www.controleng.com
Proximity Sensors for Less Over 700 models to choose from… Proximity Sensors We’ve got the high-quality, industrial proximity sensors you need at the low cost you’re looking for. Our vast selection of inductive, magnetic, capacitive and ultrasonic sensors is constantly growing and includes many sensing options and ranges, sizes, body styles, etc. All at prices you won’t find anywhere else.
Inductive Proximity Sensors
Starting at $14.00 (AES-AN-1A) • Industrial and harsh duty applications - Food and beverage (IP69K) variants - Stainless steel variants - NEW! Weld Spatter Resistant Models - NEW! Correction Factor 1 (K1) Models • Standard, extended and triple sensing distances • Tremendous variety of sizes: - Tubular (3mm, 4mm, 5mm, 6.5mm, 8mm, 12mm, 18mm and 30mm) - Rectangular (from 5mm to 40mm profiles) • AC, DC and AC/DC powered models • Ratings from IP65 up to IP69K • Quick-disconnect or axial cables • cULus & CE approvals • Lifetime warranty
Magnetic Proximity Sensors Starting at $41.00 (MDR-AP-1F) • Industrial and harsh duty models • Wide variety of sizes: - 8mm round - 12mm round - 18mm round - Rectangular • IP65/IP67 or IP68/IP69K rated • Quick-disconnect or axial cables • cULus & CE approvals • Lifetime warranty • Damping magnets also available
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Capacitive Proximity Sensors
Starting at $91.00 (UK6A-DN-0E) • Industrial automation models • Sensing distances from 300mm to 600mm • Discrete and analog output models • Wide variety of sizes: - 18mm round - 30mm round - Rectangular - Flowline® liquid level sensors • IP67 protection rating • Quick-disconnect or axial cables • cULus & CE approvals • Lifetime warranty on most models
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input #1 at www.controleng.com/information
the #1 value in automation
Learn How Industry Leaders Are Improving Operational Performance with IoT
Your peers are using Kepware solutions to: • Optimize real-time data communications across the enterprise • Improve process efficiency through enhanced asset connectivity • Make more informed decisions, based on in-depth, data-based insight
Visit www.kepware.com/industryusecases to learn more and read industry-diverse use cases.
input #2 at www.controleng.com/information
— ABB Ability™ Smart Sensor
motors that let you know when it’s time for a service. ABB’s new condition monitoring solution revolutionizes maintenance for low voltage motors. ABB Ability™ Smart Sensor monitors key parameters and sends the data to a secure server for analysis. Users can access detailed status reports from their smartphone or PC. The solution enables proper maintenance planning for longer motor lifetimes, lower energy consumption and big reductions in downtime. www.abb.com/motors&generators input #3 at www.controleng.com/information
Vol. 65 Number 12
®
DECEMBER 2018
22 | Temperature measurement with RTDs, thermocouples
16
COVER IMAGE: Most modern ball valves have pre-drilled mounting holes for adding actuators. Courtesy: Cross Co.
25 | The best cable management strategy is foresight in selecting components 28 | Analyzing DIN and Deutsch connectivity options INSIDE MACHINES
INSIGHTS 5 | Research: Five findings on salaries, end-user insights 6 | International: New software helps with industrial cloud, AI, microservices, IoT 8 | Legalities: Catch up with cybersecurity NEWS
10 | Four ways to encourage manufacturing expansion 12 | Research grant: Big Data sensing analysis; Automation Competency Model: third update; Online headlines 14 | Think Again: Industrial robot safety, risk management
ANSWERS 16 | COVER: How to automate an existing manual valve 18 | Leveraging process simulation throughout the plant lifecycle 21 | Control system simulator teaches operators how to fight hackers
M1 | What is machine vision, and how can it help?
INNOVATIONS NEW PRODUCTS fOR ENgINEERS
35 | Safety integrated controller system; Analog output sensor for flowmeters; EtherNet/IP module with valve terminal, diagnostic details; Adaptive grippers for collaborative robots; Industrial managed PoE switch; Power distribution blocks; Integrated stepper motor package; IoT gateway for machine and networking BACK TO BASICS
40 | Ladder Logic: Fault detection and messages ONLINE • Review 102 Engineers’ Choice finalists; vote if you’re eligible. Polls close in December. www.controleng.com/NP4E • See the new website: www.controleng.com • Need to catch up on learning? www.controleng.com/webcasts and http://cfeedu.cfemedia.com
CONTROL ENGINEERING (ISSN 0010-8049, Vol. 65, 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 2018 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, $165/yr; Canada/Mexico, $200/yr (includes 7% GST, GST#123397457); International air delivery $350/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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control engineering
December 2018
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Re-Route Your Temperature Measurements Around Potential Roadblocks The new THZ3/TDZ3 Dual Input Smart HARTÂŽ temperature transmitters can help you avoid costly process interruptions and maintenance delays by ensuring your measurements always make it safely to your control system. Our Sensor Backup and Failover protection feature means you will never miss those critical readings - even if something goes wrong with one of the sensors. Plus, with Device Intelligence, a series of new and advanced features that enable smarter control and monitoring, the THZ3/TDZ3 gives you the conďŹ dence that your temperature measurements will get from Point A to Point B despite any potential roadblocks.
Demand Moore Reliability
50
Years of R
e li a b
ilt y
1968 - 2018
To learn more about our Dual Input Temperature Transmitter, go to: www.miinet.com/THZ3TDZ3 Or call 800-999-2900
input #4 at www.controleng.com/information
Estimated expenditures for VSDs Don't know
INSIGHTS
RESEARCH
Less than $10,000
More than $100,000
9%
17%
26% 28% 20% $50,001 to $100,000
$10,000 to $50,000
Figure 1: End users estimate an average annual spend of $148,000 on ac/dc variable speed drives (VSDs). Source: Control Engineering 2017 Motor Drives Study
75%
of end users need their human-machine interface (HMI) software to be easily scalable ranging from a few inputs/outputs (I/Os) to thousands. Source: Control Engineering 2018 HMI Software & Hardware Study
39%
of end users report their companies outsource control panel build/wiring/fabrication to third-party providers. Source: Control Engineering 2018 Career & Salary Study
7 in 10
end users purchase their programmable controllers from local distributors. Source: Control Engineering 2018 Programmable Controllers Study
More research Control Engineering covers several research topics each year. All reports are available at www.controleng.com/ media-library/research.
www.controleng.com
2018 CAREER & SALARY SURVEY:
Five findings on salaries, end-user insights
I
n addition to compensation details, respondents to the Control Engineering 2018 Career & Salary Study provided their insights on job satisfaction, stability of the manufacturing industry, and the skilled worker shortage: 1. Base salary: The average automation engineering professional earned an annual salary of $100,339 in 2017; 48% earned $100,000 or more, 44% earned between $50,000 and $100,000, and 8% earned less than $50,000. Threequarters of professionals expect an increase to their salary in 2018, 23% don’t expect any change, and 2% anticipate a decrease. 2. Bonus compensation: Sixty-eight percent of automation engineering professionals received non-salary compensation in 2017—the average amount received was $10,091. Company profitability and personal performance top the criteria for bonuses being awarded, followed by product profitability, safety metrics, and sales increase. 3. Perspective: Forty-six percent of survey respondents enjoy their current job, 40% are just happy to be working,
and 14% are open to or actively seeking other opportunities. Job satisfaction is most impacted by technical challenges, the feeling of accomplishment, and financial compensation. 4. Manufacturing industry: While 73% of respondents consider manufacturing to be a secure career, significant threats to manufacturing businesses include the lack of available skilled workers (37%), competition (36%), the economy (30%), and frequent changes to codes, standards, regulations, etc. (20%). 5. Skilled worker shortage: Eightytwo percent of respondents agree more public, private, and/or academic partnerships related to science, technology, engineering, and mathematics (STEM) need to be made to get more youth interested in engineering-related studies. ce
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View additional findings at www.controleng.com/media-library/ research/2018-career-and-salary-survey. Amanda Pelliccione is the research director for CFE Media, apelliccione@cfemedia.com.
Skilled worker shortage vs. budget There wouldn't be a shortage if companies were willing to budget enough for talent
We cannot get the talent we need at any price
We cannot pay an adequate about for talent because that would make us uncompetitive
21%
6%
50%
23% Strongly agree Agree
5% 0%
24% 10%
20%
30%
40%
50%
60%
70%
Figure 2: Proper budgets—rather than lack of skills—for talented workers are a challenge for respondents’ companies. With an appropriate budget, new talent can be hired and trained, if companies allocate the time and resources accordingly. Source: Control Engineering control engineering
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INSIGHTS international
Stone Shi, Control Engineering China
New software helps with industrial cloud, AI, microservices Control Engineering China: advantech announced its internet of things (iot) platform architecture and solution ready packages (SrP) at the advantech iot summit in Suzhou, China.
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dvantech’s Internet of Things (IoT) CoCreation Summit in Suzhou, China, is intended to assist companies in the integration and integration of hardware and software in various industries and build a complete Industrial IoT (IIoT) ecosystem and value chain. The company had a pair of announcements at the event: their IoT platform architecture WISE-PaaS 3.0 and 30+ sets of solution ready packages (SRP) created by software and industry partners for the IoT industry. WISE-PaaS 3.0 provides four functional modules to assist with industrial upgrades:
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A successful IoT supply chain requires cooperation and integration between platform technology suppliers and industry experts to form a standardized and reproducible software and hardware system.
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• WISE-PaaS/SaaS Composer, which is a process visualization cloud configuration tool that can import application scenarios into 3-D modeling drawing and interaction. • WISE-PaaS/AI Framework Service (AFS): Artificial intelligence (AI) model training and deployment service framework provides a simple drag-and-drop interface, allowing developers to import industrial data combined with artificial intelligence algorithms to establish an effective inference engine that can automatically deploy to edge computing platforms. • WISE-PaaS/Asset Performance Management (APM): This equipment networking remote operation and maintenance service framework can interface with many on-site industrial equipment control and communication protocols. • Microservices development framework: The microservices development framework is designed to assist developers, quickly generate microservices
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design framework, reduce development threshold. At the same time, there are flexible mechanisms for microservices such as service discovery, load balancing, service management, and configuration center. KC Liu, chairman of Advantech, said that in view of the diverse and extensive IoT applications and the fragmentation of the market, his company will assist industries to integrate existing hardware and software to establish a complete industrial value chain as an IoT industry. Key to a successfully implemented supply chain is the full cooperation and integration between platform technology suppliers and industry experts to form a standardized and reproducible software and hardware system product with SRP, Liu said. SRP installs and performs subsequent maintenance on-site to become a complete field solution to form the industrial chain of IIoT. Based on the membership-based operation; the cooperation between SRP software development and domain-focused solution integrators.ce Stone Shi is executive editor-in-chief, Control Engineering China. Edited by Chris Vavra, production editor, Control Engineering, CFE Media, cvavra@cfemedia.com.
