting a wide variety of automation hardware and wiring from ambient environments. There are thousands of part numbers for different types and sizes of electrical enclosures made from a variety of materials. Selecting electrical enclosure features based on the required size and environmental conditions is the starting point of the design. The design phase includes panel layout, enclosure layout, and thermal considerations to determine how the enclosure must be customized to meet requirements. The main customization step usually is making cutouts in the enclosure, a procedure that can be performed in-house or by the manufacturer (see Figure 1). Customizing the electrical enclosure

In some cases, it can be beneficial to have the manufacturer provide an enclosure with customized cutouts. The types of enclosure cutouts include human machine interface; gauges and meters; pushbuttons, switches, and lights; potentiometers and thumbwheels; and DIN controllers. Cutouts made by the manufacturer reduce end-user labor costs and can improve quality. If the same type of enclosure and cutouts are repeatedly required, as is the case for many OEM machine builders, the manufacturer often can provide a part number to simplify ordering. Cutouts often take significant time to layout, drill, and cut. In many cases, there is little room for error. Crooked or oversized cutouts present a poor appearance and compromise the enclosure rating. Touch-up paint may be required after cutouts are made, further adding time and expense. When a manufacturer makes cutouts, they can use their manufacturing and fabrication facility’s resources to ensure all work is done correctly and www.controleng.com

precisely, and without compromising the enclosure. Precautions for electrical enclosure cutouts

Do-it-yourself (DIY) cutouts can be made in the electrical enclosure after delivery, but this requires several steps. Each cutout needs to be carefully measured and marked (see Figure 2), with care to avoid any scratches, which may require taping. With the cutout’s shapes properly aligned, spaced, and marked—drilling and cutting can begin. Significant time is required to layout and cut the holes. Power tools and special supplies are required. While polycarbonate or fiberglass can be easy to cut, carbon steel and stainless steel enclosures quickly consume cutting blades, and special tools are needed to make large holes. Once the holes are cut, they must be smoothly filed to remove burrs and rough or sharp edges. Cleanup of cutting debris, oil and tape and removal of cutout markings also is required. After cleanup, the bare steel edges, exposed by cutting, must be painted to inhibit corrosion. At this point, the actual panel build and assembly can begin. Despite the care required when making DIY cutouts, this can be the best option if just a few simple cutouts are needed, particularly for polycarbonate or fiberglass enclosures. Another scenario where DIY cutouts are the best option is when the OEM or end-user has significant machine shop resources on-hand for cutting, grinding, and painting. Quicker cutouts for electrical enclosures

To get to the build and assembly stage faster, purchasing a customized enclosure directly from a manufacturer is another option. This does not eliminate the design phase, and cutouts still may need to be added. But it does significantly

Figure 1: This standardsize AutomationDirect enclosure was customized by the manufacturer. All graphics courtesy: AutomationDirect

ADVICE KEY CONCEPTS Electrical enclosure design features. How to customize electrical enclosures. Purchasing a customized electrical enclosure. GO ONLINE For related links about electrical enclosures, read this article online. In the digital edition, click on the headline or search the headline for www.controleng.com. CONSIDER THIS For you, would there be a lower total cost of ownership with ready-to-use enclosures?

CONTROL ENGINEERING

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Bring Your Machine To Life With Connectivity

MACHINES protecting automation

Figure 2: Manually cutting electrical enclosures requires careful layout and measurement, along with the correct equipment and skill set.

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Aerotech can partner with you to design connectivity for your specific application at a minimum price. In our concept machine above, a wireless connection would be made to send command and control information to the wasp and to receive back state information (location, airspeed, and altitude), status information (operation mode: walking, flying, stinging, eating), as well as a feed from the vision system to “see” where the wasp is going. Aerotech can accommodate your custom automation controller needs by creating specific drivers for your communication interface. If you have a need for special connectivity, contact Aerotech today. We customize Aerotech automation for you • Hardware • Software • HMI • Firmware • Packaging • I/O • Motors • Electronics

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Figure 3: The Enclosure Customizer tool from AutomationDirect was used to quickly create this custom cutout enclosure drawing.

