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Vol. 64 Number 12
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DECEMBER 2017
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COVER IMAGE, ABOVE: Immersive 3-D virtual reality technology simulates robotic welding processes for more efficient design and concept review prior to build. Courtesy: Robotic Industries Association (RIA)/Genesis Systems Group LLC COVER IMAGE, RIGHT: Virtual manufacturing began as a way to design and test tools and has grown to become a powerhouse for supporting production processes and product development. Digital models capture information about the product for rapid prototyping and eventually mass production on the factory floor. Courtesy: L&T Technology Services
05 |
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18 | Virtualized manufacturing, simulation opportunities 21 | 3-D robotic welding simulation benefits 23 | Customers need process control building blocks and standardization 25 | One cable automation combines communication and power INSIDE PROCESS
INSIGHTS
M1 | Picking the right discrete sensor for a machine application
06 | 2017 Programmable Controllers Software & Hardware study: Five industrial controller findings 08 | Companies need to address collaborative robot issues 10 | Using a virtualization approach can save time, money, and resolve backup and recovery issues 11 | Five technology trends for 2018 12 | Using energy management software to lower overall costs 13 | Collect, optimize data NEWS
14 | Electronics manufacturing drives industrial robotics market growth; Industrial Internet groups announce digital solar plant testbed; Online articles 15 | Think Again: Looking ahead
ANSWERS
M4 | Wireless as a means to overall equipment efficiency 33 |
INNOVATIONS NEW PRODUCTS
34 | Apps control functions of digital pneumatics; Metal-sealed ball valves; Fiber optic microswitch series; Surge protective device 35 | Embedded computer for DAQ applications; Temperature transmitter with intrinsically safe sensor connections 36 | Splicing connectors for grounding and bonding; Pressure transmitter with low-power voltage output; Industrial UPS system BACK TO BASICS
40 | 3 cybersecurity changes for manufacturers
CONTROL ENGINEERING (ISSN 0010-8049, Vol. 64, No. 12, GST #123397457) is published 12x per year, Monthly by CFE Media, LLC, 3010 Highland Parkway, Suite #325 Downers Grove, IL 60515. 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 Downers Grove, IL 60515 and additional mailing offices. Circulation records are maintained at 3010 Highland Parkway, Suite #325 Downers Grove, IL 60515. Telephone: 630/571-4070. E-mail: customerservice@cfemedia.com. Postmaster: send address changes to CONTROL ENGINEERING, 3010 Highland Parkway, Suite #325 Downers Grove, IL 60515. Publications Mail Agreement No. 40685520. Return undeliverable Canadian addresses to: 3010 Highland Parkway, Suite #325 Downers Grove, IL 60515. 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 US and $35 foreign. Please address all subscription mail to CONTROL ENGINEERING, 3010 Highland Parkway, Suite #325 Downers Grove, IL 60515. 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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December 2017
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INSIGHTS ®
TECHNOLOGY UPDATE RESEARCH
6
Five industrial controller findings
12
Energy management software is designed to measure costs and deliver quantifiable results for companies, from 5% to 25% annual energy cost savings. It also can be integrated with the cloud to lower energy costs and provide more immediate, hands-on data for users.
Respondents to Programmable Controllers Software & Hardware study identified five key findings regarding what end users expect and how they purchase or specify industrial controller software and hardware.
M More INSIGHTS More research details, other topics www.controleng.com/ce-research
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CONTROL ENGINEERING EUROPE
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Companies need to address collaborative robot issues Collaborative robots are a hot topic in manufacturing and their use will grow as companies implement Industrie 4.0, but companies need to consider safety issues and how collaborative robots compliment the workforce.
TECHNOLOGY UPDATE
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Overcoming compatibility issues with virtualization
Using energy management software to lower costs
TECHNOLOGY UPDATE
Collect, optimize data Use automation to collect pertinent operations data in the right format for worthwhile outcomes. See three data structure tips.
NEWS
14
Using a virtualization approach can save time, money, and resolve backup and recovery issues.
Electronics manufacturing driving industrial robotics market growth; Industrial Internet groups announce digital solar plant testbed; Online articles THINK AGAIN
TECHNOLOGY UPDATE
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Five technology trends for 2018
With advancements in automation, industries need to stay on top of the challenges ahead.
M More INSIGHTS Need a topic-based, answer-oriented Control Engineering newsletter? www.controleng.com/enewsletters www.controleng.com
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Top 10 Control Engineering topics for 2018 Hottest 2018 topics in automation, controls, and instrumentation are here, but don’t take my word for it; help write future history.
Weekly Top 5 articles recap the most-read articles at www.controleng.com posted during the prior two months.
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Estimated expenditures for MV drives
INSIGHTS
RESEARCH
Don't know
23%
2017 CONTROLLERS STUDY
Five industrial controller findings
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26%
4. Cybersecurity: Seventy-six percent of respondents reported that their companies restrict access to controllers in an effort to protect these devices; 55% have increased password protection procedures. 5. Looking ahead: Eight in 10 end users expect to buy industrial controller software or hardware in the next 12 months; end users expect to use/purchase an average of 9 industrial controllers during this time frame. ce
he Control Engineering 2017 Programmable Controller Software & Hardware Study unveiled five key findings regarding what end users expect and how they purchase or specify industrial controller software and hardware: 1. Usage of industrial controller software, hardware: Programmable controller software or hardware is most commonly used for discrete and continuous manufacturing (22%), continuous manufacturing (22%), or continuous and batch manufacturing purposes (19%). 2. Justifications: The top situations in which end users purchase new industrial controller software and/or hardware are an automation upgrade (67%), a new installation (56%), and an operations/ engineering upgrade (44%). 3. Annual spend: Over the past 12 months, the average respondent’s company was estimated to have been spent $158,000 on industrial controller software and hardware; and an average of $157,000 is expected to be spent in the next year on these products.
View additional findings at www.controleng.com/2017ControllersReport. Amanda Pelliccione is the research director at CFE Media, apelliccione@cfemedia.com.
M More RESEARCH
Control Engineering covers several research topics each year. All reports are available at www.controleng.com/ce-research
How industrial controllers help 65%
Remote monitoring
Modeling
28%
39%
Simulation Mobile interface for alarming Mobile interface for programming Digital twins of control systems
22%
55%
Maintenance
33%
29% 21% 21% 18%
37% 35% 27% 33%
Already doing Considering doing
More than half of respondents already use industrial controllers to help with remote monitoring and maintenance tasks; another 39% use these products for simulations, and 29% as a mobile interface for alarming. Source: Control Engineering
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$250,000 or less
CONTROL ENGINEERING
31%
20% $250,001 to $500,000
$500,001 or more
End users estimate an average expenditure of $509,000 for medium-voltage (MV) drive products over the past 12 months. Source: Control Engineering 2017 Motor Drives Study
66%
of end users have had a somewhat challenging wireless integration experience within the past year. Source: Control Engineering 2016 Mobility, Ethernet, and Wireless Study
69%
of end users expect an increase to their salary; 29% expect it to remain the same as 2016. Source: Control Engineering 2017 Career & Salary Survey
35%
of end users expect to spend less than $20,000 on HMI software and hardware in the next 12 months. Source: Control Engineering 2017 HMI Software & Hardware Study
More research Control Engineering covers several research topics each year. All reports are available at www.controleng.com/ce-research.
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schneider-electric.com/smartoperations input #4 at www.controleng.com/information
“Profitable Reliability”
INSIGHTS
INTERNATIONAL
Suzanne Gill, Control Engineering Europe
Address collaborative robot issues Collaborative robots are a hot topic in manufacturing, and their use will grow as companies implement Industrie 4.0. Consider safety and how collaborative robots complement a workforce.
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Manufacturers use robots for collaborative operations more often as Industrie 4.0 expands. Courtesy: Control Engineering Europe
M More INSIGHTS KEYWORD: collaborative robots Robots used collaboratively have safety considerations as they complement human workers. Collaboration between robots and humans will be imperative as Industrie 4.0 grows.
GO ONLINE Read this article online at www.controleng.com/ international for more.
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ollaborative robots—and their safe interaction with humans on the plant floor—have become a hot topic in manufacturing. Discrete manufacturers are using these robots more often and their use will grow as Industrie 4.0 becomes more common on the plant floor. To address the safety issues related to the interaction of robots and humans, the ISO/TS 15066 standard was published in February 2016 to provide guidelines on safety in collaborative robot systems. Four types of collaborative operation are listed 1) Safety-rated monitored stop; 2) Hand guiding; 3) Speed and separation monitoring; and 4) Power and force limiting. When it comes to the safety-rated monitored stop, the robot system needs to stop before the human operator can access the collaborative workspace. The robot can move as a non-collaborative robot only when there is no human operator in its workspace. The robot system and the human operator can move, but not at the same time. This method cannot take advantage of collaborative operation, and it requires safeguarding of a traditional industrial robot. Benefits are the ease and speed to resume automatic operation. With respect to hand guiding operation, the human operator uses a hand-operated device and the robot system moves based on motion commands of the operator. It is a kind of manually controlled operation where the operator is in direct control of the robot system’s operation. This is considered automatic rather than manual operation. In reality, only options 3 and 4 are used for beneficial collaborative applications in industry, according to Roberta Nelson Shea and Seungmin Baek of Universal Robot. “Currently, most collaborative robots are inherently designed to limit power and force. If the robot detects a certain level of power or force, the robot stops to protect the human operator. Due to the safety-functions for motion, speed, force, and power monitoring, the human and robot system can move at the same time in the same workspace,” said Shea and Baek. “As long as the risk assessment is conducted properly, traditional guards and protective devices are not needed.” The power and force limiting method assumes the human can contact the moving robot system. “It is important to consider the impact to the human body during the risk assessment process. To prevent pain or injury, the application also restricts payload and speed. As a result, the robot speed will likely be too low to
December 2017
CONTROL ENGINEERING
be useful for high risk applications,” continued Shea and Baek. “To use the speed and separation monitoring method, external safety devices, such as a safety scanner, have been used to lower speed as a person approaches the collaborative workspace.”