M More INSIGHTS Keywords: Internet of Things, IoT, SRP Advantech’s Internet of Things (IoT) Co-Creation Summit in China is intended to assist companies integrate hardware and software. Advantech announced an IoT platform architecture and more than 30 solution ready packages for IoT software and industry partners. online Go to the IIoT and Industrie 4.0 page on www.controleng.com for more information about potential benefits for manufacturers.
Consider this What other benefits can the IoT provide for a company’s industrial chain? www.controleng.com
Automation & Control Freak?
Same here.
We carry more automation & control brand names than any other distributor in North America. It’s true – we checked. input #5 at www.controleng.com/information
© Allied Electronics & Automation, 2018
Get your A&C fill at
alliedelec.com
1.800.433.5700
INSIGHTS
LEGALITIES
Mark Voigtmann, Faegre Baker Daniels
Playing catch-up with cybersecurity Cybersecurity risks need help from contracts and insurance beyond technologies, policies, and people. Pretending cybersecurity risks aren’t there isn’t on any list of best practices.
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IF XPSE PO UIF GBDUPSZ GMPPS JG ZPV BSF UIF POF QFSTPO JO UIJT JOEVTUSZ XIP TUJMM IBT OPU IFBSE JT NBOVGBDUVSJOH QSPDFTTFT BSF WVMOFSBCMF UP IBDLT /PU GSPN IBDLT ESFTTFE JO TVJUT BOE UJFT UIBU EJTDVTTJPO JT GPS B EJGGFSFOU EBZ CVU GSPN UIF POFT JO IPPEJFT TJUUJOH JO GSPOU PG B DPNQVUFS TDSFFO PS BNPOH UIPTF TJOJTUFS PQT UFBNT PWFSTFBT 5IPTF TDPVOESFMT XJMM IPME EBUB GPS SBOTPN TUFBM JOUFMMFDUVBM QSPQFSUZ *1 PS UVSO UIJOHT PO BOE PGG GPS UIF GVO PG JU "DDPSEJOH UP UIF FYQFSUT UIFSF T OPU NVDI TUBOEJOH JO UIFJS XBZ 8IBU FYBDUMZ JT UIF TUBUF PG UIF BSU JO IBDL SFTJTUBOU TFOTPST BOE BDUVBUPST UIFTF EBZT BOZXBZ -FU T KVTU CF LJOE BOE TBZ UIBU JO B TFDVSJUZ TFOTF UIF BVUPNBUJPO BOE SPCPUJDT JOEVTUSZ JT TUJMM JO JUT BEPMFTDFODF 0S BT * SFDFOUMZ QVU JU EVSJOH B QBOFM EJTDVTTJPO BU $'& .FEJB T (MPCBM "VUPNBUJPO JO .BOVGBDUVSJOH 4VNNJU JO $IJDBHP BU *.54 i8F XFSF BU UIF TUBSUJOH HBUF B EFDBEF BHP CVU XF KVTU EJEO U LOPX JU w
‘
It matters little whether you can push the contract responsibility for cybersecurity risk to the “other guy” if the “other guy” has no way of paying for the liability or insuring it.
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4P IPX EPFT B QFSTPO NBOBHJOH DZCFS SJTL IPQF UP OBWJHBUF UIPTF XIJUF DBQQFE XBUFST 5IFSF BSF OP FBTZ BOTXFST 1BSU PG UIF TPMVUJPO PG DPVSTF XJMM BMXBZT CF UFDIOJDBM CVU CFDBVTF * N BO BVUPNBUJPO BOE SPCPUJDT MBXZFS OPU BO FOHJOFFS ZPV XPO U HFU UIBU TPMVUJPO GSPN NF
Minimize cyber risk, impact 8IBU ZPV XJMM HFU BSF UIF OFYU CFTU JEFBT GPS DPOTJEFSBUJPO NFBOJOH *G UIF UFDIOPMPHZ DBOOPU ZFU QSFWFOU UIF IBDL XIBU DBO ZPV EP UP NJOJNJ[F UIF PEET PS UIF JNQBDU 8IFSFWFS QPTTJCMF BEESFTT UIF SJTL JO ZPVS DPOUSBDUT 8IJMF UIJT JT SBUIFS PCWJPVT MPX IBOHJOH GSVJU JU JT OPOFUIFMFTT JNQPSUBOU *G DZCFS JOUSVTJPO PDDVST CF TVSF UP BTL
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CONTROL ENGINEERING
t 8IBU XBT ZPVS DPNQBOZ T DPOUSBDUVBM DPOOFDUJPO UP UIF FWFOU FWFO JG KVTU WJB QSPQPTBM PS QVSDIBTF PSEFS t *T UIFSF BOZ BSHVNFOU UIBU UIF JOUSVTJPO IBQQFOFE CFDBVTF UIFSF XBT B WVMOFSBCJMJUZ JO ZPVS FRVJQNFOU PS QSPDFEVSFT t $PVME CFTU QSBDUJDFT IBWF QSFWFOUFE UIF JOUSVTJPO *G UIF FWFOU JT TFSJPVT FOPVHI BMM UIPTF RVFTUJPOT BOE NPSF BSF MJLFMZ UP CF EJSFDUFE BU ZPV BOE ZPVS DPNQBOZ XJMM CF JO B NVDI CFUUFS QMBDF JG UIF BOTXFST DBO CF GSBNFE CZ TVQQPSUJWF MBOHVBHF JO UIF BQQMJDBCMF QSPKFDU UFSNT BOE DPOEJUJPOT
Beyond the scope *G ZPV BSF UIF JOUFHSBUPS PS TVQQMJFS JU NFBOT XIFSFWFS QPTTJCMF HFOFSBMMZ EJTDMBJNJOH BOZ PCMJHBUJPO UP QSFWFOU PS JOEFNOJGZ BHBJOTU DZCFS JOUSVTJPO GPS UIF TJNQMF SFBTPO UIJT XPSL JT IPQFGVMMZ CFZPOE UIF TDPQF PG XIBU ZPV XFSF IJSFE UP EP PS BTTVNJOH UIBU TVDI B CSPBE EJTDMBJNFS DBOOPU CF IBE BU MFBTU TQFDJGJDBMMZ FYDMVEJOH MJBCJMJUZ GPS DZCFS JOUSVTJPO UP UIF FYUFOU JU BSJTFT GSPN QSF FYJTUJOH WVMOFSBCJMJUJFT JODMVEJOH MFHBDZ TZTUFNT PS FRVJQNFOU 1SPDVSJOH UIJT UZQF PG FYDMVTJPO OFFE OPU JOWPMWF VTF PG UIF QSPWPDBUJWF XPSET MJLF iDZCFS w iIBDLJOH w iJOUSVTJPO w iTFDVSJUZ w BOE UIF MJLF 5IF PQUJNBM QSPUFDUJPO JT BO PWFSBMM MJNJUBUJPO PG MJBCJMJUZ GPS BOZ UZQF PG DMBJN 0S GBJMJOH UIBU QSPUFDUJPO DPVME WFSZ XFMM CF FOTVSJOH UIBU UIF DVTUPNFS JT POMZ MJBCMF UP UIF JOUFHSBUPS PS WJDF WFSTB UP UIF FYUFOU UIFSF IBT CFFO TPNF EFHSFF PG OFHMJHFODF JO BOZ LJOE PG XPSL XJUIPVU BOZ NFOUJPO PG UIPTF LFZXPSET 5IJT MFBWFT UIF JOUFHSBUPS GSFF UP DPOUFOE UIBU UIF JOUSVTJPO iXBT OPU NZ GBVMU w FTQFDJBMMZ JG BT JT PGUFO UIF DBTF OPXIFSF JO UIF DPOUSBDU QBQFST JT DZCFSTFDVSJUZ GMBHHFE BT BOZ TPSU PG EFMJWFSBCMF
Cybersecurity insurance *G ZPV BSF BO FOE VTFS UIF DPOTJEFSBUJPOT BSF WFSZ EJGGFSFOU VOMFTT UIF JOUFHSBUPS JT B NBKPS DPNQBOZ XJUI B TJHOJGJDBOU GPPUQSJOU XIJDI NPTU GSFRVFOUMZ JU JT OPU 8IJDI JT UP TBZ GPS UIF FOE VTFS JU NBUUFST www.controleng.com
little whether you can push the contract responsibility to the “other guy” if the “other guy” has no way of paying for the liability or insuring it. Putting aside for the moment the coverage that current insurance products provide and that the insurance industry is still playing catch-up like the rest of us, end users might begin their analysis of risk by considering what those insurers are looking at. An examination of applications for cyber insurance coverage can be helpful as a guide for curtailing potential exposure, according to suggestions from my partner Patrick O’Connor. Among the questions asked: • How much of the information technology (IT) is outsourced? • How many names can be found in databases under your control? • Do you have a third-party endorsement of your privacy processes and practices? • What is your encryption strategy? • What physical security strategies are in place to control human access to the servers? • Do you have a chief security officer? I am not the one to tell you how the actuaries take all that information and turn it into a premium, but I do know the people who figure out that equation will be the insurance heroes of tomorrow.
The larger lesson is more basic: at present, contracts and insurance can only do so much. The cyber “front line,” for now, is in your own company’s ways of doing things. ce Mark Voigtmann leads the automation practice at Faegre Baker Daniels, a law firm with offices in the U.S., the U.K. and China. Voigtmann is a member of the Control Engineering Editorial Advisory Board. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media, mhoske@cfemedia.com.
M More INSIGHTS
KEYWORDS: Cybersecurity risk mitigation, legalities Cybersecurity considerations extend beyond technologies to contracts and insurance. Contract wording can limit liability without sounding ominous. Ask these questions to broaden understanding of cybersecurity risk. CONSIDER THIS Beyond technologies, do your contacts and insurance address cybersecurity risk?