simplify the build phase, especially if multiple, duplicate enclosures are produced. Many enclosure manufacturers offer customized enclosures with factory cutouts per each end-user’s or OEM’s specifications. Some of these manufacturers also offer an online graphical configuration utility that can be used to select several cutout types and sizes, which the user can place in one of several standard enclosures. Once the electrical enclosure is designed and the drawings are approved, the next steps that take place are that the customized enclosures are typically cut and fabricated by automated equipment including laser cutting, bending, and welding machines. The enclosures are then painted, and baked in an oven if required The electronic drawings also are typically included. Customized enclosures are built to order and cannot be returned unless they are damaged during shipping. This highlights the need to carefully design the enclosure cutouts. Careful attention to the cutout’s dimensions or using standard cutouts provided by the enclosure manufacturer helps guarantee the customized enclosure meets the design requirements. Figure 3 depicts a customized enclosure design that was created using an online graphical configuration utility provided by a manufacturer. Using standard cutouts and enclosure sizes works for many applications and helps ensure an accurate design that is simple to create. After the design is created, reviewing and approving the customized enclosure drawings is the final step to purchase the customized enclosure. Many steps are required to specify and customize an electrical enclosure. For some end-users and OEMs, it may be advantageous to have the enclosure manufacturer make the required cutouts, particularly if in-house resources are limited. ce Jim Krebs is a technical marketer at AutomationDirect; edited by Emily Guenther, associate content manager, Control Engineering, CFE Media, eguenther@cfemedia.com.

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The Industrial Internet of Things (IIoT) is a transformational strategy that is revolutionizing manufacturing operations across the world. CFE Media publications take an in-depth look at IIoT-related issues, strategies, and opportunities in the 2017 IIoT Webcast series.

The 2017 Industrial Internet of Things (IIoT) Webcast Series: Webcast One: Get your head into the cloud Thursday, April 13, 2017 Automation technologies are converging with information technologies. To handle growing volumes of data generated by IIoT-enabled devices, companies will need powerful data processing capability. Cloud-based environments transform how process-automation projects are engineered and instantiated, replacing client/server. This Webcast focuses on how emergent IIoT technologies change the way process and automation engineers execute projects and sustain productivity in today’s, and tomorrow’s, cyber-physical world.

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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.

DIGITAL EDITION EXCLUSIVES

DE1 Understanding upstream and downstream pipe diameters for flow measurement

While there are some creative ways to get flow meters piped, there are certain installation best practices that should be adhered to whenever possible.

DE3 Achieve proper motor alignment

by detecting and correcting soft foot

A soft foot exists when not all of a machine’s feet sit flat on the supporting base, so that tightening the foot bolts distorts the machine case. This can make a machine difficult to align and result in poor overall machine performance.

ONLINE EXTRAS

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

Researchers developing 3-D printed skin for robots An MIT Computer Science and Artificial Intelligence Laboratory (CSAIL) team is developing a “skin” of sensors on a robot using 3-D printing as a potential cost-effective solution.

Cybersecurity guidance for industrial safety

Different working groups that focus on cybersecurity have faced challenges with securing industrial control and related systems have discussed, debated, and analyzed the issue for a long time and have worked on the problem from many angles because they are so vital to manufacturing.

Energy and fourth industrial revolution happening at same time Ulrich Spiesshofer, chief executive of ABB, said the fourth industrial revolution and the energy revolution are happening at the same time and how their changes are impacting one another as well as the workforce in profound ways.

Three steps to updating your LinkedIn profile for career advancement A LinkedIn profile can help position you for the next step in your career.

Causes of arc flash and arc flash blast incidents Arc flash incidents are common causes of injury in a facility and knowing how and why they occur is a good strategy to prevent them from occurring in the first place.

www.controleng.com

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APRIL 2017

| 57

DIGITAL EDITION exclusive

Understanding upstream and downstream pipe diameters for flow measurement While there are some creative ways to get flowmeters piped, there are certain installation best practices that should be adhered to whenever possible.

ne of the most common issues with flow measurement is an incorrectlysized flowmeter, followed by poor installation. While there are some creative ways to get flowmeters piped, this neglects the fact that there are certain installation best practices that should be followed for each flow meter type and those should be adhered to whenever possible. Incorrect flowmeter installation

ADVICE KEY CONCEPTS There are installation best practices that should be followed and adhered to for each flow meter type. One size does not fit all with flowmeters and there are many options to consider. Use relevant standards and ask questions to get the most out of your flowmeter investment. GO ONLINE Read this story online at www.controleng.com for more information on upstream and downstream pipe diameters, as well as related stories from Cross Company. CONSIDER THIS What other questions should be asked when measuring flowmeters?