Assess the risk, help the workforce
Improvements in safety technology allow industrial robots to be used in collaborative operations, providing many of the same benefits a cobot brings, along with increased speed and accuracy. Collaboration only can be implemented after the appropriate risk assessment, which is no different than choosing a cobot. “What many are unaware of is that almost any robot is capable of collaborative operation with the appropriate safety mechanisms in place,” said Nigel Smith, TM Robotics CEO. “It is the application that defines the ability for human and machine to collaborate. Some manufacturers may specify a cobot assuming it will work without caging... they may find their risk assessment shows the need for a safety cage or force limiters to keep human workers safe.” Added safety feature costs can make a cobot cost similar to that of an industrial robot, without the added capabilities of speed and accuracy, which usually isn’t the plan. Martin Walder, vice president industry at Schneider Electric in the U.K., believes the breakthrough to ensuring continued production facility modernization lies in human-robot collaboration, where compact and easy-to-use synergic automation will drive the market in future years. “In many cases, robots can be employed to complement rather than replace workers. This concept, often known as ‘cobotics,’ teams operators and machines in order to make complex parts of assembly processes faster, easier, and safer,” Walder said. In meat packaging lines, humans and robots working in the same area with a more flexible and efficient outcome. “Robotic functionality provides full adaptability to new processes, reduces footprint requirements and even enables the automation of manual tasks—often the most dangerous, monotonous, and/or dirty ones which help keep our workforces safe.” ce
Suzanne Gill, editor, Control Engineering Europe; This appeared on Sept. 29 on the Control Engineering Europe website, www.controlengeurope.com. Edited by Chris Vavra, production editor, Control Engineering, CFE Media, cvavra@cfemedia.com. www.controleng.com
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INSIGHTS
TECHNOLOGY UPDATE Jon Breen, Breen Machine Automation Services LLC
Overcoming compatibility issues with virtualization Using a virtualization approach can save time, money, and resolve backup and recovery issues.
T ‘
Virtualization
allows migration to go from
he proliferation of smart devices, software tools, and networks has created many new opportunities in the world of automation and controls, but also has caused a lot of clutter on computers. Sometimes new software and features are celebrated and other times cursed. One thing that’s always true is that the controls engineer will have one more piece of software to manage (that is, another install, another license, another backwards compatibility concern, and another tool to keep in the support toolbox for the next 10 to 20 years). This isn’t likely to change any time soon, so it’s important for an engineer to have a system that minimizes the management of these new developments.
being hardware- Managing software with virtualization Plenty of software management concerns exist dependent
beyond the sheer number of applications such as: What happens if my laptop breaks? What would it take to support this automation 10 to 20 years from now? Will antivirus or user account control interfere free. with this installation? Is this 32-bit (or 16-bit application compatible with my operating system (OS)? How many days will this take to install? Controls engineers commonly will keep a stack of old laptops under their desks to keep backwards compatibility and access to older OSs, but that’s obviously a gamble (old laptops aren’t known for reliability and can be a cybersecurity risk), and it doesn’t scale very well into the future. It’s more of a workaround than a real solution to the software management that is needed. Controls engineers can use virtualization to help manage software. Virtualization is usually thought of on an enterprise scale, where virtual machines (VMs) dwell on servers and provide certain functionality across a KEYWORD: Virtual machine network, like supervisory control and data acquisition (SCADA) systems. Controls Defining a virtual machine engineers, on the other hand, usually beneThe benefits of a virtual fit the most from local virtualization, where machine for engineers. the VM dwells on a laptop. CONSIDER THIS:
to hardware-
’
M More INSIGHTS
What cybersecurity measures should be considered when working with virtual machines?
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The benefits of a virtual machine
A VM is a computer where all hardware— hard drive, random-access memory (RAM), CONTROL ENGINEERING
central processing unit (CPU), and network card— is not physically present but made to appear so with software. Now imagine if instead of saving those old laptops under a desk, what if they were saved digitally? Virtualization disconnects software from hardware that may be fragile or lacking a compatible power supply. Virtualization allows migration to go from being hardware – dependent to hardware-free. A laptop can run old software and new software, and each VM quickly can be backed up and restored. Without ties to hardware, other benefits arise. A VM, stored on a laptop as a group of files, can be copied to network storage as a backup, or shared with colleagues, preventing the need to install all the same software. A VM also creates a separation between the programming environment (the VM) and the host environment (the laptop’s OS and applications), which means antivirus, user account control, and operating system software updates aren’t typically needed in the VM, where they might interfere with the programming software. The cost of virtualization can range from free to a few hundred dollars. Costs might include virtualization software (“hypervisor” $0 to $250) and laptop hardware upgrades if already marginal ($0 to $300). What’s more important, and harder to measure, is time. Time will be spent implementing and managing a virtualization approach, however, a lot of time will be saved once a virtualization is in place. Get the team together and understand the organization’s software needs. Learn from other organizations already using VMs and leverage their experiences to help develop a process. If possible, get some quick-start training on virtualization to ease the implementation process. With current industry trends, there’s no end in sight for the software burdens on control engineers. Virtualization is an approach that many have employed to keep access to older software, enhance backup and recovery, save time by sharing, and stay secure without interfering with work. ce Jon Breen is the owner of Breen Machine Automation Services LLC. Edited by Emily Guenther, associate content manager, Control Engineering, CFE Media, eguenther@cfemedia.com. www.controleng.com
INSIGHTS
TECHNOLOGY UPDATE Kyle Voosen, National Instruments
Five technology trends for 2018 With advancements in automation, industries need to stay on top of the challenges ahead.
T
echnology has never advanced faster, with the global adoption of smartphones, self-learning and agile robots, affordable genome sequencing, and ubiquitous data storage. The National Instruments (NI) Trend Watch examines topics such as the mass deployment of the Industrial Internet of Things (IIoT), machine learning, and upcoming challenges in testing increasingly connected and electrified systems. The following is a summary of the five trends in NI Trend Watch 2018.
circuit doubles about every two years) is dead. Though it may be experiencing some health challenges, it’s not time to start digging the grave for the semiconductor and electronics market yet. New computing techniques and new applications for existing technology continue to advance the capabilities for high-speed input/output (I/O) and processing. As previous architectural leaps, such as multicore processors, have shown, the keys to riding the wave are the software tools and frameworks that leverage the diversifying computing elements.
1. Three mandates to successfully
4. Vehicle electrification: Disrupting
Accenture estimates that 95% of companies will adopt the IIoT in the next three years to maximize uptime, optimize performance, and drive product and process innovation. Now, smart and connected “things” give companies opportunities for increased performance and lower costs, but managing these distributed systems is often an overlooked challenge. Companies across all industries are adopting a new breed of disruptive platforms and ecosystems that will transform businesses into engines of innovation and growth by taking advantage of intelligent technologies. With IIoT technologies, they can harness the benefits of these state-of-the-art platforms to reduce maintenance costs and improve asset utilization. To successfully manage an IIoT strategy, companies must manage data, software configuration, and remote systems.
Ten years ago, a fully-mechanical coupling between the steering wheel and the front wheels was common. However, the explosion of drive-by-wire technology, combined with government mandates toward fully electric powertrains, has changed this paradigm—and it impacts more than just the automotive industry. The reliance on power electronics and electric motor drives adds complexity to control systems, and combining these control systems makes that complexity grow exponentially. Directly, these factors increase the complexity of vehicles. Indirectly, they create an immediate need for growth in infrastructure. Making it happen requires an interdisciplinary approach to building safe and reliable control systems among other needs.
manage IIoT efforts
2. Progress of 5G is set
to disrupt test processes
5G signifies a generational transformation that will profoundly impact businesses and consumers globally. It promises faster data, shorter network response times (lower latency), instant access anywhere and everywhere, and the capacity for billions of devices. Though test and measurement solutions will be key in the commercialization cycle, 5G is set to disrupt test processes because it requires a different approach to test than previous generations of wireless technologies. A platform-based approach that is flexible and software-configurable will be essential to the development of this ecosystem.
3. Breaking Moore’s law
Recent publications say Moore’s law (the observation that the number of transistors on an integrated
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the automotive industry and beyond
5. Automating engineering insights with machine learning
Machine learning already has delivered beneficial results in certain niches, but it has potential for a bigger and longer lasting impact because of the demand for broad insights and efficiencies across industries. As machine learning applications migrate from the consumer space alongside development platforms and converging IIoT edge node technology, business leaders are looking to engineers and the next wave of machine learning to help find uptime, yield, and efficiency improvements in a sea of analog Big Data. As these advancements become a reality, it’s important to keep pace with how these developments will make an impact across many industries. ce
Kyle Voosen is the section manager of data acquisition and control marketing at National Instruments. Edited by Emily Guenther, associate content manager, Control Engineering, CFE Media, eguenther@cfemedia.com. CONTROL ENGINEERING
M More INSIGHTS KEYWORD: Industrial Internet of Things
Trends to lookout for in 2018. The challenges that advancements in technology bring across many industries. How these advancements will impact processes within industries.
CONSIDER THIS: What are the top challenges engineers will face as more companies adopt an IIoT strategy?
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INSIGHTS
TECHNOLOGY UPDATE Melissa Topp, Iconics
Using energy management software to lower overall costs Energy management software is designed to measure costs and deliver quantifiable results for companies, from 5% to 25% annual energy cost savings. It also can be integrated with the cloud to lower energy costs and provide more immediate, hands-on data for users.
M More INSIGHTS
KEYWORD: energy efficiency
Energy management can save operational costs and help the environment. Energy management software analyzes consumption rates, costs, conditions, and carbon elements.
GO ONLINE Read this article at www.controleng.com for more articles about energy efficiency and the cloud.
C
ompanies seek operational costs savings and environmental responsibility. Energy management initiatives can help, which involves ensuring all energy sources and users are identified and measured. Energy management software analyzes factors such as: • Consumption rates, such as kilowatt hours (kWh) provided from electric, wind, solar, or cogeneration sources; or l/hr from steam; or cu3/h from gas; or gph from water. • Cost for electricity, steam, water or gas. • Conditions, such as people per hour for occupants; hours of equipment runtime; lumens of sunlight; cubic feet per minute (CFM) in air handling units; square feet in zone footage; Energy management software can be used to measure how much energy is consumed and provide a detailed breakdown for companies.