ONLINE If reading from the digital edition, click on the headline for more resources. For other discussion of engineeringrelated legal issues, search “Faegre” at www.controleng.com.
input #6 at www.controleng.com/information
INSIGHTS
NEWS
Four ways to encourage manufacturing expansion Harting announced a $6 million expansion in its existing Elgin, Ill., facility, with an Oct. 26 ribbon cutting involving company, state, local officials, and others. Cooperation to facilitate faster start-up of new lines helped in addition to more than $1.5 million in incentives offered. Harting’s latest investment is expected to add 50 or more jobs to 112 already employed at the Illinois site, along with a lab, showroom, and expanded injection molding and die-casting processes for the connector and industrial communications manufacturer. The manufacturing expansion is targeted for completion in January 2019 and other work is to be finished by October 2019. Manufacturers bring value to local and state governments such as: • High-paying jobs with good benefits • Developing clean, high-technology facilities that support other area jobs and suppliers • Adding to the tax base • Adding critical mass to an area’s posterity and talent pool.
In return, manufacturers try to negotiate a positive set of incentives for locating or expanding in an area. Harting, a family-owned company founded in 1945, manufactures products for the connector industry for use in mechanical and plant engineering, broadcast and entertainment, factory automation, power generation and distribution, and industrial electronics and telecommunications. Harting North America president and CEO, Jon DeSouza, praised the workforce and strategic location, saying the company was looking to “build upon our current successes within the North American market.”
1. State incentives
Illinois Gov. Bruce Rauner said the state has worked with Harting on expansion details since early 2018. Incentives: Illinois Department of Commerce and Economic Opportunity has Edge incentive agreements to encourage relocation and expansion in the state. State tax credits of $1,534,645 are tied to creation of 50 jobs and retention of 112 (or about 150, including sales and other support positions, Harting said). A 28-page Oct. 26 State of Illinois Edge document said Harting had also considered Charlotte, N.C., and Mexico City, Mexico, for the expansion. Visits: Rauner visited Harting facilities in Espelkamp, Germany, in April and saw the company at Hannover Fair and visited IMTS 2018 in Chicago in September. Intersect Illinois, the state’s jobs agency, coordinated the April trade mission to Germany and Poland to enhance the state’s Foreign Direct Investment (FDI) strategy.
2. Local incentives Partial factory view of Harting manufacturing’s Elgin plant shows space along the back wall for part of the expansion. Outside these walls, a 10-year expansion plan includes land to double manufacturing at the Elgin site. Images courtesy: CFE Media
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Streamlined permitting: To help speed manufacturing startups and expansions, Mayor Kaptain told CFE Media that Elgin helps business expansion by expediting permitting and inspections and ensuring the right people are available to help avoid startup delays and related manufacturing revenue.
control engineering
Harting products help make Harting products: A Harting Ethernet gateway (left-center) on the manufacturing cell reports workcell information at Harting’s Elgin plant.
Educational partnerships: The city also works with area schools to improve job skills through the use of certification programs and the “National Career Readiness Certificate.”
3. Educational institutions
Community colleges offer manufacturing-related course, certifications, and workforce development programs. They encourage students to consider available jobs at expanding manufacturing locations, like Harting. Elgin Community College includes studies in computer integrated manufacturing, energy management, and machine tool operations; and nearby Harper College includes electronics engineering technology, maintenance technology, and manufacturing technology.
4. Area and national chambers of commerce
Encouragement and networking connections about area benefits, business development resources, and programs are offered by chambers of commerce, such as the German American Chamber of Commerce of the Midwest and Elgin Area Chamber of Commerce. Mark T. Hoske, content manager, Control Engineering, www.controleng.com CFE Media, mhoske@cfemedia.com, with more information provided by Harting and state of Illinois.
M More Online
Read this story online, www.controleng.com, for more images and information. www.controleng.com
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INSIGHTS
Digital edition? Click on headlines for more details. See news daily at www.controleng.com/news
NEWS
Research grant: Big Data sensing analysis Rochester Institute of Technology (RIT) researchers are taking on Big Data to reduce the negative impact of faulty measurements in data collected from complex sensing systems. “Based on tremendous developments in hardware, and we can now collect, store and process very large amounts of data across many different sensing modalities. However, for these data to be useful, we have to learn how to process them efficiently and reliably, to get as much knowledge out of them as possible,” said Panos Markopoulos, an expert in signal processing and data analysis. The assistant professor is developing more reliable data analytics by building new system algorithms that can automatically decrease the emphasis placed on corrupted or faulty data through a threeyear, $499,236 grant from the National Science Foundation’s Office of Advanced Cyberinfrastructure. With the increase in data collected from applications such as social networks, health care, and computer vision, there
is a need for more reliable data analysis. Intelligent systems rely on data collected across diverse sensing modalities (such as time, frequency and 3-D space) and organize them in multi-dimensional arrays, also referred to as “tensors.” However, many existing methods of data analysis are sensitive to faulty measurements and may provide false conclusions, Markopoulos explained. “These applications have their foundations in signal processing algorithms,” he said. “Our work is about taking large data sets, analyzing them and extracting knowledge. It is inevitable that some of this data will be faulty, noisy or corrupted and will not represent the system we are trying to understand. Our analysis should be robust against such faulty data. This is the real problem this project tries to solve—to do data analysis in a reliable way.” The team’s approach is three-fold: • Improve current algorithms to better assess data across the tensor arrays
Group completes third review and update of the original Automation Competency Model
A
review team of automation experts convened in Research Triangle Park, N.C., for the third critical review of the Automation Competency Model (ACM). The Automation Federation (AF) was invited by the U.S. Department of Labor (USDOL) in 2007 to be the first industry-related technical society to create a competency model using the National Institute of Standards and Technology (NIST) pyramid framework for advanced manufacturing. Team leader Steve Huffman, AF chairman of government relations and the driving force within AF behind the original creation of the model, remarked that this activity “was the best review of this important work yet thanks to the passion, attention to the details, respectful deliberation, and diversity of professional perspective.” The group consists of five professional engineers, three Certified Automation Professionals (CAP), two technology fellows, a doctoral degree holder, two senior educators, and four ISA Fellows. All team members expressed confidence the improvements made to the ACM are consistent with the latest trends in the automation industry. The primary task remaining is for all automation professionals to use the model to improve their own skills and to gain recognition by all for the inherent value of automation for production safety, efficiency, and capacity. - Edited from an Automation Federation press release by CFE Media.
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• Develop software solutions to reflect the new processing capabilities • Allow the development of prototypes that use the new algorithms for social network analytics to train machines on how to understand differences between different classes of data and computer vision.
Corruption-resistant analysis
“There is not much research in corruption resistant analysis of Big Data sets. This project will set the theoretical and algorithm foundations for this work,” Markopoulos said. He will be working with Andreas Savakis, RIT professor of computer engineering and researcher in computer vision, and Vagelis Papalexakis, a professor of computer science from the University of California at Riverside, who specializes in data mining.
Michelle Cometa, Rochester Institute of Technology (RIT). Edited by Chris Vavra, production editor, Control Engineering, CFE Media, cvavra@cfemedia.com.
Headlines online Standards group names leaders ODVA’s board of directors announced Dr. Al Beydoun, the vice president of technology and standards, appointed as president and executive director of ODVA. Four challenges for aerospace robots Robot users and integrators face challenges such as increased human-robot collaboration and the constant demand for precision and efficiency in aerospace applications. Machines learn language like kids MIT researchers developed a semantic parser to learn by observation, which could greatly extend computing capabilities. Top 5 Control Engineering articles Nov. 5-11 Articles about process tuning, Engineers’ Choice finalists, pharmaceutical manufacturers, machine metrics, and functional safety. Industrial Ethernet specification with TSN CC-Link Partner Association (CLPA) completed the CC-Link IE TSN specification. www.controleng.com
M o n i t o r, c o l l e c t , e x c h a n g e , a n a l y z e a n d d e l i v e r p re d i c t i v e m a i n t e n a n c e a n d d a t a m o n i t o r i n g w i t h C o m t ro l ’s I O - L i n k M a s t e r . W i t h O P C - U A a n d M Q T T embedded, it can be deployed anywhere in the factory to collect and deliver valuable sensor data s t r a i g h t t o t h e c l o u d w i t h a P L C , o r w i t h o u t . T h a t ’s r i g h t , n o P L C n e e d e d .
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Industrial robot safety, managing industrial risk
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Five ways to lower robotic system risks: Industrial safety, while a widely used term, is a misnomer; nothing is without risk.
Kevin Parker, Senior Contributing Editor, IIoT, OGE 630-571-4070, x2228, KParker@CFEMedia.com
hen something is declared safe in an industrial setting, those involved should think again about risk assessment and determine if the risk is acceptable. Five topics on robot risk reduction from the International Robot Safety Conference follow.
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1. Design safer motion
project. Should in-house staff be used for a robot integration project or should an outside integrator be hired? Without adequate capabilities and safety standard knowledge, consider a robotic system integrator, Salvalaggio suggested.
3. Standards for whom?
Standards target different groups and functions; know which address manufacturers, system integration, and users, advised Roberta Nelson Shea, global technical compliance officer for Universal Robots and convener of working group 3 for an update of ISO 10218-1,2.
Robotic safety shouldn’t be a reactionary afterthought, said Jeff Pratt, Crown Equipment, senior corporate EHS Engineer (and vice-chair on the RIA R15.08 standard development committee), and César Reyes Núñez, Crown Mexico, EHS coordina4. Help for mobile tor. A Crown risk assessment industrial robots team works to ensure safety is Mark T. Hoske, An RIA standard, expectdesigned into the process. In Content Manager ed in 2019, will cover R15.08: examining a workcell where a Industrial Mobile Robot Safety, robot gripper dropped a large fabricated fork after it came out of an said Michael Gerstenberger, chair for the oven, nine outcome branches were identi- R15.08 committee, in part because many fied to ensure that accident wouldn’t hap- available products don’t fit in automated pen again. A proximity sensor was applied guided vehicle (AGV) categories; they’re to the gripper and the robot was repro- mobile robots. The scope covers industrial grammed to not rotate the fork in a shear mobile robots in semi-structured environ(weak) position for the magnet. No fork ment with trained personnel (no members of the public), ground-based, on indoor or has been dropped since. outdoor applications, on tracks, wheels, 2. Get help with robots and/or legs and with or without a robot Craig Salvalaggio, vice president of arm or a non-actuated attachment. sales and engineering, Applied ManufacA flow chart in the standard will help turing Technologies (AMT), co-chair of guide which standard to use. the RIA robotic integrator committee, said end users and machine builders have to 5. Beware the effectors A bump from a slow-moving robot arm consider resources when starting a robotic may not injure, but the end-effector, with a welding tip, gripper, paint tip, grinder, or knife, could cause serious harm regardless of robot design, said Carolann QuinlanIf reading from the digital edition, click on the headline for related images and more Smith, CRSP, Workplace Safety and Preinformation. vention Services. System integrators must www.controleng.com/magazine perform a task-based risk assessment for www.controleng.com/CE-research the lifecycle of a robot with its effectors, she said, including considering potential conwww.controleng.com/discretemanufacturing/machine-safety/ tact situations and human interactions. ce
M More INSIGHTS INSIGHT
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ANSWERS
COVER STORY: PROCESS ACTUATORS Ronnie Moore, Cross Co.