DE1

APRIL 2017

After all the trouble you went through selecting the proper meter for an application, why not ensure it’s installed in a manner that will produce optimal measurement results? A lot has changed over the years in terms of flow meter technology; however, you can’t argue with physics. Fluid flowing through a pipe generally assumes a desirable flow profile at or near the center of the pipe. Flow disturbances (distortion and swirl) can occur via improper flow meter installation, thus reducing measurement accuracy. Aside from improper sizing, material incompatibility, and meter misapplication, a number of issues with flow measurement arise from improper piping practices. A lot of time, effort, and money can go into the purchase of a flowmeter. However, it seems that not as much consideration is given to its installation. Perhaps this is due to limited changes that can be made to existing piping (time and expense), the end users having a technology they are not familiar with and making assumptions based on what they have done in the past, or a mechanical contractor having limited experience with various flowmeter technologies, etc. In this case, when talking about improper installation, the focus is on the placement of the meter in the process piping and its relation to valves, elbows, strainers, reducers, and a host of other devices that can be inserted into the piping that can have an effect on the flow profile. There

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are some general guidelines and best practices that all users should follow. The old adage, “If you don’t know something, ask,” applies here. There are no bad questions when trying to determine proper meter placement. Ask the manufacturer

Each technology has specific recommendations for meter placement and recommended pipe diameters upstream and downstream. Perhaps one of the most overlooked resources is speaking with the account manager/sales resource for that particular vendor. Most, if not all, flow measurement professionals have been through extensive training on their products and are familiar with a host of applications. They should be the first call when you have questions or concerns about where the meter should be placed in the pipe. In many cases, these professionals will assess each installation and give you the recommendations needed to ensure proper performance.

One size does not fit all

One technology does not fit all applications. We all have our favorite technology that we swear by, but you can’t fit a round peg in a square hole and the same goes for flowmeters. Just because there’s a spare meter lying in the storeroom doesn’t mean it will be the most suitable. There are many options to consider, especially if you have existing piping that can’t be modified easily. It’s important to start thinking about the importance of installation effects and how this could impact the type of meter that is chosen. If you find that your flowmeter performance is suffering from installation effects, all is not lost. Ideally, the meter could be moved to a more suitable location that would ensure proper upstream and downstream straight pipe. Another option would be to change the type of meter or change to a different design of the same kind of meter. www.controleng.com

For example, changing from a standard vortex to a reducer vortex. Upstream and downstream requirements

As there are multiple flow technologies available, so too are the recommendations for proper meter placement in process piping. While each manufacturer may have different guidelines, below is a general overview of typical upstream and downstream piping requirements to get started.

Magnetic flowmeters

Magnetic flow meters are fairly forgiving in terms of varying flow profile. To ensure specified accuracy over a broader range of process conditions first, ensure that the meter is piped in a manner so it always remains full. Second, install the flowmeter a minimum of five straight pipe diameters upstream and a minimum of two straight pipe diameters downstream from the electrode plane.

Vortex flowmeters

Vortex flowmeters like a fully developed flow profile and typically require long straight upstream piping runs. Elbows, reducers, and other devices upstream of the sensor will distort the flow profile, so adequate straight runs need to be accounted for. Typical recommendations suggest 35 straight pipe diameters upstream and five straight pipe diameters downstream. If you don’t have sufficient upstream straight run, some manufacturers allow for K factor corrections that could reduce this requirement. If using temperature and pressure compensations to derive mass flow, then the temperature and pressure transmitters should be installed downstream of the flow meter at a minimum of four to six straight pipe diameters.

Coriolis flowmeters

Coriolis flow meters are designed to measure mass flow and density directly. Their measurements are insensitive to fluid profile, have very few installation limitations and therefore don’t require upstream and downstream straight pipe runs. The main guidelines for Coriolis sensors are to make sure the sensor tubes remain full. If installed in a vertical pipe, make sure the fluid (liquid and slurries) flow up and gasses flow down and do not use the meter to align misaligned pipe.

Turbine flowmeters

Turbine flow meters must be installed in a manner that minimizes measurement errors www.controleng.com

caused by turbulence or damage to the moving parts caused by high flow rates. It also is recommended that a strainer is used upstream of the turbine meter to capture any contaminants that could damage the moving components. Sufficient back pressure should also be maintained to avoid any potential flashing or cavitation. The general guidelines suggested by manufacturers of turbine flowmeters are 15-20 straight pipe diameters (inclusive of the strainer) straight pipe runs upstream and five straight pipe diameters straight pipe runs downstream. The upstream requirement can be increased if, for example,

‘

Aside from improper sizing, material incompatibility, and meter misapplication, a number of issues with flow

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measurement arise from improper piping practices. there are two elbows in different planes (up to 50 straight pipe diameters). Alternatively, the upstream straight run requirement can be reduced if some form of flow straightening is used, down to 10 straight pipe diameters upstream. Ultrasonic flowmeters

Ultrasonic flowmeters require fully developed flow conditions to ensure the meters will perform as specified. There are two basic types of measuring principles, Doppler and transit time, with the latter being more commonly used for fiscal custody transfer applications of gas and petroleum liquids. As with other technologies, these sensors do require adhering to basic installation guidelines to minimize errors caused by flow profile disturbances.