Software developments and the advent of the cloud can provide users with a detailed breakdown of energy usage in many ways and even across multiple buildings. All graphics courtesy: Iconics
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degrees in outside air temperature; or units in component counts. • Carbon elements, such as measured carbon dioxide or methane. A comprehensive energy analysis tool should be able to deliver the back-end calculations, key performance indicator (KPI) analytics, rapid data historian storage and retrieval abilities, reporting, and visualization tools to manage and reduce an organization’s energy costs and carbon footprint. Users can receive reports covering the energy cost per square feet, or average kWh based on degree days, or measured CO2 per meter, or energy consumed per unit of product produced. Real-time views into current energy trends help catch problems early, which lead to better power utilization and avoid costs. Modern energy analytics tools in a software-asa-service (SaaS) model do not require on-premises computing hardware to interpret and analyze an organization’s energy data. Many cloud service providers also have adopted energy analytics software within their massive data centers globally. An organization’s energy calculations can be computed on a server in a data center being monitored by the same software. Users have noted savings of between 5% and 25% annually on utility bills without sacrificing building occupant comfort using energy management software. Another benefit is its scalability. Users can connect sensors to monitor and measure one room, which can be expanded to a floor, to a building, and an enterprise. City administrations have also implemented energy management software because they have the ability to show citizens quantifiable energy savings. Adopting an energy management plan—whether installed on-site or connected to the cloud—is a first step towards cost reduction and environmental responsibility as companies continue to strive to do more with less. ce Melissa Topp is senior director of global marketing, Iconics. Edited by Chris Vavra, production editor, Control Engineering, CFE Media, cvavra@cfemedia.com. www.controleng.com
INSIGHTS
TECHNOLOGY UPDATE Paul Figie, EZAutomation
Collect, optimize data Use automation to collect pertinent operations data in the right format for worthwhile outcomes. See three data structure tips.
T
wo common sayings about information are contradictory: “You can never have too much information,” and “Information overload.” It’s challenging to use data collection in real-time processes and to determine what data to collect and how often. A collective effort is required to make collection schemes that work. It’s common to make data collection schemes that generate files that never get looked at, not because the information wasn’t useful, but because those who had access to that information did not apply the data in a way that helped the process. Other data collection schemes are used daily and make production and processes more efficient.
Data perception, presentation
Data that isn’t understood or is misinterpreted may be useless, misleading, or even dangerous. Engineers need to have a good understanding of data collected and how it applies to the process. Data must be meaningful and applicable to increase its relevancy to those who are going to use it. It must be presented in a clear format. Data and trends can be accessed through smart phones, tablets, and other devices. Industrial programmable logic controllers (PLCs) can incorporate Industrial Internet of Things (IIoT) capabilities by using message queuing and the message queuing telemetry transport (MQTT) protocol, which can send real-time data to the cloud and relay it to smart phones, tablets, and other devices. Historical data points to past trends, helps analyze mistakes, and highlights corrective actions to make the process more effective. Analysis and decisions take time. Historical data can be stored on PLCs that can use a USB drive and then used for later analysis. Combining real-time and historic data can help predict and take corrective action, which will help companies to be more productive. Data collection in the automotive, oil and gas, pharmaceutical, packaging, and other process industries plays a vital role. It helps personnel of all departments know where they stand, what is their target, and what they have achieved. What if machine-level controllers like a PLC or a programmable automation controller (PAC) have a built-in data collection and storage feature? What if the same controllers could send data to a cloud? The IIoT is emerging, and implementing IIoT in
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an appropriately equipped industrial controller will give companies a competitive edge by making data more available for decisions when needed. For effective data collection, assemble a diverse team and get them involved in the process of determining what data should be collected or how it should be structured. What’s obvious to some may be overlooked by others. Set goals on how collecting data is expected to improve the process or increase production. Doing so helps with buy-in and drives the use of collected data from the beginning. Measuring production process improvement will keep team members accountable and make it easier to duplicate success and minimize failures. Data structure is important. Raw data collected over a period of time will be of little value, or may be too cluttered to be used effectively. Three tips for data structure follow. 1) Data should not be nested. Instead it should be kept simple, perhaps stored in a .csv or a table format for ease of use and manipulation. 2) For different data types, such as Boolean, integer, or string, consider storing each in separate files to help simplify the process of data analysis. 3) Collected data should include an option to send to and store in a secure SQL database for future use. ce
M More INSIGHTS KEYWORDS:
Data acquisition, DAQ Data can be useful in real time and in historical analysis. Programmable logic controllers can help collect and store data. Data structure matters.
ONLINE Find more information with this article online at www.controleng.com.
CONSIDER THIS How often do you revisit what data is being collected and how it’s being used?
Paul Figie is an application engineer at EZAutomation; edited by Mark T. Hoske, content manager, Control Engineering, CFE Media, mhoske@cfemedia.com.
Data logging feature in the EZRack PLC from EZAutomation can structure and store data on a USB flash drive plugged into a CPU. The resulting .csv file can be opened in Microsoft Excel and easily manipulated. Courtesy: EZAutomation CONTROL ENGINEERING
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INSIGHTS
Digital edition? Click on headlines for more details. See news daily at www.controleng.com/news
NEWS
Electronics manufacturing driving industrial robotics market growth Global sales of industrial robots rose 16% in 2016, bringing the world market value up to $13.1 billion. Industrial robot sales are forecasted to grow at a faster rate in 2017, and sustain this rapid rate of growth through 2020. While industrial robot sales have grown consistently, the dynamics of this growth are changing. For decades, the automotive industry was the major driver of growth in industrial robots. However, in 2016 the electronics manufacturing industry accounted for nearly as many robot shipments as the automotive industry. Industrial robot sales jumped 41% in the electronics industry in 2016. As robots become smaller, cheaper, and more precise, these manufacturers increasingly are adopting robots to combat the enormous demand for batteries, chips, and displays. Robots allow for miniaturization, increased throughput, and reduced lead
times for electronics manufacturers. Industrial robots inherently are more precise than humans, and have a major impact on assembly work that revolutionizes the rest of the electronics supply chain. Industrial robots can place parts faster and more accurately, clearing the way not only for smaller electronics, but also faster production and higher throughput. This, in turn, allows manufacturers to optimize their supply chains by reducing lead times and by moving production closer to the product’s destination.
Industrial robot applications
Industrial robots perform a wide variety of tasks in electronics manufacturing. Many of them involve advanced vision systems and sensors to accommodate for task variations and careful handling of delicate parts. Robots are used to handle display
Industrial Internet group announces digital solar plant testbed The Industrial Internet Consortium (IIC) announced the Digital Solar Plant testbed. The testbed is led by IIC members LTI, a global technology consulting and digital solutions company, and GE Digital. It will deploy in multiple phases at an L&T Solar plant in Rajasthan, India, beginning in early 2018. “Testbeds are the major focus and activity of the IIC and its members,” said IIC executive director, Dr. Richard Soley. “Our testbeds, including the new Digital Solar Plant testbed, are where new technologies, applications, products, services and processes—the innovation and opportunities of the industrial Internet—can be initiated, thought through and rigorously tested to ascertain their usefulness and viability before coming to market.” “Utility companies face several issues as global interest in solar energy soars—from mitigating operational and regulatory risks to maintaining efficiencies and improving capacity utilization,” said Rohit Kedia, chief business officer, manufacturing and ERP, LTI. “Renewable energy is a transformative solution that will meet energy as well as economic challenges globally,” said Shyam Varan Nath, director, technology integrations, IoT/industrial Internet at GE Digital. “Using real-time data analytics, utilities also can ensure that all of their assets are working properly and that their plants are running efficiently.” - Edited from an Industrial Internet Consortium (IIC) press release by CFE Media. The IIC is a CFE Media content partner.
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screens, assemble connectors and other subassemblies, apply adhesives and sealants, perform inspections and tests, and even populate and coat circuit boards. They play a vital role from the start of production right up through to the point of delivery. Industrial robots are important in the electronics manufacturing industry and enable not only major supply chain changes but revolutionized production processes. 2016 saw strong growth in industrial robotic sales in the electronics manufacturing industry, and adoption rates will likely increase. The electronics industry is on par with the automotive industry and is adopting a wider range of robotic solutions than previously used. This article originally appeared on the Robotics Online Blog. Robotic Industries Association (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.
Headlines online Top five Control Engineering articles Nov. 13-19: Most visited articles included stories on the Engineers’ Choice finalists, industrial mobile robot safety standards, process engineers and analytics, the IoT and ERP, and a motor and drive webcast Q&A. Ensuring OT cybersecurity Cybersecurity breaches that affect operation technology (OT) systems and devices. Master data management’s benefits for ERP Master data management (MDM) is a technology-enabled business discipline. Hurricanes create an ill wind, but PMI remains strong Four reasons why electric motors overheat Using a PHA for process valve safey Organization outlines 10 manufacturing predictions for 2018 www.controleng.com
INSIGHTS ®
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www.controleng.com/EAB Doug Bell, president, InterConnecting Automation, www.interconnectingautomation.com David Bishop, president and a founder Matrix Technologies, www.matrixti.com Daniel E. Capano, president, Diversified Technical Services Inc. of Stamford, CT, www.linkedin.com/in/daniel-capano-7b886bb0
Frank Lamb, founder and owner Automation Consulting LLC, www.automationllc.com Joe Martin, president and founder Martin Control Systems, www.martincsi.com Rick Pierro, president and co-founder Superior Controls, www.superiorcontrols.com Mark Voigtmann, partner, automation practice lead Faegre Baker Daniels, www.FaegreBD.com
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 or 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
Top 10 topics for 2018 Hottest 2018 topics in automation, controls, and instrumentation are here, but don’t take my word for it; help write future history.
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rediction articles are fun, especially the 10 most important Control Engineering topics for 2018. These are difficult choices, given the 2018 topics at www.controleng.com/2018articles. Selections are based on past site traffic, discussions, and input from our research, and my observations in industry since 1987, but don’t take my word for it. Think again about what’s important to you, prioritize your list, and help write the future of Control Engineering. Learn how at www.controleng.com/contribute.
Predictions for 2018
the control loop and put information where it’s needed for smarter, faster, and more costeffective decisions, whether automated or not.
6. Industrial Internet of Things (IIoT) device and system integration ensure that information technologies (IT) and operational technologies (OT) are working more effectively together, locally and connected to an increasing wealth of cloud-based resources, such as artificial intelligence (AI), machine learning, predictive analytics, and 3-D printing ecosystems.