How to automate an existing manual valve Automating an existing valve instead of replacing it can save time and reduce costs.
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ometimes process requirements change and it becomes necessary to replace an existing manual process valve with an automated on/off or control valve. Instead of pulling the old valve out of service and replacing it with a new valve, users should consider automating the existing valve. If the valve is in good condition and has the means to mount an actuator, automating it can save time and money.
Safety first
The preferred method is to remove the valve from the line and automate it in the maintenance shop, but that is not always possible. If you choose to automate the existing valve inline, make sure the valve is not under pressure and follow the plant’s lockout tagout (LOTO) procedures before working on the valve.
Know what you’re working with
To start, identify the size, make, and model of the valve. Consult the valve manufacturer’s literature or consult with a manufacturer’s representative for the torque (rotary valves) or thrust (linear valves) requirement of the valve. Ask the manufacturer or the representative if it is recommended to automate the valve. Make sure the valve has an actuator mounting pad or body bolts that can be used to mount the actuator without compromising the integrity of the valve. Most modern ball valves have pre-drilled mounting holes for actuation (see Figure 1). If using body bolts to mount the actuator, make sure the bolts are long enough to engage the bracket and valve body when they are reinstalled. Ask the valve manufacturer for its recommendations for length and grade of bolts if existing bolts need to be replaced (see Figure 2).
Selecting an actuator
Figure 1, cover image: Most modern ball valves have pre-drilled mounting holes for actuation. All images courtesy: Cross Co.
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Determine the additional safety factor you want to add to the manufacturer’s recommended torque and add it to the manufacturer’s torque. This safety factor will ensure the valve will operate even if the air supply drops slightly or if the mounting kit binds slightly and increases the required torque. Also, as an actuator wears and air bypasses the pistons, the torque output will start to decrease. Determine the desired function of the actuator and make sure it is the proper size. After choosing an actuator, consult with the valve manufacturer or rep and obtain the proper mounting kit to adapt the actuator to the valve. Please note, there are custom bracket manufacturers that will adapt just about any brand actuator to just about any brand valve so don’t worry if the valve and the actuator are different name brands (see Figure 3). The important thing is to make sure you are using a rotary actuator on rotary valves and linear actuators on linear valves. The actuator supplier can help obtain the correct mounting kits in most instances. Before installing the actuator, make sure the valve position matches the actuator. If the actuator www.controleng.com
Figure 2: The valve is a pressure vessel and death or serious injury can occur if you use the incorrect bolts or if the existing bolts do not engage the body properly.
‘
Some linear actuators require the user to add lowpressure air to slightly open
Figure 3: An actuator with a valve mounting bracket is shown. There are custom bracket manufacturers that will adapt most actuators to most valves.
the actuator before attaching
’
the stem clamshell.
is a fail-closed actuator, make sure the valve is in the closed position. When an actuator is mounted on a rotary valve, leave the mounting bolts slightly loose and stroke the actuator a couple of times. This will ensure the mounting bracket is properly aligned and is not binding. Torque the bolts to the proper tightness. After the bolts are tightened, stroke the actuator fully open and fully closed a few more times to make sure nothing is binding and the valve opens and closes smoothly. Most linear valves and actuators use a two-piece stem coupling (clamshell coupling). The linear actuator will include a yoke that attaches to the valve. Some linear actuators require the user to add low-pressure air to slightly open the actuator before attaching the stem clamshell (see Figure 4). This will preload thrust to hold the valve tightly in the closed position. Consult the valve and actuator manufacturer. Finally, add any controls such as solenoids, limit switches, or positioners to the assembly if they are needed. Attach it to the plant air and wiring and test one more time before returning the valve to service. ce Ronnie Moore is resident valve expert working in inside sales and support at Cross Co., a CFE Media content partner. This article originally appeared on Cross Co.’s process instrumentation and valve blog. Edited by Jack Smith, content manager, Control Engineering, CFE Media, jsmith@cfemedia.com www.controleng.com
Figure 4: A clamshell stem coupling is shown. Most linear valves and actuators use a twopiece clamshell stem coupling.
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KEYWORDS: process actuator, automated
control valve If the valve is in good condition and it has the means to mount an actuator, you can save time and money by automating it. Determine the additional safety factor you want to add to the manufacturer’s recommended torque and add it to manufacturer’s torque. Before installing the actuator, make sure the valve position matches the actuator.
CONSIDER THIS Can your plant save time and reduce costs by automating existing valves instead of replacing them?
ONlINE Link to additional online resources, process actuators and related content at www.controleng.com/archives, under December 2018. control engineeering
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SIMULATION FOR TRAINING Scott Michel, Honeywell
Lifecycle process simulation Using simulation for plant design, process automation system validation, and operator training will help optimize plant operations.
D
igital transformation is rapidly influencing the hydrocarbon processing industry. Up to 60% of refining operations are spending more on digital technologies in 2018 and 67% believe a lack of digital solutions would reduce their competitive edge, according to a research report by Accenture. While new software and hardware are being developed to address this demand, established strategies also stand to play an important role in the digital revolution. The change will be in how these tools, such as operator training simulators, are implemented, deployed, and used to achieve optimal plant performance. Process simulation has been a key tool in the hydrocarbon industry for decades. Simulators have been used in two key phases of the plant lifecycle. During the initial design phase, steady-state models enable engineers to design and size key equipment and Figure 1: A diagram ensure that heat and material balances are satisfied. shows a plant lifeLater, when the plant is online, the operations staff cycle’s key phases uses dynamic operator training simulators (OTS) to and where simulatrain new personnel and refresh experienced workers’ tion can be used. skills in phase 3 and part of phase 5 of the Figure 1 All graphics courplant lifecycle. This leaves many phases of engineering tesy: Honeywell and operations without simulator interaction.
Management can use high-fidelity simulation throughout the plant lifecycle to yield the greatest return on investment by treating the simulator as a digital copy of the physical plant not limited to narrow use-cases. Advancements in computational technology have filled the gap between design and operations so a full plant model of the highest fidelity can be used simultaneously for engineering studies and operator training. In bridging this gap, a much larger percentage of the plant lifecycle comes into scope and unlocks the potential of the process simulator as a tool that covers the plant from design to operation.
Static and dynamic simulation models
Static process simulation software is heavily relied upon during the front-end engineering and design (FEED) phase of brownfield and greenfield projects. Comprehensive plant models provide engineers with a complete view of heat and material balances for limiting design cases and other operating conditions. Additionally, simulation software is used to perform feasibility studies, assess different process configurations, and identify risks. Engineers can leverage this information to ensure designs are safe, meet environmental regulations, and maximize the operational and business performance of the asset (see Figure 1). Generally, static simulation is a tool used most often during this stage of the plant lifecycle. However, dynamic models can be useful for feasibility studies. Mature simulation software allows the end user to seamlessly migrate from a static to a dynamic model. In this case, services required to build the initial model are performed upfront, during the FEED phase. Simulator benefits can be realized in the downstream lifecycle phases with minimal services investment.
Simulation for plant design, validation
While static models ensure operation at defined steady-state conditions, a dynamic simulator allows engineers to validate that the plant can successfully operate at every point from black start to full capacity. Once the plant design has been finalized, engineers can use the simulator to ensure the design is fit for purpose and all equipment can meet the demands of the startup procedures and operational sequences. By adhering to process and mechanical datasheets during the model development phase, end users can be confident all equipment in the simulation matches
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its physical counterpart in the field. With this knowledge, engineers can scrutinize every piece of equipment in plant from individual piping segments to complex, multi-pass heat exchangers. With the ability to pre-program model scenarios, engineers can continuously run the plant through defined operational procedures and examine the process responses using incremental changes in the plant design. While the benefits of examining the plant process with a simulator are immense, much of the value is realized upon integration with the control system. After the design and testing the controls, the simulator can provide an additional layer of process automation insight. Most modern control systems can simulate values so rudimentary testing can be performed on control loops. However, a high-fidelity simulator provides realistic process responses that are almost impossible to replicate with empirical correlations. Sophisticated modeling software is based on first principles, thus providing meaningful insight into countless “what if ” scenarios. The controls will be exposed to more advanced testing that is more closely aligned with the actual plant response. This allows engineers to identify potential problems early in the design phase before they become expensive and time-consuming to correct. The safety system’s validation and design is a vital part in the commissioning of any new facility. All production companies aim to minimize the number of safety incidents that occur onsite. However, safety systems are exercised so infrequently it may take years for a flawed design or procedure to be recognized. A simulator provides real-time process responses to allow users to scrutinize and dissect safety schemes during abnormal operating conditions. Using defined operating scenarios, users can run the plant through various upset conditions such as: compressor surge, depressurization/flaring events, and total plant shutdown. This allows for an iterative process wherein safety systems are constantly tested and upgraded to account for all possible outcomes. Once changes have been proposed, the hazard and operability (HAZOP) team can use the simulator to support studies and investigate the integrity of planned designs.
Virtual plant commissioning and startup
While a simulator will not aid in constructing a new facility, the engineering staff can continue to use the simulator during this time to ensure commissioning and startup (CSU) is as smooth as possible. Many pieces of the plant, from process equipment to controls and alarming, are being exercised to full functionality for the first time. Many unforeseen issues are uncovered during this time that require immediate attention to avoid lengthy and expensive delays. Issues faced during the CSU can be addressed much earlier by performing the CSU in a virtual environment. A virtual commissioning and startup (vCSU) that involves all key stakeholders will expose many flaws and allow them to be rectified in a timely www.controleng.com
Figure 2: Screenshot: An operator training simulation environment is available in Honeywell UniSim Operations.
and controlled manner. For example, vCSU provides engineers an opportunity to test the detailed startup procedure, fully exercise the distributed control system (DCS) human-machine interface (HMI), validate alarm suppression, and tune vital control loops. Many of these activities are often crowded into an already tight startup schedule leaving little room for error. This second layer of validation ensures the assets handed off to operations have been validated and tested in an environment that mirrors real life.