Consult the standards, ask questions

Requirements vary by manufacturer, which could lead to some confusion. In a fiscal custody transfer application of either a liquid or gas, make sure to be fully versed in the current standards. By asking the right questions, consulting with the manufacturer, and having a good understanding of the existing guidelines and standards, you should be well on your way to getting the most for your flowmeter investment. ce

Jeff Weiss is an account manager with Cross Company, a CFE Media content partner. Edited by Chris Vavra, production editor, Control Engineering, CFE Media, cvavra@cfemedia.com. CONTROL ENGINEERING

APRIL 2017

| DE2

DIGITAL EDITION exclusive

Achieve proper motor alignment by detecting and correcting soft foot A soft foot exists when not all of a machine’s feet sit flat on the supporting base, so that tightening the foot bolts distorts the machine case. This can make a machine difficult to align and result in poor overall machine performance.

ADVICE KEY CONCEPTS Soft foot can a make a machine difficult to align, and result in poor performance and increased vibration. Shaft alignment and dial indicators can be used to detect soft foot. Proper attention to correcting soft foot conditions will save time in achieving proper shaft alignment.

roper alignment of direct-coupled machinery is an essential element for the reliability of a new or repaired machine (motor, pump, gear case, etc.). One common impediment to achieving proper alignment and smooth operation is a “soft foot” condition. A soft foot exists when not all of a machine’s feet sit flat on the supporting base, so that tightening the foot bolts distorts the machine case. A common occurrence with four-footed electric motors, this condition may result if machine feet aren’t coplanar, individual feet are bent, angled or corroded (see Figure 1), or the baseplate isn’t flat. A soft foot can a make a machine difficult to align, and a distorted case can increase bearing load and create internal misalignment of the machine’s rotating and stationary elements, resulting in poor performance and increased vibration. Proper shimming usually can correct noncoplanar feet, and to some extent feet that are

GO ONLINE Read this story online at www.controleng.com and see more images associated with this story, as well as links to other stories from EASA. CONSIDER THIS What other methods can be used to detect soft foot?

0.008

0.001

Drive

0.0005

0.001

Driven

0.011

Diagonal soft foot

0.0002

0.012

Bent or angled foot

Figure 1: Common soft foot results of dial indicator test. All graphics courtesy: EASA

DE3

APRIL 2017

CONTROL ENGINEERING

bent or angled. Feet with significant corrosion damage must be re-machined to avoid the consequences of a soft foot condition. Detecting soft foot

There are several methods for detecting a soft foot condition and suitable tests should be performed during every machine installation. Some of these tests employ shaft alignment tools, making it convenient to incorporate them into the shaft alignment procedure. Probably the best test for soft foot, though, is to insert feeler gauges between each foot and the base foot pad before tightening the feet. This can be done without setting up shaft alignment instruments or indicators and is recommended whenever a machine case is set in place. When using shaft alignment instrument or dial indicator setups to detect soft foot, the usual approach is to first tighten all feet bolts and then loosen only one of them while observing the movement on the shaft alignment indicators. The bolt is then re-tightened and each remaining foot is tested in the same way. Dial indicators and some laser systems are indicated in a single plane (vertical or horizontal), so the vertical plane is the preferred plane to monitor for soft foot. Laser systems that indicate in both planes simultaneously are slightly better at detecting movement when the foot bolt is loosened. Some alignment technicians prefer not to retighten the bolt, but instead successively loosen each bolt and observe the total indicated movement. They may then reverse the procedure, successively tightening each bolt while observing the indicated movement until all are secured. This extended procedure gives a good indication of how a soft foot condition might affect the alignment process. www.controleng.com

Correct the soft foot condition

While this procedure of using shaft-mounted alignment indicators may detect the presence of a soft foot with reasonable accuracy, it should not be used when attempting to correct the condition. Rather, manual testing with a dial test indicator mounted at each foot provides a much more effective and efficient means of correcting soft foot (see Figure 2). With all four bolts tightened, the dial test indicator is mounted to the foundation and set to indicate upward movement of the foot as one foot bolt is loosened. An upward movement of more than 0.002-in. (0.05 mm) indicates a soft foot condition that should be corrected. The foot bolt is then re-tightened, and the test is repeated for each remaining foot bolt.