7. Cybersecurity: Advances in packet inspection and device Mark T. Hoske, mation control, process control designs augment cybersecurity Content Manager systems, edge computing, embedeven as a greater amount of trainded controls, motion controls, ing and higher levels of awareness and robotics controls (and robotic designs) are required. Like safety, cybersecurity is are advancing quickly. everyone’s responsibility. 1. Controllers: factory auto-
2. Product innovation in automation, controls, and instrumentation: Engineers’ Choice Awards are announced in February; these products can help increase the effectiveness of your next implementation. 3. Career and salary survey: Bench-
marking provides comparisons; next steps and other advice are provided.
4. Advanced controls include proportional-integral-derivative (PID) control: acquiring, analyzing, and integrating input from advanced sensing to optimize closedloop control and make open-loop control designs more effective. 5. Communications: advanced industrial Ethernet and wireless communications connect the sensors, controllers, and actuators of
M More INSIGHTS www.controleng.com/2018articles www.controleng.com/contribute
8. Engineering Leaders Under 40: Annual recognition (in September) of upcoming talent fueling the next-generation of innovations in automation, controls, and instrumentation. 9. Training is increasingly important as the demographic crunch continues, and more-intuitive human-machine interfaces (HMIs) and next-generation augmented reality (AR) are helping. 10. Energy efficiency, especially measurement and monitoring to make energy a controlled resource of the manufacturing processes, and linked to enterprise and supply chain systems. Sensors, motor and motion efficiency, and networking play critical roles. Learn more and share your knowledge in Control Engineering articles, research, webcasts, CFE Edu training, digital reports, newsletters, and CFE Media supplements, such as Global System Integrator Report, IIoT for Engineers, and Oil & Gas Engineering. Thank you for your support. ce
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2017 Programmable Controller Software & Hardware Study
Turning research into insights makes for better business decisions This study was conducted by Control Engineering to acquire information related to the buying and specifying habits of automation engineering professionals for programmable controller software and hardware. Respondents to the Control Engineering 2017 Programmable Controller Software & Hardware Study unveiled several key findings regarding what end users expect and how they purchase or specify industrial controller software and hardware. According to the study, the top uses for programmable controller software or hardware are discrete and continuous manufacturing (22% primary, 22% secondary), and continuous manufacturing (22% primary, 17% secondary). In addition; in the past 12 months, respondents spent an average of $157,678 on industrial controller hardware and software—with 21% having spent $200,000 or more. Eighty-two percent of respondents expect to buy industrial controller software or hardware in the next 12 months. On average, respondents plan to use nine controllers over this period. Access the 2017 Programmable Controller Software & Hardware report with additional findings and insights. www.controleng.com/2017ControllersReport
ANSWERS FEATURE ARTICLES
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One cable automation combines communication and power
New connector technologies expand EtherCAT and EtherCAT P communication with additional power supply options.
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Virtualized manufacturing, simulation opportunities
A simulated factory floor can monitor parameters, expose production gaps, highlight cost inefficiencies, reduce carbon footprint, and, applied to one product, can simulate its role in the real world while still on the drawing board.
Courtesy: Beckhoff Automation
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3-D robotic welding simulation benefits
Teaching robots how to weld using 3-D simulation is beneficial because welding is a complex, precise process that cannot be explained or taught easily to humans.
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Customers need process control building blocks and standardization
www.controleng.com Related topics are available under the “Discrete Manufacturing” navigation menu.
INSIDE MACHINES
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There are many considerations for picking a discrete sensor for a machine application. These include if the sensor is being used for position detection or part detection or if the application is hazardous.
Despite the demand for standardized communication protocols among manufacturers, both the manufacturers and end users face challenges when it comes to agreeing on a path.
M More ANSWERS Check out the IIoT: Machines, Equipment, & Asset Management digital report at: www.controleng.com www.controleng.com
Picking the right discrete sensor for a machine application
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Wireless as a means to overall equipment efficiency
Accurate machine run-time data helps determine why production goals aren’t met.
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COVER STORY: SIMULATION Mayank Pandya, L&T Technology Services
Virtualized manufacturing, simulation opportunities A simulated factory floor can monitor parameters, expose production gaps, highlight cost inefficiencies, reduce carbon footprint, and, applied to one product, can simulate its role in the real world while still on the drawing board.
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he key to transforming manufacturing is to take operations off the floor by virtualizing functions, creating simulations, and using those digital models to create advantages. Design and assembly must expand their roles and produce two products—a virtual model that contains pure information about the product as well as its actual physical counterpart. Digitalization has enabled us to do exactly that. Digital manufacturing empowers operators with the agility to scale production volume and deliver multiple product variants early in the process—factors essential to maximize program revenue and ultimately, profits. At its inception, the manufacturing process can be virtually conceptualized at a prototype center and subsequently transferred to volume production centers, increasing business flexibility and cost control within the global marketplace. Furthermore, digital manufacturing makes room for operators to freely exchange design knowledge and technical knowledge. In turn, digital manufacturing allows effective identification of production bottlenecks, which permits factories KEYWORDS: Simulation, to meet peak demands with optimally virtualization adjusted output. Simulating manufacturing has In collaboration with a leading softadvantages for operations and ware multinational, a French porcelain product design. manufacturer is overhauling its manUse of a digital twin allows simulation of how something ufacturing ethos by taking the entire will behave before changes are design and development process to the made. cloud. The platform aims to do away Modeling increases with cost-intensive physical prototyping opportunities to correct problems practices, enabling the manufacturer to at a lower lifecycle cost. create and validate virtual models that CONSIDER THIS can serve as reference points for develWhat part of your operations oping molds. The company also plans to would most benefit from digitize its existing catalog—preserving simulation, modeling, and use of a digital twin? 150 years of design contributions.
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Digital manufacturing allows effective identification of production bottlenecks, which permits factories to meet peak demands with optimally ad-
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justed output.
Virtual product prototyping techniques have been characterized by the same 3-D wireframe technique that George Lucas used to create the Death Star in the original 1977 “Star Wars” movie. Engineering has further leveraged the process, layering virtual models with scanned samples to identify suitable materials for manufacturing the product. However, as sustainability has become a critical performance indicator, the process of testing and selecting materials needs to be simplified. Virtual prototyping must therefore support conservation goals—saving valuable resources and promoting sustainability.
Data-driven approach
Following the prototyping stage, manufacturing begins to struggle with the need to replicate the design and functionality of the first product. Currently, this requires expensive physical quality audits with debatable accuracy. Addressing this particular challenge will require a data-driven approach from an engineering perspective. The manufacturing process will www.controleng.com
Building blocks of virtual manufacturing, simulation Cover image: Although virtual manufacturing started out as a way to design and test tools, it has grown to become a powerhouse for supporting production processes and even product development. Digital models capture information about the product for rapid prototyping and eventually mass production on the factory floor. Courtesy: L&T Technology Services
need to capture product data as it is being built, concurrently crafting a virtual model that mirrors the physical product. This sets the stage for implementing a product specification management (PSM) system that can ensure quality as part of the product lifecycle management process. On page 20, see the five steps for digital replicas and rapid prototyping.
Manufacturing ecosystem
The idea is to work towards building a manufacturing ecosystem that is capable of creating components and tools on demand in space, on land, or at sea. At present, laser-forming technologies and digital design data is being used to transmute powder materials into complex avionic structures, such as F/A-18E/F ducts. In a process called selective laser sintering, titanium and other materials are used to print parts small and large.
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A product specification management (PSM) system that can ensure quality as part of the product lifecycle manage-
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ment process.
The case for virtualizing manufacturing is strengthening. When an enterprise uses physical prototypes to carry out design iterations, certain material classes, like metal, cannot be digitally fabricated or machined at a favorable cost. If the final production material varies from the prototyping material, the material properties of the end product cannot be accurately predicted, even when a company implements rapid prototyping or 3-D printing. CONTROL ENGINEEERING
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COVER STORY: SIMULATION When it comes to structural design, tea cups, airplanes, and automobiles involve the same set of challenges. Material selection, durability, and design feasibility will need to be aligned with how the product interacts with real-world forces, heat, and vibration. In this context, virtual manufacturing has been able to take finite element analysis (FEA) to the next level. Welding simulations that factor in thermal and residual stress will help optimizing tooling design and the actual welding process. R&D efforts are under way to develop FEA software to simulate and develop predictions
5 STEPS for digital replicas, rapid prototyping Digital replicas and rapid prototyping can be implemented in five steps.
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Integration and data collection. Physical inspection hardware such as scanners, coordinate measuring machines, and gauges, can be integrated with sensors.
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Data transfer of collected data. Data capture, while the product is making its round on the assembly line, needs to be relayed to the middleware layer.
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Software restructuring of data. At this point, automated mechanical design software refines and structures the data, creating a perfect as-built replica.
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Replica storage for reference, use. The replica is stored in the manufacturing execution system for reference and homologation (certifying to required regulatory standards and specifications).
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CAD, 3-D printing anticipate needs. For maintenance, repair, and overhaul (MRO) operations, a network-centric manufacturing environment can use computer-aided design (CAD) data to almost organically grow production parts. These steps can be used to implement rapid engineering changes in the field or at the maintenance depot. Three-dimensional printing technology is being used by leading aerospace original equipment manufacturers (OEMs) and others to streamline product design and build operations—enabling them to deliver world-class support and eliminate the need for warehouse tools and spare parts.
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A simulated factory floor can monitor various parameters to expose gaps in the production process, highlight cost inefficiencies, and
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reduce carbon footprint.
for automatic process optimization. Once integrated with the control system, it should be able to re-calibrate tools on the factory floor to accept design, tooling, fabrication or material changes without human intervention.