Plant operation, maintenance
Traditional custom-built plant simulators help train operators. Many plants implement programs that require employees to follow extensive, simulator-based training regiments to maintain a certain level of training. The best practice is to track and record the performance of board operators using training scenarios to evaluate key performance indicators (KPIs) against plant standards. Management can track plant performance and see the efficacy of the hands-on training program in real-time (see Figure 2). Recent improvements to augmented reality (AR) and virtual reality (VR) techKEYWORDS: Operation training simulators (OTS), augmented nologies have extended simulator-based reality (AR) training to field operators. Workers can Enhance personnel and plant practice non-routine tasks in the safety of operator training with simulators a virtualized or mixed reality environment Extend the plant lifecycle with with instructors. Hands-on training leads training simulation environments to a safer and more competent workforce. Support the plant lifecycle with By viewing a process simulator as a plant’s simulation. digital clone, users can explore new aveCOnSiDER thiS nues to support the plant lifecycle. ce
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Scott Michel is senior product marketing specialist, Honeywell. Edited by Emily Guenther, associate content manager, Control Engineering, CFE Media, eguenther@cfemedia.com. control engineeering
How can training simulation software improve the lifecycle?
OnLinE Read more online with this article at www.controleng.com, on operations, virtualization, and cloud-based project execution.
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ANSWERS
SIMULATION TRAINING John Toon, Georgia Tech University
Control system simulator teaches operators how to fight hackers Georgia Tech university researchers developed a simulator designed to help operators of chemical processing plants better understand security issues.
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simulator that includes a virtual explosion could help the operators of chemical processing plants—and other industrial facilities—learn to detect attacks by hackers bent on causing mayhem. The simulator developed by researchers at Georgia Tech university will also help students and researchers understand better the security issues of industrial control systems (ICSs). Facilities such as electric power networks, manufacturing operations and water purification plants are among potential targets for malicious actors because they use programmable logic controllers (PLCs) to open and close valves, redirect electricity flows and manage large pieces of machinery. Efforts are underway to secure these facilities, and helping operators become more skilled at detecting potential attacks is a key part of improving security. “The goal is to give operators, researchers and students experience with attacking systems, detecting attacks and also seeing the consequences of manipulating the physical processes in these systems,” said Raheem Beyah, the Motorola Foundation professor in the School of Electrical and Computer Engineering at Georgia Tech. “This system allows operators to learn what kinds of things will happen. Our goal is to make sure the good guys get this experience so they can respond appropriately.” The simulated chemical processing plant, known as the Graphical Realism Framework for Industrial Control Simulations (GRFICS), allows users to play attackers and defenders—with separate views provided. Attackers might take control of valves in the plant to build up pressure in a reaction vessel to cause an explosion. Defenders have to watch for signs of attack and ensure security systems remain operational. Of great concern is a human-in-the-middle attack in which a bad actor breaks into the facility’s control system—and also takes control of the sensors and instruments that provide feedback to the operators. By gaining control of sensors and valve position indicators, the attacker could send false readings that would reassure the operators—while the damage proceeded. “The pressure and reactant levels could be made to seem normal to the operators, while the pressure is building toward a dangerous point,” Beyah said. “The
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Screen capture shows a chemical processing plant in which critical parameters are rising due to false process data and control commands injected by an attacker. Courtesy: Georgia Tech University
more the operators know the process, the harder it will be to fool them,” he said. The GRFICS system was built using an existing chemical processing plant simulator, as well as a 3-D video game engine running on Linux virtual machines. At its heart is the software that runs PLCs, which can be changed out to represent different types of controllers appropriate to a range of facilities. The humanmachine interface also can be altered as needed to show a realistic operator control panel monitoring reaction parameters and valve controller positions. GRFICS is available as an open source, free download for use by classes or individuals. An online version is planned, and future versions will simulate the electric power grid, water, and wastewater treatment facilities, and other manufacturing facilities. “Several years ago, we talked to a lot of process control engineers as part of the NSF’s I-Corps program,” Beyah said. “We’ve seen changes, and lots of people are now taking system security seriously.” ce John Toon, Georgia Tech. Edited by Chris Vavra, production editor, Control Engineering, CFE Media, cvavra@cfemedia.com. control engineeering
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Keywords: simulator,
chemical engineering, PLC, cybersecurity Georgia Tech researchers developed a simulator to help chemical processing plant operators. Operators can better understand and prepare for attacks by hackers. Future versions are planned to simulate electric power grids, treatment facilities, and manufacturing facilities.
online Read this story online at www.controleng.com for more about cybersecurity threats against manufacturing.
Consider this Would these simulated programs help you?
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PROCESS SENSING Gary Prentice, Moore Industries
Temperature measurement with RTDs, thermocouples The most common process sensor measurement is temperature. Resistance temperature detectors (RTDs) and thermocouples are widely used sensors for industrial temperature measurements. See 11 summary tips for sensor selection.
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emperature measurements comprise the largest segment of all process measurements and their accuracy and reliability can often have a significant impact on the efficient operation and safety of a facility. Selecting the most appropriate sensor type can improve the accuracy, repeatability, and stability of temperature measurements and can decrease operating and maintenance costs. Resistance temperature detectors (RTDs) and thermocouples handle 90% or more of the temperature monitoring within industrial facilities, which means specific details on each detector can help with informed decisions regarding selecting the best sensor for various applications.
RTDs at-a-glance
Temperature ranges: RTD are recommended for measurements from -200 to 850°C (-328 to 1,562°F). When purchasing a new sensor, inform the supplier of the operating range for the sensor to encourage
In addition to various RTD and thermocouple sensors, different sensor construction types also are available: standard solid sheathed elements (top and middle) or a flexible trim-to-length sensor with a shorter sensor capsule (below), designed for quicker response times and better resiliency to vibration, such as the Worm from Moore Industries. Courtesy: Moore Industries
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use of the best materials and manufacturing techniques for that operating range. Operation: RTDs operate on the principle that the electrical resistance of their metal elements increases as temperature increases. Construction: Common resistor materials are Platinum (Pt), Nickel (Ni) and Copper (Cu). Because platinum is more stable, more linear and covers wider temperature ranges, it has become the industry standard today. While nickel and copper may be found in existing builds, most new installations will use platinum throughout. High purity platinum is often used to manufacture an RTD sensing element in either a wire-wound design (platinum wire is wound around a substrate spool) or thin film design (pure platinum is deposited onto a ceramic substrate). Modern RTDs can be used at higher temperatures because the substrate materials used today are stable at elevated temperatures. Suggestion: Use thin-film sensors from -40 to 850°C (-40 to 1562°F) and wire-wound sensors when dropping to temperatures near -200°C (-328°F). RTDs with 2, 3 or 4 wires: RTDs can be built with 2-wire, 3-wire and 4-wire construction. Suggestion: Use RTDs instead of thermocouples (T/C) whenever possible for superior accuracy, repeatability, and stability. An RTD only functions properly when the element is insulated/isolated from the protective sheath surrounding it. Typical insulating materials are Magnesium oxide (MgO) or Alumina oxide (Al2O3). Should the insulation break down due to moisture and contamination, the RTD must be replaced. As an RTD must be insulated, using a measuring circuit that is not isolated could provide cost savings. When a close coupled temperature transmitter is not used with an RTD, the RTD is connected to the measuring circuit by copper wire. Things to keep in mind when preparing to select an RTD include: • The sensor’s name indicates its resistance at 0°C (32°F). Example: 100Ω Pt RTD measures 100Ω www.controleng.com
at 0°C; 500Ω Pt RTD measures 500Ω at 0°C, etc. • Modern measuring circuits use a constant current source to generate excitation current. • High impedance voltage measurements factor in to RTD performance. (High impedance means there is no current flow through the voltmeter and its leads.) • Resistance is calculated using Ohms Law: V = IR or R = V/I
RTD sensor accuracy It is best to use RTDs over T/Cs when possible. The best RTDs are built to the IEC 60751 standard, which calls for accuracy values as shown in table 1 below. Premium/special-grade RTD sensors: When RTDs are aged by the manufacturer, it minimizes drift once they get into the field. RTDs that are temperature cycled for 1,000 hours at 0 and 600°C and will maintain higher accuracy for 5+ years. Typically, only Class A sensors are thermally aged. Premium-grade T/C wire helps with thermocouple measurements; upgrading to Class A RTD sensors also helps by cutting uncertainty in half.
Thermocouples at-a-glance Thermocouple (T/C) technology is based on the Seebeck effect wherein two dissimilar metals fused together at both ends will generate an electric current when one junction is at a different temperature than the other. Temperature ranges: Various combinations of dissimilar metals are used to construct T/Cs. The finished products are referred to as the T/C type. For each type, mV vs temperature tables exist and are included in this reference manual (all mV vs temperature tables are created with the T/C cold junction at 0°C (32°F)). Operation: A T/C sensor has two junctions. The measurement junction (sometimes called the hot junction) is where the two metals connect. The reference junction (also called the cold junction) is the open circuit end that connects to the measuring circuit. When a temperature difference exists between the hot and cold junctions, an mV signal is generated that is proportional to the temperature difference. The mV value increases with the rising temperature. The relationship between the mV and temperature is non-linear. In a real world T/C measurement, the measuring circuit will likely be any temperature but 0°C (32°F). The measuring circuit must measure the temperature of the cold junction and reference that temperature back to 0°C (32°F). This electrical compensation is called cold junction compensation (or reference junction compensation). Most T/C measuring circuits perform this operation. Construction: T/C junctions can be built with the hot junction grounded to the external sheath or www.controleng.com
Table 1: RTD accuracy values RTD temperature range on validity oC (oF) Class
Tolerance values | t | in oC
Wire-wound resistor
Thin film resistor
AA
± (0.1 + 0.0017 | t |)
-50 to 250°C (-58 482°F)
0 to 150°C (32 to 302°F)
A
± (0.15 + 0.002 | t |)
-100 to 450°C (-148 to 842°F)
-30 to 300°C (-22 to 572°F)
1.11°C/ 2.00°F
B
± (0.3 + 0.005 | t |)
-196 to 600°C (-320.8 to 1,112°F)
-50 to 500°C (-58 to 932°F)
2.71°C/ 4.88°F
C
± (0.6 + 0.01 | t |)
-196 to 600°C (-320.8 to 1,112°F)
-50 to 600°C (-58 to 1,112°F)
5.42°C/ 9.76°F
Error at 482°C/ 900°F
Table 2: Premium or special grade wire reduces thermocouple uncertainty Sensor special tolerance
Accuracy spec greater of:
482°C / 900°F
Type E
0°C to 870°C: ±1.0°C or ±0.004 * | t |
± 1.9°C / 3.5°F
Type J
0°C to 760°C: ±1.1°C or ±0.004 * | t |
1.9°C / 3.5°F
Type K
0°C to 1260°C: ±1.1°C or ±0.004 * | t |
± 1.9°C / 3.5°F
Type T
0°C to 370°C: ±0.5°C or ±0.004 * | t
ungrounded (insulated from the sheath). A grounded T/C will respond more quickly but the T/C is then in contact with the process voltage. For this reason it is important that the measuring circuit be isolated to block the formation of a ground loop and resulting measurement error. Within a temperature assembly, the T/C is usually embedded in magnesium oxide (MgO) and a metal sheath. Then it’s inserted into a thermowell or protection tube. This helps protect the sensor from environmental contamination. Even an ungrounded T/C will eventually go to ground when the MgO becomes contaminated with moisture and salts. Suggestion: Measure the T/C with an KEYWORDS: Temperature isolated measuring circuit. sensor selection, RTD, Thermocouple sensor accuracy: It is thermocouple best to use thermocouple sensors that are Measure temperature with built to the ASTM E230 standard, which RTDs rather than T/Cs. governs thermocouple accuracy for types Premium wire T/Cs should be used, if T/Cs are needed. E, J, K, and T. 11 tips help with temperature Thermocouple reference tables are sensor selection. provided in ASTM E230/E230M-12 Standard Specification and TemperaCONSIDER THIS ture-Electromotive Force (emf) Tables Is it better to spend nominally more for a better sensor or for Standardized Thermocouples.