How to correct soft foot

The most common soft foot conditions are two diagonal soft feet or a single soft foot. These usually indicate two different types of soft foot. Diagonal soft feet tend to indicate a short foot, that is, feet are flat but not coplanar. A single soft foot often results from a bent or angled foot. Correcting a short foot is pretty straightforward; correcting a bent or angled foot is more complex. To correct a short foot (diagonal feet are soft), tighten only the two diagonal feet that were not soft, leaving the soft feet bolts loose. Remove all shims from those two feet. Use feeler gauges between the soft feet and the base foot pad to determine the number of shims required for each of the two soft feet. Place the required shims and retest for soft foot. When testing indicates a single soft foot, the foot is likely bent or angled. Loosen only that foot bolt and remove all shims. Use feeler gauges to determine the amount of shims required to correct the soft foot, carefully profiling the gap by measuring in from each side as well as from the front and back of the foot to the bolt hole.

General recommendations for shims

When correcting a soft foot that results from a non-coplanar foot or feet, each shim should cover at least 80% of the foot’s area. Best practice is to place no more than five shims between a machine case foot and the base plate or foundation (excluding those used to correct angled foot conditions). In addition, no more than one shim should be less than 0.003-in. thick, and the sum of the three thinnest shims should be 0.010-in. or www.controleng.com

Figure 2: A dial indicator setup for a soft foot test.

greater. It’s also important to accurately measure the thickness of any shims that are more than 0.020-in. thick, and to verify the thickness of the entire shim stack. For a bent or angled foot, step or stagger a maximum of five shims in a single direction to match the angle of the gap variation. For best results, do not use shims to correct a total gap variation greater than 0.015-in. Bent or angled feet with a larger gap variation There are several methods should be straightened or re-machined to correct for detecting a soft foot the condition. Proper attention to condition and suitable tests detecting and correcting soft foot condishould be performed during tions on new or repaired machine installations every machine installation. will save time in achieving proper shaft alignment, prevent frame or casing distortion that reduces machine reliability and efficiency, and avoid increased vibration levels. ce

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’

Eugene Vogel is a pump and vibration specialist at the Electrical Apparatus Service Association (EASA), a CFE Media content partner. Edited by Chris Vavra, production editor, Control Engineering, CFE Media, cvavra@cfemedia.com. CONTROL ENGINEERING

APRIL 2017

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NEW PRODUCTS and software Robot monitoring system for material handling applications ABB Robotics’ SafeMove2 robot monitoring system is designed to enable people to work safely alongside ABB robots with payloads ranging from 6 to 800kg. It also provides an optimum level of collaboration and flexibility to higher speeds and throughput applications which typically require more insular, intrusive levels of safety. SafeMove2 also is designed to simplify production scenarios and provides tools that speed the commissioning workflow for faster set-up and validation. The innovative software option also integrates safety fieldbus connectivity and addresses the needs of the material handling and machine tending industries for flexibility, ease of use, compactness and short cycle times, while maintaining large working envelopes. ABB Robotics,

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Six-axis collaborative robot series

Mobile robot series for material transportation applications Mobile Industrial Robots’ MiR 200 is designed to quickly and cost-effectively automate material transportation applications. An updated web-based user interface makes programming even easier for users without prior experience and allowing for even more optimized implementation. Updates include customizable dashboards, improved mapping, easier creation of robot missions and tasks, multi-level permissions, responsive web design and browser support. It doubles the payload capacity of the MiR100 to 200 kg/440 lb and offers a MiRHook option for autonomous towing of carts up to 500 kg/1102 lb. It is flexible for top modules, which can be customized and mounted as needed. Mobile Industrial Robots (MiR)

Stäubli’s TX2 line of collaborative robots are six-axis machines designed to operate in high-volume manufacturing, Industrie 4.0 applications, and human-robot collaboration under all production conditions. The new TX2 line is offered in six model series—TX2-40, TX2-60, TX2-60L, TX2-90, TX2-90L and TX2-90XL—and can handle loads between 2 to 15 kg with a reach between 515 and 1,450 mm. They also have a separate safe digital encoder for each axis and an integrated safety board. All safety features comply with the stringent requirements of the highest safety category, SIL3/PLe. The TX2 series also feature configurable, safe input/output (I/O) modules as well as real-time Ethernet fieldbus systems. They are also IP65 and IP67-certified, which allow them to be used in cleanroom and hygiene conditions. Stäubli,

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Redundant process control system for demanding applications Mitsubishi Electric Automation’s iQ-R Series Process CPU/Redundant System is designed for industries such as oil and gas, wastewater and building automation for applications that require near 100% uptime to prevent harmful or costly disruptions. Features include redundancy across multiple levels, reducing single-point failures and high availability at multiple levels for improved system reliability. It has visualization and data acquisition and can be configured with integrated engineering software. The control system provides security features to protect intellectual property and plant safety, and a built-in SD memory card database that provides recipe and data logging functionality without the need for an external server. It can have up to four CPUs per rack for motion, sequence and process control.