Digital twins simulate everything
Manufacturing’s future lies beyond using virtual product information to improve output quality. We are close to practically replicating the entire factory floor using amalgamated data from the entire production ecosystem, creating a digital twin. A major technology conglomerate already is exploring the concept, creating working simulations of wind farms to forecast equipment failure and increase daily power output by 20%. In this regard, virtual commissioning allows operators to comprehensively verify the sustainability of a manufacturing system by creating a virtual plant and linking it to a real controller. This requires the plant simulation model to be described fully, down to the level of sensors and actuators. By connecting the model to a real controller, engineers can detect potential errors of control programs long before the actual commissioning stage. A simulated factory floor can monitor various parameters to expose gaps in the production process, highlight cost inefficiencies, and reduce carbon footprint. The same concept can be scaled down, and applied to a product in isolation, to understand how it would perform in the real world without taking it off the drawing board. ce
Mayank Pandya is head-manufacturing engineering, L&T Technology Services, a Control Engineering Content Partner. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media, mhoske@cfemedia.com. www.controleng.com
ANSWERS
COVER STORY: SIMULATION Tanya M. Anandan, RIA
3-D robotic welding simulation benefits Teaching robots how to weld using 3-D simulation is beneficial because welding is a complex, precise process that cannot be explained or taught easily to humans.
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lements of advanced motion control, 3-D vision, and robotic control combine in 3-D simulation software for robotic welding. The future in robotic welding is digital and simulation helps show possibilities that might not have been considered before. Genesis Systems Group uses simulation to visualize and demonstrate complex or large-scale robotic processes before anything is built. This is especially helpful for welding, which is a complex, precise process that cannot be easily explained or taught to humans. The 3DG Environment at the Genesis Systems Group Virtual Solutions Center is designed to combine virtual reality and immersive 3-D visualization to visualize a robotic process in the concept and design phases. The 3DG technology is designed to ergonomically evaluate parameters such as welding torch access and robot reach. The
system consists of a 16-panel audiovisual wall that displays 2-D and 3-D images. It’s also portable, which makes it easy to dismantle and set up. “It’s a great tool for us,” said Brendan Brown, virtual solutions engineer at Genesis Systems Group. “With the 3DG Environment, we’re able to draw clients into the experience and give them a real-life feel for what they will get with one of our systems. They get to see what we do upfront and all the pre-order work we do to give them the right solution.” They also use the 3DG system to conduct reviews with their in-house design and tooling groups for a collaborative process. “You wear a set of regular 3-D glasses like you would get at a movie theatre,” Brown said. “Then with the joystick, you can drive around the model, to go around the machine, get underneath it, come inside, and look at it from all angles.”
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KEYWORD: robot, simulation 3-D simulation can be used to teach robots how to weld. Teaching laser welding to robots can reduce distortion and deflection and improve accuracy overall. While robots can be taught how to weld, humans need to have a strong understanding of the process. GO ONLINE
Read this story online at www.controleng.com to learn more about welding’s benefits in manufacturing and see additional stories from the RIA.
CONSIDER THIS What other ways can robotic simulations help manufacturing?
Figure 1, cover image: Immersive 3-D virtual reality technology simulates robotic welding processes for more efficient design and concept review prior to build. All images courtesy: Robotic Industries Association (RIA)/ Genesis Systems Group LLC www.controleng.com
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COVER STORY: SIMULATION
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Simulations show how traditional MIG welding might have 5 mm of draw or deflection in it, but with laser
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welding it’s down to 1 mm.
Figure 2: Reach simulation study for a robotic laser welding application shows possible problems before setup.
Figure 3: Robotic laser seam stepper combines clamping force with laser welding technology to replace traditional resistance welding.
For example, a welding robot on a three-axis gantry is positioned to MIG weld the frame of a large dump truck used in the mining industry and the multicolored sections represent the part. “Some of these parts are 40 ft long,” Brown said. “This part requires multi-pass, heavy thick-plate welding. It’s a 48-hour cycle time to weld one piece. This part actually grew 2- to 3-in. during the welding process just because of the heat and draw on it (distortion).” Brown said the simulation environment allows them to demonstrate advanced processes to their clients that they may not have imagined were feasible. The automotive and appliance industries are starting to take a closer look at laser welding. “We won a handful of customer orders because we were able to laser weld, which has a lot less heat
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and distortion. We’ve done simulations to show them. One gentleman in my department does strictly weld distortion and heat analysis. He can show a customer how with traditional MIG welding on a certain part you might have 5 mm of draw or deflection in it, but with laser welding it’s down to 1 mm.”
Laser welding benefits
Across the hall from their Virtual Solutions Center is Genesis’ Automated Solutions Center, where they test technologies such as remote laser welding and a laser seam stepper. Genesis is using the robotic laser seam stepper to test customers’ parts that have been traditionally spot-welded. They also have a few robotic systems already in the field. The laser seam stepper is a servo-driven, selfcontained laser head. “One of the advantages is that you don’t need the large laser safety cabinets common with most laser welding processes,” Brown said. “The robot will move above the part, then drive the laser head down, basically applying force with the head, which helps push the two materials together. Then it runs a bead up to 40 mm in length. You don’t need the giant light-tight enclosure, and a lot less fixturing is involved. It’s a much better finish than a traditional spot weld and certainly more consistent.” Brown said advanced welding technologies such as remote laser welding and the laser seam stepper still prompt the same concerns for part fit-up and other critical variables as do conventional welding processes. The process still has to be understood in its entirety to successfully automate it. ce
Tanya M. Anandan is contributing editor for the Robotic Industries Association (RIA) and Robotics Online. RIA is a not-for-profit trade association dedicated to improving the regional, national, and global competitiveness of the North American manufacturing and service sectors through robotics and related automation. This article originally appeared on the RIA website. 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. www.controleng.com
ANSWERS
PROCESS | STANDARDIZATION Chris Sullivan, Valin Corp.
Customers need process control building blocks and standardization Despite the demand for standardized communication protocols among manufacturers, end users and manufacturers face challenges when trying to agree on a path.
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n the industrial refining marketplace, process control building-block manufacturers of transmitters, valves, and flowmeters are positioning themselves to become single-source suppliers for their customers. Although the manufacturers’ portfolios are attractive and support most engineering applications, the future desire of the marketplace is to convert to universal language protocols that communicate with the best-in-class building-block products in their applications. What refineries really want are the best-inclass products that employ a universal language that will communicate with their legacy instrumentation to improve productivity and the bottom line. Universal language protocols may reduce process control building-block variable risk and increase process throughput. Customers are looking for their suppliers to become partners who help improve their processes, standardize communications protocols, and drive their profitability.
Universal language protocols may reduce process control building-block variable risk and increase process throughput.
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Despite the demand for standardized communication protocols among manufacturers, both the manufacturers and end users face challenges when it comes to agreeing on a path.
The pitfalls of single-source suppliers
Before the internet, business between manufacturers and customers was carried out between engineers and salespeople. Businesses received their information, parts, and application understanding from competing sales representatives.
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However, after the internet began to take hold of the market, that relationship diminished due to the availability of online information and product offerings. Engineers and purchasing personnel found that they could choose what was best for their processes without a middleman. Unfortunately, understanding the qualified products available in the market and where to find them took a great deal of time that the engineers didn’t have. This brought back a rise in the relationship between engineers who were experts in their processes and salesKEYWORD: Process control people who were experts in their marSelecting best-in-class process kets and products. Refineries wanted instrumentation is what is best for a single-source supplier to take care the customer, but standardization of their product and process partsis becoming more necessary buying, isolating the variety of prodfor profitability because of the difficulty of communicating ucts available to them. These suppliers between parts that are not from became single-source and the only the same supplier. resource a refinery could use for proThe oil refineries in today’s cess-control building blocks. marketplace are using legacy However, there are a few concerns technology that has not been upgraded to 21st century with using a single-source supplier.
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1. Best-in-class product ideal for the application may not be on the refinery’s approved vendor list, and therefore, unavailable for purchase to the single-source supplier. 2. A single source prevents learning about better products that may be available to become qualified products. 3. If a single source is unable to provide a product due to floods and natural disasters, the refinery has no alternative to replace the singlesourced product it needs. This can mean a serious loss of productivity and profits. Of course, pulling process CONTROL ENGINEEERING
standards because what they are using works for their current profitability models. The market has decided that the next step in employing process control building blocks is universal communication with manufacturers and distributors that can improve their processes and profit.
GO ONLINE Read this story online at www.controleng.com for more information on process control building blocks and standardization.
CONSIDER THIS How can a product help make your processes more efficient and profitable?
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PROCESS | STANDARDIZATION control building blocks from multiple sources has an internal cost, but the improved process performance and uninterrupted process flow may outweigh the cost of finding out.
What is best for the consumer?
For obvious reasons, selecting best-in-class process instrumentation is what is best for the customer, but standardization is becoming more necessary for profitability. This is due to the difficulty of communicating between parts that are not from the same supplier. For example, an engineer might find a transmitter that works best with his or her process, but can’t properly communicate with the much-older flowmeter already in
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Cost management, unit performance, experience, and process knowledge, along with universal communication
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protocols, are all part of the answer.
the process because they are from different suppliers. This requires the engineer to make a software upgrade in the process to compensate for the different language protocols. The problem here is a software upgrade is essentially just a Band-Aid on the process, and doesn’t allow it to run at maximum efficiency. Another concern is that with the attrition rate of older personnel retiring, the software upgrade employed may be outside the awareness or not understood by the new personnel inheriting the process. In a single application, this may not be a concern. However, in hundreds of applications it may be.
Making the change
The challenges manufacturers must overcome to realize a universal protocol are enormous. Some refining customers have been making oil products since 1900. Oil refineries in today’s marketplace are using legacy technology that has not been upgraded to 21st century standards because what they are using works for their current profitability models. For refining customers who want to upgrade their refinery’s technical capability and make the investment, universal protocol is being requested to support their needs. This includes communicating to legacy instrumentation seamlessly, securely, and robustly. Manufacturers are being asked to consider
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universal protocols in their process control building-block strategies to bring these older refineries up-to-date. The challenges refinery engineers and procurement personnel have in making this transition are equally vast. Even though upgrading processes can be expensive, the reward for manufacturer and customer is increased product throughput and profitability. Refining customers also need manufacturers to provide experience and knowledge of the customer’s process to improve it. Manufacturers can provide this capability through their distributors. With standardization comes the risk of creating a commodity mentality in the marketplace. To overcome this, distributors must provide good technical knowledge of their customers’ processes including not only instruments they are providing, but a clear understanding of all available products on the market. Distributors now can become the resource of information, experience, and best-in-class products for their refining customers. A partnership can be created to strive toward universal protocol communication for process control building blocks and encourage the marketplace to continue to strive for that outcome. It is in the best commercial interest of all.