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replace them more often?
Special thermocouple wire
ONLINE
Thermocouples can be constructed with premium or special grade wire which reduced uncertainty by half. The premium/special designation essentially indicates that this wire has a higher purity alloy mix. Suggestion: If an application requires
If reading from the digital edition, click on the headline for more resources. www.controleng.com/magazine See related New Products for Engineers under the sensors product category at www.controleng.com/NP4E
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PROCESS SENSING T/Cs instead of RTDs, use a premium grade T/C; the cost difference is negligible and premium wire provides greater stability. Wire contamination is a consistent problem with thermocouples. Accuracy chart values assume wire has not been contaminated by the chemicals in the process or environment. As contamination occurs,
error generally increases to a point necessitating sensor replacement.
Sensor trimming for high accuracy
After considering the sensing element, consider the application. If it demands the best accuracy possible, a temperature measurement system with bath calibration. A
Class A RTD sensor is calibrated in a bath to calibrate it to the transmitter or remote input/output (I/O) measuring device. This process eliminates the final “as-built” offset error that exists in every sensor. The sensor should include a traceable calibration report from the National Institute of Standards and Technology (NIST) that indicates the combined sensor and temperature transmitter uncertainty is typically better than ±0.01°F.
Sensor selection: 11 tips
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input #9 at www.controleng.com/information
To optimize measurement performance and minimize long-term maintenance expenses, use the following tips as a practical guide for temperature sensor selection. 1. Use an RTD when measuring in ranges between -40° and 850°C (-40° and 1,562°F) 2. For temperatures as low as -200°C (-328°F), use a wire wound RTD 3. Best practice is to use 4-wire and Class A RTDs 4. Make sure the sensors are temperature cycled and “aged” for long term stability 5. When applying RTDs below 0° and above 600°C, you want to know the process conditions in order to optimize the build: Temperature range, cycling, pressure, flow, media, vibration and surrounding environmental conditions (chemicals/ atmosphere) 6. When highest accuracy is needed, use sensor trimming 7. If using 3-wire RTDs with long wire runs, and you cannot convert over to 4-wire RTDs, replace the 3-wire RTDs with 1,000Ω Platinum RTDs 8. If monitoring temperatures above 850°C (1,562°F), use thermocouples 9. If using thermocouples, use premium grade thermocouples and extension wire 10. If using long thermocouple extension wire, be sure it is noise protected 11. Replace contaminated TC extension wire with remote I/O. ce
Gary Prentice is vice president, sales, Moore Industries. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media, mhoske@cfemedia.com.
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INDUSTRIAL CABLE MANAGEMENT Sree Potluri, Beckhoff Automation
The best cable management strategy is foresight in selecting components Reduce or eliminate unnecessary cables through pluggable I/O terminals and one-cable strategies in control cabinets and machines.
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hen designing a new machine or retrofitting a legacy system, cable management is typically an afterthought. It’s possible to bundle wires and add a conduit to keep them in place, but ignoring the effects of required cabling until the end of the design process increases expenses and overall equipment footprint. Engineers will likely spend more time wiring a system during the commissioning phase, tracing wires during troubleshooting, and adding costs by not having the correct cable lengths. Assessing the impact of cabling before commissioning provides significant benefits beyond creating better-organized enclosures and a cleaner plant floor. Strategic cable management planning in the design phase can result in a cleaner system that reduces cable count and eliminates potential errors and points of failure. The most effective cable management strategy starts with selecting intelligent components. Engineers should implement input/output (I/O) terminals, fieldbus systems, motion control devices, and other machine components that minimize cabling requirements in the application.
Reducing cable requirements
It is important to remember that most cabling in factory settings provides either power or networking signals. Although these are not minor tasks, having a tangle of wires connecting sensors, control cabinets, and other equipment isn’t necessary. In most cases, the excess cables are due to the shortcomings of industrial devices and networks, not the control engineers. For example, traditional Ethernet-based fieldbuses, such as EtherNet/IP or Profinet, require multiple managed switches. This often makes it impossible to run cables directly from control cabinets to components in the field without using cascading switches or hubs. As a
www.controleng.com
result, this requires more hardware to configure the system and introduces additional points of failure. Similar issues arise when supplying machines with power. When attempting to improve a system’s cable management, it is important to identify the available fieldbuses and individual components that require fewer cables to get the job done. Engineers should first consider fieldbus and I/O systems and give preference to those that provide flexibility in topology and eliminate switches.
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The most effective cable management strategy starts with
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selecting intelligent components. The EtherCAT industrial Ethernet system offers flexibility in topology without using additional nodes. EtherCAT also integrates a wide range of third-party devices, from drives to I/O and field devices, and shares data to the main controller. Also, gathering data from legacy devices on other protocols without running cables back to the controller is easy to accomplish over EtherCAT. System-integrated hardware and software gateways can bring data from all manner of fieldbuses and industrial Ethernet systems into the EtherCAT network. Choosing a fieldbus based on these concerns is the first step, but the network provides the best results when paired with cable-reducing components. One-cable technology (OCT) and pluggable I/O terminals are two important pieces. control engineeering
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INDUSTRIAL CABLE MANAGEMENT Providing power and data with one-cable technology
Figure 1: One-cable technology (OCT) minimizes cabling concerns by providing both power and signal for HMI hardware, servo systems and other field components through a variety of connector types. All graphics courtesy: Beckhoff Automation
While it may be difficult to eliminate all cables in the field, it is possible to significantly reduce the number of cables; OCT provides an important tool to accomplish this. Various products have been introduced over the years to provide power and a signal through one cable. Power over Ethernet (PoE) has been an IEE 802.3-IEEE Standard for Ethernet standard since 2003, and the technology has been used in industrial applications. Other cable types combine power with USB 2.0 and a DVI signal for human-machine interface (HMI) hardware. There are also types that provide power and feedback from servo drives to servomotors or directly from the control cabinet or a distribution module to servomotors with integrated drives. Because these cables can span up to 100 m, they must offer a rugged wire jacket to ensure they withstand wear and tear in industrial environments and reduce the chance of damage and potential points of failure. For example, EtherCAT + Power (EtherCAT P) can supply power to applications from 24 to 400 Vac or 600 Vdc and carry currents up to 64 amps, as well as provide two voltages for both EtherCAT slaves and connected sensors or actuators. In this case, the two voltages—US for system and sensor supply and UP for peripheral voltage for actuators—are electrically isolated from each other and can each supply up to 3 amps to connected components. Streamlined motion architectures, such as distributed servo drive systems, can be daisy-chained, but may require a separate distribution module. However, some distribution modules can supply a signal from the control cabinet to as many as five drives. EtherCAT I/O modules with an IP67 rating can be installed outside the enclosure and closer to the machine, so the cable run is confined to a smaller area while providing signal and power for multiple EtherCAT P slaves. EtherCAT P (EtherCAT Ethernet communications with power, ECP) technology supports multiple connector families, including ECP (EtherCAT with integrated 24 Vdc power supply) and ENP (EtherCAT Ethernet with no power, ENP, without integrated 24 Vdc power supply). The designs are very similar with a trapezoidal power core element for the power supply and several points for a signal. ECP cables work in EtherCAT environments with high voltage demands. ENP cables work with any Ethernet-based protocol, such as EtherNet/IP or Profinet, as an open solution. Both types reduce cabling efforts when used with components powered through OCT.
Pluggable I/O terminals reduce cabling in cabinets
input #10 at www.controleng.com/information
Beyond eliminating cables and switches in the field, simplifying the control cabinet cabling also promotes a cleaner system with fewer points of failure. When numerous I/O points are involved, cabinets become crowded, which complicates wiring and increases the likelihood of errors. A wireless I/O terminal that plugs directly into the signal distribution board is an important advancement. Using prefabricated cables with application-specific plug connectors and power and control signals are distributed from the routing circuit board to the plug-in terminals. The approach
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Beyond eliminating cables and switches in the field, simplifying the control cabinet cabling also promotes a cleaner system with
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fewer points for failure.
offers an especially good return on investment (ROI) for production machinery integrated in series. This method is designed to eliminate point-to-point wiring within cabinets through a compact, application-specific electromechanical design. By embedding the I/O system into the machinery, machine builders and end user manufacturers also minimize cable management efforts, labor costs, and potential wiring errors. These pluggable terminals are often more compact than DIN rail-mounted I/O—as much as 50% smaller in some cases. Combined with the wiring reductions, this makes reduced equipment footprint an additional benefit of the plug-in terminal approach. This demonstrates how effective fieldbus and I/O technology can mitigate cable management concerns in electrical enclosures. However, circuit board-based I/O systems are best suited for new installations rather than retrofits. Reducing cables in the field via OCT is just as amenable to brownfield and greenfield applications.
Figure 2: Some pluggable I/O terminals are half the size of traditional hardware, and by eliminating point-to point wiring, they reduce points of failure while minimizing footprint.
The automation industry is quickly churning out streamlined products for each step in the engineering design and implementation processes. Cable management should not be an area that gets tangled up in hindsight. ce Sree Potluri is an I/O application specialist at Beckhoff Automation. Edited by Emily Guenther, associate content manager, Control Engineering, CFE Media, eguenther@cfemedia.com.