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Laser profiler for verifying part dimensions Cognex Corporation’s In-Sight Laser Profiler is an easy-to-use measurement system that verifies part dimensions such as height, gap, position, and angle measurements as well as detects defects on the factory floor. Part profile verifications are used across a wide range of industries such as automotive, electronics, consumer products, and food and beverage to ensure parts are manufactured within specified tolerances. Slight dimensional variations can adversely affect product quality, consumer safety and brand integrity. The In-Sight Laser Profiler identifies these issues before they reach customers. It is designed to make it easier to monitor production line activity from anywhere on the factory floor using a web-enabled laptop, tablet or smartphone. Cognex Corp.,

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Motion controller for air bearing positioning stages Physik Instrumente’s A-81x motion controller is designed to handle 1, 2, or 4-axis of PIglide air bearing positioning stages. Equipped with ultra-low noise PWM drives, the A-81x controller integrates closed loop servo control, motor drives, and power supplies in a 19-in. rackmount design. High-resolution incremental encoders with sine/ cosine output and absolute encoders based on BiSS-C protocol are supported. Air bearing positioners are designed to deliver precise and vibration-free motion, with excellent velocity stability, and zero wear of mechanical components. They are made for high precision applications such as metrology, photonics alignment, semiconductors, wafer inspection, laser marketing, flat panel displays, precision scanning applications, and cleanroom applications. Physik Instrumente (PI),

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Compact limit switch line series AutomationDirect’s AEM2G compact limit switch line includes four electrical connection types. They also include 5-Pin M12 quick disconnect (bottom and right exit) and 3m pre-wired pigtail cable (right exit) connection options, as well as a 3m pre-wired pigtail cable (bottom exit) connection. The choice of connection types provides more convenient limit switch installation options. The AEM2G series of compact limit switches has die cast metal housings that are epoxy resin filled for IP67 rating and are equipped with one normally-open and one normally-closed contact. These compact limit switches have a standard 25 mm mounting hole spacing and are available in a variety of actuator types, including metal plunger, lever, rod, and spring. AutomationDirect,

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Controller combines single-axis controller, servo amplifier Yaskawa’s Sigma-7Siec, a unit that combines a Servopack servo amplifier with a one-axis motion controller, is designed for automation applications that require control of one servo motor. It has an amplifier/controller combination while using the smaller footprint of one amplifier, conserving space in tight control cabinets. Other features include EtherNet/IP and Modbus/ TCP for connectivity, IEC 61131-3 programming, and programmable outputs to reduce panel cost and space requirements when a few outputs are needed. Thirdparty input/output modules can be interfaced with the system, and it has a built-in web server that eliminates the need for special monitoring/ maintenance software.

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Motors for robotic, medical applications TQ Systems’ RoboDrive motors are compact and feature strong dynamics and precision and can be used for medical, robotic, and aerospace applications. The variable concept offers solutions for a variety of demanding drive applications. Alternative voltage levels, increased speeds and customized torque adaptations are also available on special order. The optional hollow shaft motors allow designers to run fluids, cables or lasers through the center of the motor, providing maximum functionality with minimal footprint. RoboDrives are available in sizes with different stator lengths, and outer diameters from 25 to 115 mm and a wide torque range from 0.024 to 11.2 Nm. TQ Systems,

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Angle ring encoder for safety-related wapplications

Festo’s Multi-Carrier System can enable customization of batch sizes as small as one. By employing RFID technology and task-specific automation stations, products and product variations can be produced on one manufacturing line quickly and efficiently. It has zero changeover time and embodies Industrie 4.0 manufacturing concepts of modularity, communications, and diagnostics. Each transport carrier moves independently from other carriers. Positioning accuracy is rated at 50 microns. The carriers move collision-free at constant velocity from station to station.

Heidenhain’s ECA 4410 angle ring encoder series is designed for use in safety-related applications and can be used in dangerous conditions and automation applications such as in robotic arms. It has an EnDat data interface and a modified mechanical connection that now includes fault exclusion. The drum has a centering collar on the inside diameter of the mating shaft. The scale drums have back-off threads for disassembly. With a safe control, it can be used as a one-encoder system in applications with control category SIL 2 (as per EN 61508) and Category 3 PL performance level “d” (as per EN ISO 13849-1). The drums are mechanically-compatible with the ECA 4000 and ERA 4000 lines of angle encoder feedback devices.