Future standardized communication
Refinery customers always will ask, “How can a product help me make my process more efficient and profitable?” Cost management, unit performance, experience, and process knowledge, along with universal communication protocols, are all part of the answer. Manufacturers face the challenge of convincing their customers to upgrade processes with their products, and standardized communication among process control building blocks could give them an advantage. The refinery will be more inclined to invest and improve their process because the universal protocol language will make it easier and more efficient. Essentially, the customer is the market, and the market has decided that the next step it wants to take in employing process control building blocks is universal communication with manufacturers and distributors that can improve their processes and profit. Suppliers who provide this capability will have priority over those who do not. ce
Chris Sullivan is director, refining and petrochemical, at Valin Corp., a technical solutions provider for the technology, energy, life sciences, natural resources, and transportation industries. Edited by Jack Smith, content manager, CFE Media, Control Engineering, jsmith@cfemedia.com. www.controleng.com
ANSWERS
POWER OVER ETHERNET Sree Potluri and Andy Garrido, Beckhoff Automation
One cable automation combines communication and power New connector technologies expand EtherCAT and EtherCAT P communication with additional power supply options.
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onnecting individual field devices, decentralized terminal boxes, and machine modules using one cable is accomplished by combining industrial Ethernet communication via EtherCAT with the power supply required by the connected components. For the 24 V field level, this was implemented using the EtherCAT P technology expansion connected via special M8 connectors. To provide additional power supply capabilities via one cable, new ENP and ECP connector types combine EtherCAT or EtherCAT P communication with additional power conductors in one cable. They are easy to use, are mechanically coded to prevent installation errors, and offer an IP67 protection rating. The flexible single-cable automation design works
for many applications. Different sections in a network can be connected by selecting appropriately designed combined power and Ethernet cables for devices and components according to power requirements. Unrestricted openness for mixed network topologies enables flexible transitions between: • EtherCAT P communication with integrated power supply (one cable solution with M8 connector) • One cable solution using hybrid cables that combine an EtherCAT or EtherCAT P communication element with additional power conductors (one cable solution with the new ENP or ECP connectors)
With various performance classes for the connection of components via the ECP and ENP connector variants, One Cable Automation provides the ideal foundation for modular machine and plant design. Courtesy: Beckhoff Automation
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ANSWERS
FEATURE
• A conventional two-cable solution with separate power supply (EtherCAT via M8/RJ45 connector or EtherCAT/EtherCAT P via ENP/ ECP connector).
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KEYWORDS: Power over Ethernet, EtherCAT, industrial Ethernet Communications and power in one-cable design The various applications for EtherCAT and power over one cable Explaining EtherCAT and EtherCAT P communication with new connector types. CONSIDER THIS:
How much time or space could an automation design save by using one cable power and EtherCAT in a standard Ethernet cable design?
ECP and ENP connector types implement the combination of communication and power elements in different performance classes that range from 3 amps to 64 amps, in one compact design. The connector system is new development and meets the full scope of OCA requirements regarding connected devices and modules, including drives, sensors and actuators, electrical cabinets, and entire machine modules. The benefits of this connector system include: • Reducing the system to the essentials – namely the EtherCAT or EtherCAT P communication element and dc or ac power supply lines – creates cost-effective connection concepts • The system is easy to use due to the bayonet connections with mechanical and color coding • The power transmission integrated into EtherCAT P can eliminate the four wires normally required for 2 x 24 V • Allows the use of thinner, lower-cost cables and, alternatively, the supply of other voltages.
Power over Ethernet (PoE) standards from IEEE Multiple standards in various industries and applications are included in Power over Ethernet (PoE). The original PoE task force from The Institute of Electrical and Electronics Engineers (IEEE) was created in 2000. According to a July 10, 2017, presentation, “Practical PoE Tutorial,” the standards include:
Power delivery over BASE-T PHYS (4-pair, 2-pair, 1-pair) • IEEE Std 802.3af-2003 DTE Power via media dependent interface (MDI) • IEEE Std 802.3at-2009 DTE Power Enhancements • IEEE P802.3bt DTE Power via MDI over 4-Pair Task Force • 10M/100M/1G/2.5G/5G/10G (4-pair, 2-pair) • IEEE Std 802.3bu-2016 1-Pair Power over Data Lines (PoDL) • 10M/100M/1G/10G (2.5G/5G) (1-pair). ISO/IEC standards support PoE, and more are under development. Voltages and currents were increased from nominal beginnings (14 and 24 V) using RJ-45 connectors to larger cables, now up to 50 V (45, 60 W) and 52 V (75 and 90 W). See www.ieee802.org for more information. Mark T. Hoske is content manager, Control Engineering, CFE Media, mhoske@cfemedia.com.
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EtherCAT P, 24 V, one cable
With EtherCAT P, EtherCAT technology has expanded to combine high-speed EtherCAT communication with a 24 V system and peripheral power supply (US or UP), in a standard Ethernet cable. Special M8 connectors were developed for EtherCAT P with mechanical encoding that eliminates possible confusion with connectors used for standard EtherCAT devices. A specific machine’s design or plant installation is simplified using PC-based control software tools that help specify all individual EtherCAT P consumers and cable lengths to configure the highest performance and most cost-effective EtherCAT P network.
Connector types: EtherCAT, EtherCAT P
If higher power or supplies are required in addition to the 24 V system and peripheral power supply via EtherCAT P, power can be supplied via corresponding hybrid cables with the ECP and ENP connector types for this purpose: • ECP (EtherCAT P + Power): This connector series combines a compact, trapezoidal EtherCAT P element (using the same pin allocation as the EtherCAT P encoded M8 connector) with additional power pins. In this way, the 24 V supply integrated into EtherCAT P is complemented with an additional power supply line. • ENP (EtherCAT/Ethernet + Power): These connectors combine a trapezoidal, central communication element with additional power pins in the same way as ECP. The trapezoidal element has an inverse design to prevent incorrect connections and provides data transmission via EtherCAT, standard Ethernet, or other Ethernetbased communication protocols. Connector sizes from B12 to B36 are available with a varying number of power pins (two to six pins) so they can be adapted to the requirements of different network types and the power consumption for connected consumers. The complete and fulllength 360-deg shielding of the central trapezoidal element continues the typical high-performance of EtherCAT. (See cable photo on p. 17.) Expanding the one-cable designs with the growing diversity of the EtherCAT P, ECP, and ENP devices and components also expands the range of application options for users. ce
Sree Potluri, I/O application specialist and Andy Garrido, I/O product marketing, Beckhoff Automation. Edited by Emily Guenther, associate content manager, Control Engineering, CFE Media, eguenther@cfemedia.com. www.controleng.com
ANSWERS
INSIDE MACHINES Frank Lamb, Automation Consulting LLC
DPM-COUNTERS-TIMERS UPM-F
Picking the right discrete sensor for a machine application There are many considerations for picking a discrete sensor for a machine application. These include if the sensor is being used for position detection or part detection or if the application is hazardous.
W
hen designing machinery, one of the first tasks for an engineer is to select discrete sensors for the application. Generally, discrete sensors can be divided into two categories: those that detect the positions of mechanisms and tooling (parts of the machine) and those that detect the parts being processed.
Types of discrete sensors
It’s easy for designers to select hall-effect sensors for pneumatic cylinders since these often are presented as accessories. Halleffect sensors are designed to detect the magnetic piston inside of a cylinder body and determine whether it is extended or retracted. This works fine as long as the cylinder shaft can’t become unattached from the tooling; detection of tooling using an inductive proximity switch is the only foolproof way to determine that the tooling is in the correct position. Photoelectric sensors are useful for applications when the tooling is not made of metal. Photoelectrics and inductive proximity switches often are used for part detection. Photoeyes are useful for designers since they can be located farther from the target. This opens up several sensing possibilities such as through-beam (separate emitter and receiver); retroreflective (using a corner-cube bicycle type reflector or reflective tape); or diffuse (using light reflected off of the target). Form factor, such as fiber optics that can reach into tight spaces or larger self-contained
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BARGRAPHS NTM-M
sensors that may have a longer range, also should be considered. Visible beam photoelectrics are often easier to align and infrared sensors also have a longer range. Laser sensors, while more expensive, can be used to detect smaller parts and also extend the sensing range. The other important consideration that needs to be made is the voltage and output type of the sensor. With the exception of some large conveyor systems and process control facilities, discrete sensors are almost always 24 V dc. Positive-negative-positive (PNP) sourcing sensors are used most commonly in the U.S., but equipment from other countries may use negative-positive-negative (NPN) sensors, or sinking types. Sensors with contact closure type outputs such as limit switches also are used occasionally, but like ac sensors, they are becoming less common. Contact closures are best for applications where the sensor does not switch often. Physical contacts wear and often have a specified lifetime number of operations. Sensor specification depends on a lot of factors, such as: • How much space is available for mounting • What type of target is being detected • With what type of control system it needs to be interfaced • Sensor cost and availability of replacements.
CONTROL ENGINEERING
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COMMON FEATURES (ALL SERIES)
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Bring Your Machine To Life With Advanced Control Algorithms
ANSWERS
INSIDE MACHINES
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Generally, discrete sensors can be divided into two categories: those that detect the positions of mechanisms and tooling (parts of the machine) and those that detect the
Advanced Control Algorithms
’
parts being processed.
Ethernet Connectivity
Sensors for harsh conditions
Automation Controller Intelligent Drives Custom Motor Design
Custom Software Vision
Aerotech can partner with you to design advanced control algorithms for your specific application to maximize machine performance. In our concept machine above, Aerotech’s standard controller is flexible enough to control the simple motion of moving the head to and fro, or the more complicated coordination of the wings and legs to track its next meal detected by the vision system. Aerotech can accommodate your custom automation controller needs by creating algorithms at the application, motion engine, and/or firmware layer of the architecture to easily control complicated machines. If you have a need for special control algorithms, contact Aerotech today. We customize Aerotech automation for you
In some cases, resistance to chemicals and water are also a consideration. Coolant in metal cutting applications and caustic washdown liquids in food processing are among substances that may need to be evaluated. This may contribute to the type of electrical connection the sensor may require; quick disconnect or hard conduit. Automation vendors can help when selecting discrete sensors for a machine application. Keeping these considerations in mind when making a decision will make the process much simpler. ce
Frank Lamb, Automation Consulting LLC, is a Control Engineering Editorial Advisory Board member. Automation Consulting LLC is a CFE Media content partner. Edited by Chris Vavra, production editor, Control Engineering, CFE Media, cvavra@cfemedia.com.