Smart cable management and smart machine design
Innovative networking technologies eliminate extraneous cables. By considering these factors during the early phases of a retrofit or new machine design, engineers are far less likely to face cable management issues later on. Many of these cablereducing strategies are still emerging technologies. While they already offer numerous benefits, their capabilities will increase as the technologies mature. Plug-in I/O terminals and one-cable solutions empower engineers to build control cabinets with drastically reduced cabling and to design fieldbus architectures with power and data in single-cable runs.
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KEYWORDS: One-cable technology (OCT), EtherCAT The benefits of OCT for machine design Exploring cable management strategies Reducing cables and smart machine design
CONSIDER THIS How could one-cable technology clean up your plant floor? input #11 at www.controleng.com/information
ONLINE Read more online about cable management at www.controleng.com. control engineering
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CABLE MANAGEMENT Paul Badowski, Cross Co.
Analyzing DIN and Deutsch connectivity options It’s important to evaluate DIN and Deutsch connector types for each application.
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here are benefits to using and ordering Deutsches Insitut für Normung (DIN) style cables pre-wired, however, there is growth in Deutsch-style connectors. While both types of connectors have their benefits, it’s important to evaluate them both depending on the application.
Selecting DIN or Deutsch connectors
Over the last few years, mobile machine products have seen a rapid growth in the Deutsch-style connector. The smaller size, improved environmental sealing, and push-to-lock connection are an improvement over the DIN-style plug. A pre-wired Deutsch two-pin connector is great because many smaller original equipment manufacturers (OEMs) don’t want to purchase the special crimping tools and supplies required to use the Deutsch-style connectors. Figure 1: A standard pre-wired One major difference in the Deutsch cable. All graphics courtesy: DIN and Deutsch connectors Cross Co. is the requirement for multiple parts and special tools. An unwired DIN connector comes with all of the parts necessary to wire the connector disassemble the connector, insert the wire, strip back the individual wires, Figure 2: A pre-wired Deutsch cable and install into the terminals. with Indicator. With the Deutsch connector, several parts need to be specified. Depending on the wire size and connection type (male or female), the socket or pin type needs to be ordered. The user also needs to determine whether to choose a solder or crimp type, the connector body, a wedge, and the connector cover and seal. Once the wires are attached to the connections, the connections are pushed into slots until positively seated and then the wedge, connector cover, and seal are installed. As a result, the electrician can spend their time doing more meaningful tasks.
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Option #1: Deutsch
Buy pre-wired two-pin Deutsch connectors with cables. A 6- or 15-ft-long cable is standard and would cover most requirements. Plug in the cable and terminate the two wires. These can be ordered with an additional cable installed on the opposite end for a complete plug-and-play system. These cables are available unlit or with an indicator light, solenoid valve, and pressure switch. With the solenoid style indicator, the indicator glows when there is power to the solenoid. With the pressure switch style indicator, the indicator glows when the switch contacts are made. A variety of ac/dc or combination voltages are available with a 10-amp rating.
Option #2: DIN
A pre-wired DIN to Deutsch adapter allows the Deutsch technology to be used on applications that already have the DIN-style connector in place or in applications where there is not an option to change the product to Deutsch connectors directly at the source. Plug in the adapter to change the connector style to Deutsch. Either DIN and Deutsch connector types will save time for more important functions other than wiring connectors. ce Paul Badowski is an OEM account manager at Cross Co, a CFE Media content partner. This article originally appeared on Cross Co.’s website. Edited by Emily Guenther, associate content manager, Control Engineering, CFE Media, eguenther@cfemedia.com.
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KEYWORDS: DIN connectors, Deutsch connectors The difference between DIN and Deutsch connectors Selecting DIN or Deutsch connectors.
CONSIDER THIS What type of connector is best for your application?
ONLINE: Read more about selecting connectors online at www.controleng.com. www.controleng.com
ANSWERS
INSIDE MACHINES Frank Lamb, Automation Consulting LLC
What is machine vision, and how can it help? Understanding how machine vision works will help you see if machine vision will clear up specific application difficulties in manufacturing or processing.
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eople are often confused about what machine vision can and cannot do for a manufacturing line or process. Understanding how it works can help people make decisions about if it will resolve problems with the application. So exactly what is machine vision, and how does it work? Machine vision is the use of a camera or multiple cameras to inspect and analyze objects automatically, usually in an industrial or production environment. The data acquired then can be used to control a process or manufacturing activity. A typical application might be on an assembly line; after an operation is performed on a part, the camera is triggered to capture and process an image. The camera may be programmed to check the position of something, its color, size or shape, or whether the object is there or not. It also can look at and decipher a standard or 2-D matrix barcode or even read printed characters. After the product has been inspected, a signal is usually generated to determine what to do with it. The part might be rejected into a container or an offshoot conveyor, or passed on through more assembly operations, tracking its inspection results through the system. In any case, machine vision systems can provide a lot more information about an object than simple absence/presence type sensors. Typical uses for machine vision include: • Quality assurance • Robot/machine guidance • Test and calibration • Real-time process control • Data collection • Machine monitoring • Sorting/counting.
Many manufacturers use automated machine vision instead of human inspectors because it is better suited to repetitive inspection tasks. It is faster, more objective, and works continuously. Machine www.controleng.com
vision systems can inspect hundreds or even thousands of parts per minute, and provides more consistent and reliable inspection results than human inspectors. By reducing defects, increasing yield, facilitating compliance with regulations and tracking parts with machine vision, manufacturers can save money and increase profitability.
An analogy for machine vision
A discrete photoeye is one of the most basic sensors in industrial automation; the reason we call it “discrete” or digital is it only has two states: on or off (Figure 1). The principal idea behind a diffuse photoeye is it emits a beam of light and detects if that light is being reflected off of some object. If the object is not present, no light reflects back into the photoeye’s receiver. An electrical signal, usually 24 V, is connected to the receiver. If an object is present, the signal turns KEYWORDS: on and can be used in a control system to Machine vision, automation make something happen. If the object is tutorial removed, the signal turns back off. MachinE viSiOn baSicS A diffuse photoeye also can be analog. Vision system components and Rather than only having two states, off and factors for selection on, it can return a number signifying how Units and communications for much light is returning into its receiver. In machine vision. the case of the photoeye shown in Figure cOnSiDER ThiS 2, it can return 256 values, from 0 (signiComplex sensing applications fying no light, dark or black) to 255 (sigmay be simpler with a machine nifying lots of light, or white). The left side vision system. photoeye is returning a value of 76, or dark OnLinE gray. This is about 30% of the maximum If reading from the digital value of 255. If a lighter object is placed in edition, www.controleng.com/ front of the sensor, it will return a higher magazine, click on the headline for more resources, including a number. If it produces 217, which is about link to the sensors and machine 85% of the full range of 255, this indicates vision page. a much lighter shade of gray. Register and view a related Imagine if thousands of tiny analog digital report on machine photoeyes could be arranged in a square vision at www.controleng.com/ DigitalReports or rectangular array and pointed at an
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INSIDE MACHINES Diffuse photoeye
The lens captures the image and presents it to the sensor in the form of light. To optimize the vision system, the camera needs to be matched with the appropriate lens. Although there are many types of lenses, machine vision applications typically use a lens with a fixed focal length. Three factors are an important part of the selection process: 1. Field of view
Figure 1: A discrete diffuse photoelectric sensor says if a value is measured or not. All images courtesy: Frank Lamb, Automation Primer
Analog diffuse photoeye
Figure 2: An analog diffuse photoelectric sensor can provide a range of measurements.
object. This would create an image of the object in black and white, based on the reflectivity of wherever the sensor was aimed. The individual sensed points in these images are referred to as “pixels.” Of course, thousands of tiny photoelectric sensors aren’t used to create the image. Instead, a lens focuses the image onto a solid-state matrix of light detectors. A charge coupled device (CCD) or complementary metal-oxide-semiconductor (CMOS) array of light sensitive solid-state devices are used in the matrix. The individual sensors within the matrix are the pixels. The series of images in Figure 3 is only a small section of the image captured by the camera. This area is considered to be the “region of interest” for a particular inspection. Machine vision can use color sensing pixels and often use much larger pixel arrays. Software tools are applied to the captured images to determine dimensions, edge locations, movement, and the relative positions of components to each other. (Figure 4 shows a CCD image.)
Four main vision system components
Lenses and lighting, the image sensor or camera, the processor, and a method of communicating results, whether by physical input/output (I/O) connections or through other communications, are the four main parts to a vision system.
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2. Working distance 3. Sensor size of the camera. There are many different methods of applying lighting to the image. The direction the light comes from, its brightness, and its color or wavelength compared to the color of the target are all important elements to consider when designing a machine vision environment. While lighting is an important part of getting a good image, there are two other things that affect how much light exposure an image gets. The lens has an adjustment called the aperture, which is opened or closed to let more or less light enter the lens. In combination with the exposure time, this determines the amount of light on the pixel array before lighting is even applied. The shutter or exposure time determines how long the image is imposed onto the array of pixels. In machine vision, the shutter is electronically controlled, usually on the order of milliseconds. After the image has been captured, software tools are applied. Some are applied before analysis (pre-processing) while others are used to determine the properties of the object being examined. In the pre-processing stage, effects can be applied to the image to sharpen the edges, increase contrast, or fill spaces. This is done to enhance the ability of other software tools.
Machine vision target
The following is a list of some common tools that can be applied to obtain information about the target: • Pixel counting: Counts the number of light or dark pixels in an object • Edge detection: Finding object edges • Gauging/metrology: Measurement of object dimensions (such as pixels, inches, or millimeters) • Pattern recognition or template matching: Finding, matching, and/or counting specific patterns. This may include location of an object www.controleng.com
input #12 at www.controleng.com/information
Bring Your Machine To Life With Custom Drives
ANSWERS
INSIDE MACHINES
Ad v an c e A l g o ri d C o n t h m t ro l s
Ethernet Connectivity Automation Controller
Custom Drives
Custom Motor Design Custom Software
Figure 3: Machine sensors make images using arrays of pixels.
Vision
Aerotech can partner with you to design a custom automation solution for your specific application at a minimum price. In our concept machine above, Aerotech’s drive packaging can be customized to fit into the wasp body with special algorithms developed at the firmware layer for flight control. Aerotech can accommodate your custom automation controller needs by using our plug-in architecture for specific algorithms such as 2D bar code, interfaces to non-standard sensors, signal outputs synchronized to servo sample time, and more. If you have a need for custom hardware or firmware in your drive package, contact Aerotech today.