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Allied Electronics . . . . . . . . . . . . . .C1, 7 . . . . . . . . . . 6 . . . . www.alliedelec.com AutomationDirect . . . . . . . . C2, IFG, OFG, 16A-16D . . . . . . 1, 2. . . . www.automationdirect.com Beijer ELECTRONICS . . . . . . . . . . .10 . . . . . . . . . . . . 8 . . . . www.beijerelectronics.com/x2pro CFE Edu . . . . . . . . . . . . . . . . . . . . . .27 . . . . . . . . . . . . . . . . . . http://CFEedu.cfemedia.com CFE Media 2017 Digital Report Motion Control . . . . . . . . . . . . . . . .26 . . . . . . . . . . . . . . . . . . www.controleng.com/DigitalReport/MotionControl CFE Media’s New Products for Engineers Database . . . . . . . . .59 . . . . . . . . . . . . . . . . . . www.controleng.com/NP4E Control Engineering Webcasts. . . .31 . . . . . . . . . . . . . . . . . . www.controleng.com/webcasts Danfoss . . . . . . . . . . . . . . . . . . . . . .15 . . . . . . . . . . . . 11. . . . www.danfoss.us Dataforth Corp . . . . . . . . . . . . . . . .23 . . . . . . . . . . . . 15. . . . www.dataforth.com Delta Computer Systems Inc . . . . .22 . . . . . . . . . . . . 14. . . . www.deltamotion.com DYNATECT. . . . . . . . . . . . . . . . . . . .25 . . . . . . . . . . . . 17. . . . WWW.DYNATECT.COM/AMSD FABTECH . . . . . . . . . . . . . . . . . . . . .45 . . . . . . . . . . . . 28. . . . www.automationtechnology.events Fluke Corp . . . . . . . . . . . . . . . . . . . .9 . . . . . . . . . . . . . 7 . . . . www.Fluke.com/TiX560 Harting, Inc . . . . . . . . . . . . . . . . . . .24 . . . . . . . . . . . . 16. . . . www.HARTING-usa.com iCONICS. . . . . . . . . . . . . . . . . . . . . .1 . . . . . . . . . . . . . 3 . . . . www.iconics.com/HMIvideo M&T: ID&E 2017 . . . . . . . . . . . . . . .19 . . . . . . . . . . . . 12. . . . www.mfgtechshow.com iDS . . . . . . . . . . . . . . . . . . . . . . . . . .39 . . . . . . . . . . . . 26. . . . www.ids-imaging.com Inductive Automation. . . . . . . . Bellyband . . . . . . . . . . . . . . . . . www.inductiveautomation.com Lapp Usa . . . . . . . . . . . . . . . . . . . . .31 . . . . . . . . . . . . 23. . . . www.lappusa.com MICROMO . . . . . . . . . . . . . . . . . . . .28 . . . . . . . . . . . . 20. . . . www.micromo.com Moore Industries - Intl. Inc . . . . . . .4 . . . . . . . . . . . . . 5 . . . . www.miinet.com Moxa Technologies . . . . . . . . . . . . .3 . . . . . . . . . . . . . 4 . . . . www.moxa.com NEXCOM . . . . . . . . . . . . . . . . . . . . .29 . . . . . . . . . . . . 21. . . . www.nexcom.com Phoenix Contact . . . . . . . . . . . . . 11, 37 . . . . . . . . . . 9, 25. . . www.phoenixcontact.com/confidence_mguard RADWELL INTERNATIONAL, INC . . . .13 . . . . . . . . . . . . 10. . . . www.Radwell.com Sealevel Systems Inc . . . . . . . . . . .43 . . . . . . . . . . . . 27. . . . www.sealevel.com SEW-EURODRIVE, Inc. . . . . . . . . . .C4 . . . . . . . . . . . . 36. . . . www.seweurodrive.com Siemens. . . . . . . . . . . . . . . . . . . C1, 21, 30, 35 . . . . . . . 13, 22, 24 . . www.sea.siemens.com TRACO POWER . . . . . . . . . . . . . . . .61 . . . . . . . . . . . . 34. . . . www.tracopower.com UNIVERSAL ROBOTS . . . . . . . . . . .26 . . . . . . . . . . . . 18. . . . Yaskawa America, Inc. . . . . . . . . . .C3 . . . . . . . . . . . . 35. . . . www.yaskawa.com Inside Machines Allied Moulded Products, Inc. . . . .M5 . . . . . . . . . . . 31. . . . www.alliedmoulded.com Aerotech Inc . . . . . . . . . . . . . . . . . .M9 . . . . . . . . . . . 33. . . . www.aerotech.com Beckhoff Automation LLC. . . . . . . .M2 . . . . . . . . . . . 29. . . . www.beckhoff.com CFE Media, Engineering Is Personal . . . . . . . . .M7 . . . . . . . . . . . . . . . . . www.controleng.com Festo Corporation . . . . . . . . . . . . . .M6 . . . . . . . . . . . 32. . . . www.festo.com IIoT Webcasts . . . . . . . . . . . . . . . . .M10 . . . . . . . . . . . . . . . . www.controleng.com/lloT WAGO Corp. . . . . . . . . . . . . . . . . . .M4 . . . . . . . . . . . 30. . . . www.wago.us