M More ANSWERS
KEYWORD: discrete sensors Discrete sensors can be divided into two categories: those that detect the positions of mechanisms and tooling and those that detect the parts being processed. Photoelectric and hall-effect sensors commonly are used for discrete applications. Depending on the application, resistance to chemicals and water also should be considered when picking a discrete sensor GO ONLINE Read this story online at www.controleng.com for related links.
CONSIDER THIS What other considerations should be made when selecting a discrete sensor?
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Access the Machine Vision Digital Report at www.controleng.com/ magazine with the November 2017 digital edition or see all available Digital reports at www.controleng.com/ DigitalReports.
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ANSWERS
II O T FOR OEE
Fritz Cleveland, Banner Engineering
Wireless as a means to overall equipment efficiency Accurate machine run-time data helps determine why production goals aren’t met.
F
ield devices make operations visible and support data-driven decision making. Using technologies associated with the Industrial Internet of Things (IIoT), device-level data is accessible to operators and plant managers, offering insight into machine performance and process inefficiencies. Real-time remote monitoring of machine status allows addressing issues as they arise, regardless of whether or not an operator is present. Personnel monitor multiple machines on a factory floor from a convenient location. Operators resolve small issues before they become big problems. Wireless technology can provide users with remote-monitoring capabilities on the fielddevice level and how this data can be used to help improve overall equipment effectiveness (OEE).
Wireless I/O devices are easier
In past, wireless systems were difficult to install and complicated to maintain. Wireless technology has advanced significantly over the years. Today many remote monitoring solutions offer reliable wireless communication integrated into one, inexpensive unit. These wireless I/O devices are easy to install, and then uninstall and move to a new location as monitoring requirements change. KEYWORDS: A wireless I/O device can collect digiOverall equipment tal and analog sensor readings and forward effectiveness (OEE), wireless this data to a central collection point for Wireless technologies provide analysis. Several sensors can connect to a remote monitoring capabilities. single node, and 47 nodes can exist withOEE components in a single radio network. This means mulMachine health and trends tiple sensor readings aggregate into one ONLINE EXTRA gateway device before being forwarded to See the discrete manufacturing a host-controlled system for analysis. navigation menu at Serial-data radios further extend this www.controleng.com for related coverage. wireless I/O network. Serial-data radios are back-haul devices that receive serial data CONSIDER THIS from another serial-data radio, or a serial Are your machines making your connection to a gateway, and forward the life easier, or more difficult?
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Six ways to lose manufacturing productivity The OEE Foundation identifies 6 “Big Losses” to manufacturing productivity:
1. Unplanned stops for equipment failure
2. Stops for setup, adjustments, or changeover
3. Idling or minor stops (for issues such as a material jam or a blocked sensor)
4. Reduced equipment speed 5.
Scrapped work
6. Rework. data to another remote serial device. Chaining data radios expands the network to meet the remote-monitoring needs of many applications.
An efficiency calculation
Overall equipment effectiveness (OEE) is a calculation of manufacturing process efficiency involving three primary factors: availability, performance, and quality. The availability factor considers events that decrease total runtime, including planned stops (such as for product changeover) and unplanned stops. The performance factor considers anything that decreases the speed of the manufacturing process while it is running. The quality factor accounts for parts or products that do not meet quality standards (parts that must be scrapped or reworked, resulting in wasted time). www.controleng.com
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ANSWERS
II O T FOR OEE
What goes into OEE
An OEE calculation taking these factors into account expresses its result as a percentage value, with 100% meaning only good parts are made (quality), as quickly as possible (performance), and without any stops (availability). Calculation results provide actionable insights into the critical sources of waste in a manufacturing operation. To reduce OEE losses and minimize their impact, visibility into where and when inefficiencies occur is essential. This is where access to data from sensors and indicator lights become very important. Logged data from sensors and indicator lights installed on machines can help calculate OEE and identify steps to improve efficiency of machines, processes, and people.
‘
By remotely monitoring motors, pumps, compressors, fans, blowers, and gearboxes for increases in vibration, problems are
’
detected before they become severe. Machine runtime trends
Tracking machine and process data trends helps identify when and where losses are occurring. However, manually monitoring production machine status is time-consuming. Depending on facility size, manually monitoring machine status slows down production and requires additional time more effectively used elsewhere. With a wireless system, on the other hand, using a tower light with a wireless radio base offers not only local indication of machine status but also remote status of each light module. By logging results from machine-status indicators like tower lights, users can track trends in individual machine up-time and cycle counts for timely updates. Data can be used to identify whether a bottleneck is caused by a machine or personnel issue. Capturing machine status helps users identify causes of production loss. This information, necessary to identify and drive efficiency improvements, was most likely previously unavailable. This was the case recently when for one manufacturer accurate machine runtime data helped
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determine why production goals were not being met. Operators blamed machine downtime for the failure and maintenance personnel blamed the operators. Based on the data, facility managers identified what exactly was transpiring.
A machine’s health
In addition to monitoring machine performance metrics, wireless sensor networks also check up on machine health. Machine predictive maintenance is challenging because minor performance changes can be hard to detect without the proper tools. Remote condition monitoring using a wireless system plays a key role in predictive maintenance and helps prevent costly downtime. To take just one brief example, vibration is a key machine parameter. Machine vibration is often caused by imbalanced, misaligned, loose, or worn parts. As vibration increases, so can damage to the machine. By remotely monitoring motors, pumps, compressors, fans, blowers, and gearboxes for increases in vibration, problems are detected before they become severe. A wireless vibration and temperature sensor serves as a “check engine light” for machines by measuring RMS velocity, which provides the most uniform measurement of vibration over a wide range of machine frequencies. After mounting the vibration sensor, a user must collect enough vibration data to establish a baseline for the machine. Initially set the threshold at 1.5 or 2 times the baseline. When the threshold has been exceeded, the wireless vibration and temperature sensor can provide local indication of the problem, the signal can be sent to a wireless tower light on a central location, or an email or text alert can be sent. The vibration and temperature data can also be sent to a wireless logic controller or programmable controller for collection and analysis.
Final words on remote monitoring
Remote monitoring capabilities are making it easier for manufacturers to identify and remedy causes of waste within their facilities. By using wireless technologies, manufacturers can quickly and easily gather data needed for OEE calculations, as well as gain valuable metrics for predictive maintenance to maximize their machine performance. ce Fritz Cleveland is product manager, wireless products, at Banner Engineering; edited by Kevin Parker, senior contributing editor, IIoT for Engineers, CFE Media, kparker@cfemedia.com. www.controleng.com
INNOVATIONS ®
BACK TO BASICS
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M More INNOVATIONS
Three cybersecurity changes that manufacturers should implement
As connectivity increases, so does the level of sophistication in cyber attacks against manufacturers and other industries.
The official ballot is open for voting for Control Engineering North American print and digital edition subscribers, until Dec. 19. Cast your vote using CFE Media’s New Products for Engineers platform at www.controleng.com/NP4E.
Three cybersecurity recommendations 1. Isolate key operations technology controls from public networks if they are to be reasonably secure.
NEW PRODUCTS
2. Governments should encourage simpler, safer control technology. 3. Market incentives must be realigned for cybersecurity.
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M More INNOVATIONS System Integrator of the Year www.controleng.com/SIY
GLOBAL SYSTEM INTEGRATOR REPORT ...was mailed with this issue and is available at www.controleng.com/Magazine under December. Need help on your next project? Find system integrators by name or various parameters at www.controleng.com/Global-SI-Database Digital edition includes easy access to supplement (including this month, Oil & Gas Engineering) and topical Digital Reports.
36 34 36 PE Have a New Product for Engineers to submit for consideration? Do so here: www.controleng.com/NP4E
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Check out the New Products for Engineers Database and search hundreds of products, with new innovations added every day. Look for this logo on the Control Engineering home page. www.controleng.comNP4E
CONTROL ENGINEERING
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INNOVATIONS
NEW PRODUCTS FOR ENGINEERS
Apps control functions of digital pneumatics Festo Motion Terminal digital piezo pneumatic valves replace more than 50 components with standard hardware and software apps; the system saves 70% design time and cuts energy use up to 90%.
F
esto Motion Terminal is said to be the world’s first standardized platform that will develop into a “cyber-physical system,” fusing mechanics, electronics, and software. The adaptable and flexible system enables design and construction of intelligent machines, ensuring Industrie 4.0ready systems, with use of digital pneumatics. Combining 10 motion apps (40 more are planned) with piezo valve technology allows the system to replace more than 50 individual components. These include flow control valves, directional control valves, proportional regulators, soft stop components, and pneumatic positioning tasks to improve energy efficiency. The valve bridge circuit in the valve allows pneumatics to be digitized. Ease programming and setup with a CODESYS controller with OPC Unified Architecture (UA) expansion capabilities. With an Ethernet interface and the intuitive web configuration user interface, parameterization of every valve can be done via a PC and a web server; no additional configuration software is
required. It also can be done directly via the machine’s control system. Up to 16 fast analog or digital inputs can be selected for control applications, such as soft stop. System sensors are integrated into the actuator, thus facilitating fast control. Energyefficient basic technologies using piezo valves control the main valve stages, allowing for proportional pilot control with minimal energy consumption. Compared to widely used conventional solenoid valves, these reduce energy consumption for pilot control by up to 90%. Among motion apps, Festo developed “ECO drive” or “selectable pressure level” to reduce energy consumption. It can be supplemented by diagnostic apps to locate leaks. Design, among the biggest costs in machine and system building, accounts for 25 to 30% of total project cost. Time saved compared with designing and parameterizing a modular valve terminal and additional individual components is up to 70%. Shipments are expected to start in December 2017.
Festo, www.festo.com/VTEM
Input #200 at www.controleng.com/information
Metal-seated ball valves for severe service environments
Conval’s Camseal metal-seated ball valves are designed for severe service environments. The valves are available in ½- through 4-in. sizes with top entry, socket weld, butt weld, flanged ends and in pressure classes ranging from ASME 900 through 4500. N and NPT stamped valves are available for nuclear applications. The Camseal design features zero body, seat, and stem leakage on stand-alone and actuated valves. The ball valves are designed for easy inspection, maintenance, and repair. The cartridge is removed easily for on-site parts replacement, reassembly, and reinstallation. Other features include robust stem-ball engagement, bearing support, enhanced chrome carbide coating, and a mounting pad. Conval, www.conval.com
Input #201 at www.controleng.com/information
Fiber optic microswitch series
Micronor’s MR386 ZapFREE Microswitch is a fiber optic microswitch designed to meet the challenging EMC requirements of MRI, medical, and industrial applications. The entirely nonelectrical, totally-passive optical sensor provides electromagnetic interference (EMI) and radio frequency interference (RFI) immunity, isolation from high voltage and lightning, safety in explosive atmospheres, and can operate interference-free over very long distances—up to 4,000 m. Two models—industrial and MRI safe—are offered. The industrial model targets challenging environments and features an extended temperature range of -40 to 80 ºC. Micronor, www.micronor.com
Input #202 at www.controleng.com/information
Surge protective device
Phoenix Contact’s Termitrab surge protective device (SPD) is designed for measurement and control applications, and starts from an overall width of 3.5 mm. This means that the protective device can protect up to 572 signals against surge voltages on just one meter of DIN rail. The integrated disconnect device is designed to ensure safe behavior in the event of overload. It signals the status on each individual protective device mechanically without auxiliary power. Optional remote signaling modules monitor the status of up to 40 neighboring surge protective devices by means of a photoelectric barrier. Installation is simplified: no additional wiring or programming is required for the protection modules. Phoenix Contact, www.phoenixcontact.com Input #203 at www.controleng.com/information
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Embedded computer for DAQ applications Advantech’s MIC-1800 series of data acquisition (DAQ) embedded computers are a compact platform designed to provide analog signals and advanced functions such as analog trigger and a waveform generator. The MIC-1800 series feature multi-function, 16-channel, and 12/16-bit resolution. With up to a 1MS/s sample rate, users can acquire enough data to display the measure waveform completely. For analog input, users can set an analog trigger to start collecting data only when a certain threshold is crossed, so unnecessary signals can be filtered out. The MIC-1800 series products also have built-in waveform generators so there is no need to purchase any extra device. A detachable terminal block that enables direct connection with sensor signal lines saves a lot of space and eliminates some wiring as well. The DIN-rail mounting makes the MIC1800 series compatible with distribution boxes and control cabinets for many different kinds of machines.
Unlock new services with your machines data!
Advantech www.advantech.com
NEW Flexy205!
Input #204 at www.controleng.com/information
IIoT gateway & remote access router
Temperature transmitter with intrinsically safe sensor connections Moore Industries’ THZ3 compact Dual Input Smart HART Temperature Transmitter in DIN Rail Mount housing comes with associated intrinsically safe (AIS) sensor connections. The AIS option allows direct connection of sensors located in hazardous areas since it includes an internal intrinsically-safe barrier. The universal mounting bracket easily snaps on and off of 35 mm Top Hat DIN-rails and standard relay tracks. The THZ3-DIN with the AIS option is an associated apparatus suitable for mounting in non-hazardous or Class I, Division 2/Zone 2 hazardous locations with sensor input terminals connected to equipment or sensors located in Class I, II, III, Division 1/Zone 0/1 hazardous locations. There is no need for the additional cost of an IS barrier, cabinet space, high integrity clean ground connection, separate power supply, or custom vendor backplanes.
Read & monitor your machine’s data in real-time (alarms, HMIs, etc.) Collect data from your PLC and push towards value-added services (Remote/Cloud) %HQHÀW IURP D ZRUOG FODVV Remote Access solution ...and much more!
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Moore Industries, www.miinet.com Input #205 at www.controleng.com/information
CONTROL ENGINEERING
December 2017
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input #11 at www.controleng.com/information
INNOVATIONS
See more New Products for Engineers. www.controleng.com/NP4E
NEW PRODUCTS FOR ENGINEERS
PE
Pressure transmitter with low-power voltage output
Endress+Hauser added a 1-5 V dc low power output option to the PMP71 pressure transmitter that draws 17 mW of power at 9 V, making the PMP71 consume less power. This low-power draw makes the PMP71 ideal for battery- and solar-powered applications such as remote oil and gas wellheads, offshore platforms, or pumping stations where low power consumption is critical. The PMP71 measures absolute and gauge pressure of gas, steam, or liquid and has built-in algorithms to calculate level, volume, and mass of liquids. Measuring spans are available in ranges from -6 to 6 psi up to -15 to 10,500 psi. For safe operation at process temperatures up to 752°F, it has a piezo resistive measuring cell and metallic welded process isolating diaphragm. Endress+Hauser, www.us.endress.com
Input #206 at www.controleng.com/information
Industrial UPS system
Falcon Electric’s SSG industrial uninterruptible power supply (UPS) family features a lithium iron phosphate LiFePO4 battery. The online rackmount UPS models (1.5 to 6 kVA) provide a longer service life, longer backup times, lower weight, and higher safety than UPSs with lead-acid batteries or other LiFePO4 batteries. In addition, the SSG UPS lowers total cost of ownership (TCO) by reducing costly battery replacements and downtime. It is designed for continuous use from -20 to 55°C with no performance degradation. It also features no thermal runaway issues that are inherent in Lithium-ion chemistry with lower lifetime costs. Falcon Electric Inc., www.falconups.com Input #207 at www.controleng.com/information
Slim industrial power supplies 80–480 Watt with excellent efficiency.
Splicing connectors for grounding and bonding
The Wago 221 Lever-Nut splicing connectors are UL467-listed for grounding and bonding applications. Lever-Nuts are built around Cage Clamp spring connection technology, which provides well-defined contact points and high contact force for each wire. They are designed to create a very low resistance connection, qualifying them for effective, efficient, and safe grounding. This additional listing expands the scope of applications for the 221 Series by providing a tool-less, intuitive, easyto-use (and re-use) method for connecting and combining ground wires up to 12 AWG. They can be used in branch circuit j-boxes in commercial and residential construction as well as in industrial control cabinets.
TIB series • High power factor by active power correction • Very high efficiency up to 94.5 % • 150 % peak current for 4 sec • Protection against back power, overload and short circuit • Alternative side-mounting for flat panels
Reliable. Available. Now.
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Wago Corp., www.wago.com
Input #208 at www.controleng.com/information
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INNOVATIONS
BACK TO BASICS Gregory Hale, ISSSource
Three cybersecurity changes that manufacturers should implement As connectivity increases, so does the level of sophistication in cyber attacks against manufacturers and other industries. Three security recommendations for manufacturers are highlighted.
I M More INNOVATIONS
KEYWORDS:
cybersecurity, IIoT Cybersecurity attacks against manufacturers are more sophisticated and are targeting more areas than ever before. Companies need to isolate operations technology (OT) from the network and governments should support simpler and safer control technology. Cybersecurity may have improved, but companies are not more secure.
GO ONLINE Read this story online at www.controleng.com for additional stories from Gregory Hale about cybersecurity.
CONSIDER THIS What else can companies do to protect themselves from potential cybersecurity attacks?
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t is difficult to paint a rosy picture of security today. Attacks are more sophisticated and the attack surface has broadened. There aren’t any easy answers, but the reality is there are solutions and manufacturers can win in the end. “The systems you are in charge of are under attack,” said Dr. Joel Brenner, MIT/Internet Policy Research Initiative (IPRI)-CIS during his keynote address at the Industrial Controls System Joint Working Group 2017 Fall Meeting in Pittsburgh, in September. “The ability to carry out the attack are not only with nation states, but by well-funded attack groups.” That means critical sectors need protection, but keeping all the critical areas secure would not be possible. “There are critical sectors and then there are really critical sectors,” Brenner said, breaking the critical areas into four key sectors. “The four sectors are oil and gas, financial, electricity, and communications.” Recent attacks on the British national healthcare services, Ukrainian power suppliers, Saudi oil company Aramco, and Qatari gas enterprise Ras Gas demonstrate that there have been an increasing amount of assaults against critical infrastructure organizations. While there are advantages to a more digital manufacturing enterprise, there are dangers. Increased connectivity, digitization, and application of the Industrial Internet of Things (IIoT) can make companies more vulnerable to new types of attacks. Brenner offered three security recommendations for manufacturers:
1. Key operations technology (OT)
controls must be isolated from public networks if they are to be reasonably secure.
Not all networks need to be segregated, only key aspects of OT controls, he said. He admitted there are differences of opinion about appropriate degrees of separation. “Taking control off the internet does not mean taking it away from digital,” he said. “Not all functions need to be facing the public internet. Some functions need to be locked up. There are lots of ways to figure out how to isolate.”
December 2017
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2. Governments should support a market for simpler, safer control technology.
In this world, complexity is the enemy and malware is easy to insert into the millions of lines of code. In addition, he said, general-purpose microchips and general purpose controls are unsuitable for controlling sensitive OT. “If we are going to have simpler controls, there has to be a market for them—and it needs support from governments across the world,” he said.
3. Market incentives must be realigned for cybersecurity.
Retirement of legacy systems should be a priority. Brenner said governments should create tax incentives to accelerate the retirement of legacy systems. When it all comes down to it, he said, “The most difficult cybersecurity challenges are economic and political—not technological.” He believes the main challenge in doing security research is to quantify network risk. There needs to be more facts and figures; the inability to quantify risk impedes security. “The biggest issue of risk is not the silicon-based element in the computers, it is the carbon-based unit in the chair,” Brenner said. The industry has been working on security issues for 20 years and Brenner doesn’t feel there has been any real difference in risk. “We have been facing the consequences of 20 years of wishful thinking,” he said. “Cybersecurity is not getting any better. We have been walking backward on cybersecurity for 20 years. Your security may be better, but we are not more secure. We have got to understand the fundamental problems are political and connected to national will. Now is the time to be clear headed and honest with ourselves on the depth of the problem.” ce
Gregory Hale is the editor and founder of Industrial Safety and Security Source (ISSSource.com), a CFE Media content partner. Edited by Chris Vavra, production editor, CFE Media, cvavra@cfemedia.com. www.controleng.com
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