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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 APRIL 2017

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BACK TO BASICS sensors

Sensors 101: Control system inputs Thinking of sensors as a physical input to a control system can help engineers understand there are a lot more possibilities than they realize.

Most engineers who specify equipment

think of sensors as discrete or analog devices, proxies or photoelectrics, flow or pressure sensors, thermocouples, and the like. If asked to classify them into categories, they might say analog and digital, machine level or process control, optical or inductive. There is another way to think of sensors: as any physical input to a control system. Broadening your thinking as to what constitutes a sensor opens up a lot of new possibilities. Is a pushbutton a sensor? Yes. It detects an operator’s decision to do something. How Sensors can detect the about a relay? Yes. It provides the status of some device or condition of the machine machine condition. or system or detect or Another way to categorize sensors other than the methevaluate the parts or od they use to detect things is by their function. All sensubstance that the system sors pretty much fall into two processes. categories: those that detect the condition of the machine or system (cylinder switches, encoders, some photoeyes and vibration sensors); and those that detect or evaluate the parts or substance that the system processes (flow and pressure sensors, machine vision, and discrete part presence detectors). MORE Thinking of sensors this way makes you realADVICE ize that not all sensors fall into neat categories KEY CONCEPTS like analog and digital. A vision system is a good Engineers should think of sensors as case in point. The actual method of detection a physical input to a control system. involves optics and millions of individual pixels. Sensors can also be categorized by The actual interface to the control system may their function. be a simple digital pass/fail signal, or involve Broadening the idea of what a sending strings of data that need to be decoded. sensor is beyond categories such as But you certainly need to understand all of the analog and digital can provide a new perspective for what sensors can do details of the complex topic of machine vision for engineers. before specifying it. GO ONLINE Encoders and resolvers are another examRead this story online at ple. The data may consist of discrete pulses or a www.controleng.com for more sinusoidal analog signal, but you can’t feed these information about sensors and other signals into your digital and analog input cards. stories from the author on ladder logic These factors need to be taken into account and programmable controllers. when deciding what kind of hardware is speciCONSIDER THIS fied, along with the sensor’s complexity and the What other definitions for sensors should be considered? cost of the interface with a control system.

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APRIL 2017

CONTROL ENGINEERING

Thermocouples are also analog, but you can’t wire them into an analog card. A thermocouple card contains an algorithm that knows which kind of response curve goes with the type of thermocouple selected. Not only that, but you can’t wire the thermocouple into a standard terminal block and run regular copper wire back to the card. Other atypical sensors include: Eddy current tester: An inductive probe inserted into a machined hole to determine if it has been threaded. Capacitive ion leakage probe: A charged probe and plate placed on the opposite sides of a piece of plastic to determine if a pin-sized hole allows ions through to the other side. Mass spectrometer: A customized spectroscopy system intended to detect the presence of a deadly nerve agent. Ultraviolet camera: A machine vision application with rubber gaskets coated with an ultraviolet ink to detect if raised areas have been molded correctly. Floating rocker arm cover measurement: A system with independent linear variable differential transformers that calculate the intercept of an imaginary plane to determine if a rubber gasket has been mounted correctly. Whether the focus is on troubleshooting existing equipment or designing new systems and machines, understanding how all of these sensing devices work together with control systems is an important part of a well-rounded education. ce Frank Lamb is the founder of Automation Consulting Services Inc. This article originally appeared on the Automation Primer blog. Automation Primer is a CFE Media content partner. Edited by Chris Vavra, production editor, Control Engineering, CFE Media, cvavra@cfemedia.com. www.controleng.com

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