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that may be rotated, partially hidden by another object, or varying in size. • Optical character recognition (OCR): Automated reading of text such as serial numbers • Barcode, data matrix and “2-D barcode” reading: Acquisition of data contained in various bar-coding standards. • Blob detection and extraction: Inspecting an image for discrete blobs of connected pixels (such as a black hole in a gray object) as image landmarks. • Color analysis: Identify parts, products and items using color, assess quality and isolate features using color.
www.aerotech.com • 412-963-7470 input #13 at www.controleng.com/information
Figure 4: The image shown was captured with a 640x480 charge coupled device (CCD). It is from an inspection of glass syringes with a plastic cap on it, the purpose of the application is to determine if the cap is on tightly.
AH0518C-CSG
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www.wago.us/leverTB input #14 at www.controleng.com/information
ANSWERS
INSIDE MACHINES The purpose of acquiring data in inspections is often to use for comparison against target values to determine a “pass or fail” or “go/no go” result. For example, with code or bar code verification, the read value is compared to the stored target value. For gauging, a measurement is compared against the proper value and tolerances. For alpha-numeric code verification, the OCR text value is compared to the proper or target value. For inspection for blemishes, the measured size of the blemishes may be compared to the maximums allowed by quality standards.
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With code or bar code verification, the read value is compared to the stored target value. For gauging, a measurement is compared against the proper value and
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tolerances.
Machine vision communications
After extracting the information using the processor and software tools, the information can be communicated to the control system using many of the standard industrial communication protocols. EtherNet/IP, Profinet, and Modbus TCP often are supported by major machine vision systems. Serial RS232 and RS485 based protocols are also common. Digital I/O often is built into the system for triggering and simple result reporting. Machine vision communication standards also are available. Understanding the physics and capabilities of machine vision systems can help qualify if an application is appropriate for camera-based systems. In general, whatever a human eye can see is what a camera can see (sometimes more or less), and deciphering and reporting the information can be tricky. Using a vendor knowledgeable in the systems, lighting, and techniques can save a lot of time and money in the long run. ce Frank Lamb is the founder of Automation Consulting LLC, the creator of Automation Primer, a CFE Media content partner and is a member of the Control Engineering Editorial Advisory Board. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media, mhoske@cfemedia.com.
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2018 Programmable Controller Software & Hardware Study 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. The Control Engineering 2018 Programmable Controller Software & Hardware Study unveiled six key findings regarding what end users expect and how they purchase or specify industrial controller software and hardware. According to data in the 2018 report, the top uses for programmable controller software or hardware are discrete and continuous manufacturing (23% primary, 20% secondary) and continuous manufacturing (24% primary, 17% secondary). In addition, in the past 12 months, respondents spent an average of $183,746 on industrial controller hardware and software (an increase of 17% over 2017 data)—with 26% having spent $200,000 or more. Download the new Programmable Controller Software & Hardware research today!
www.controleng.com/2018-programmable-controllers-study/ ce201812_research_hlf.indd 1
12/5/2018 10:10:31 AM
INNOVATIONS
NEW PRODUCTS FOR ENGINEERS Your Global Automation Partner
Safety integrated controller system
AutomationDirect’s ReeR Mosaic M1 safety controller system is modular, expandable, and configurable for managing all safety functions of one machine or an entire plant. As a stand-alone controller, the master module has eight inputs, two safety outputs, two status outputs, and two inputs for start/stop interlock (RST) and external device monitoring (EDM). By adding up to 14 expansion modules, the safety controller system can have up to 128 inputs, 16 safety outputs, 16 RST/EDM inputs, 32 status outputs, and EtherNet/IP or Modbus TCP/IP connectivity. AutomationDirect, www.automationdirect.com
Input #200 at www.controleng.com/information
Analog output sensor for flowmeters
AW-Lake’s FAC-S analog output sensor is designed to hardwire with any flowmeter to provide voltage, current, or Bluetooth reading connectivity. The FAC-S produces a scalable voltage or current output for download to a programmable logic controller (PLC) or other control system. The sensor also supports a Bluetooth interface for remote programming and flow monitoring from a smartphone. The microprocessor-based FAC-S sensor supports process monitoring, data acquisition, and signal conditioning. A Bluetooth-enabled mobile app connects to the FAC-S, enabling wireless setup and troubleshooting from a mobile device. The mobile application also supports basic scaling and advanced functions, allowing for remote correction of non-linear flow meters to keep a linear analog output. AW-Lake Company, www.aw-lake.com
Input #201 at www.controleng.com/information
EtherNet/IP module with valve terminal, diagnostic details
The Festo CPX-FB36 EtherNet/IP module is designed to provide valve terminal health and diagnostic details with Shelby, its FactoryTalk Analytics for Devices platform. When combined with the MSE6-E2M intelligent energy efficiency module, Shelby creates a dashboard that provides the pneumatic response of a system with up to a six-month look-back. The CPX-FB36 diagnostic data also is accessible by FactoryTalk TeamONE mobile app users via the Action Deck. The CPX-FB36 allows the Festo VTEM digital pneumatic valve terminal to change functionality based on Festo downloadable apps from Festo. These flexible valves can potentially replace up to 50 pneumatic components. Festo Corporation, www.festo.com
Input #202 at www.controleng.com/information
Adaptive grippers for collaborative robots
Robotiq’s 2F-85 and 2F-140 grippers are designed for collaborative robots. They are designed to be less exposed to factory air, dust, and fluids. Their finger bases have been redesigned to simplify fingertip changeover and ensure a reliable grip. The overall design is smoother and rounder, with every sharp edge removed. Each one also includes an accessories holder near the base. The 2F-85 is ideal for applications involving heavy objects and high pinch force. The 2F-140 is ideal for picking objects of almost any size and shape. Robotiq, www.robotiq.com
Reduce Costs – One Sensor Detects all Metals Detect all metals at the same range with inductive sensors from Turck – no position adjustment required. These non-contact, durable inductive sensors help you reduce the number of sensors needed for detecting the position or presence of metal parts. Plus, our IP68-rated versions stand up to challenging washdown environments. input #15 at www.controleng.com/information
Input #203 at www.controleng.com/information
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1-800-544-7769 www.turck.us
INNOVATIONS
NEW PRODUCTS FOR ENGINEERS Industrial managed PoE switch
At 3:25 a.m. a problem occurred in your factory.
PLANTREPLAY saw it. And now, you can too.
Korenix’s JetNet 7310G industrial managed Power over Ethernet (PoE) switch is equipped with 8 Gigabit Ethernet RJ-45 ports and 2 Gigabit Ethernet SFP ports. It is compliant with IEEE 802.3at/af standards with 1- and 2-event behaviors. It can perform well on power feeding to devices with high power consumption such as IP cameras. The JetNet 7310G also supports Layer 3 network routing protocols including static/dynamic routing, VLAN routing, and multicast routing. With the various routing features, the data streams will be routed in an efficient way and accelerate data streams as well. It also carries Layer 2 network performance such as IEEE802.1Q VLAN, trunk, packet filtering, DHCP server/client, traffic prioritize, and rate control. Korenix Technology, www.korenix-usa.com
Input #204 at www.controleng.com/information
Power distribution blocks
PLANTREPLAY lets operators, managers and plant engineers go to any HMI client and replay exactly what was happening at any time – last week, last month… or earlier this morning.
Phoenix Contact’s PTFIX potential distribution blocks are a flexible, modular with a push-in connection designed to minimize the need for additional tools or accessories, saving valuable time and space. Distribution blocks offer a flexible range of mounting configurations, including horizontal and transverse positioning on a standard 35-mm DIN rail and a “mini” 15-mm DIN rail. It is also available in other mounting configurations, such as direct mounting with flanges and tool-free adhesive mounting. These flexible options ensure that there is a solution for a vast array of applications. Phoenix Contact, www.phoenixcontact.com
Input #205 at www.controleng.com/information
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INNOVATIONS
See more New Products for Engineers. www.controleng.com/NP4E
NEW PRODUCTS FOR ENGINEERS
Integrated stepper motor package Applied Motion Products’ STM/SWM integrated stepper motor package combines drive and control in one package and incorporates an encoder with capabilities for automatic stall detection and prevention. The built-in encoder provides feedback to the integrated controller on the motor’s actual position and closes the feedback loop to avoid limitations associated with stepper systems. The Q Programmer motion control software incorporated into the STM/SWM integrated stepper motor package enables easy configuration of motor operation to match requirements of different conveyor applications. On-board EtherNet/IP communications of the integrated stepper motors replace noisy analog control signals with a digital signal, eliminating the need to run long signal wires from as many as 100 motors to a central programmable logic controller (PLC) while allowing the conveying equipment to perform at high speeds with high precision not affected by noise.
PE
IoT gateway for machine and networking Bosch Rexroth’s IoT Gateway software V2 is designed to network new and existing machines. The hardware allows for an adjustable and scalable concept for one or more machines and can be used for existing machines as well as directly at the original equipment manufacturer (OEM). To evaluate status and processes more completely, the user has the option of connecting additional sensors, third-party controls and higher-level information technology (IT) systems. The gateway also allows users to quickly network new and existing machines in just a few easy steps. For access to production and machine data, the web-based configurable tool can be connected to a wide variety of sensors, servers, and controls using the configurable device apps. Bosch Rexroth, www.boschrexroth.com Input #207 at www.controleng.com/information
Applied Motion, www.applied-motion.com Input #206 at www.controleng.com/information
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INNOVATIONS
Back to Basics: LaDDER LoGic Frank Lamb, Automation Primer LLC
Ladder logic, fault detection, messages in ladder logic, faults are used to capture abnormal circumstances and each cell or station in a program will usually have its own fault routine and can send messages to a human-machine interface (HMi) or programmable logic controller (PLc).
I
n ladder logic, faults are used to capture abnormal circumstances such as an actuator not completing its motion within a prescribed period of time. Each cell or station in a program will usually have its own fault routine. There is usually one fault for every motion (extend, retract, raise, lower and so on). Other faults may include lack of air pressure, emergency stop actuation, guard door switches and drive or overload alarms. A system fault disables the timer on the fault rung. It serves two purposes: 1. Only the fault that happens first is enabled. This prevents subsequent faults that may have been caused by the initial fault from occurring. If air is removed from the system several pneumatic actuators may fault within the same event. 2. After the fault occurs the timer resets allowing a new countdown. This allows physical correction of the cause of the fault by maintenance or an operator. There are a couple of methods of resetting the fault. One is to clear the register word that contains the faults, in this case word 10. This fault word may be for only this cell allowing the system reset signal to reset faults in sections if desired; word 10 for cell 1, word 11 for cell 2, etc. Another method is to reset or unlatch faults individually. These reset signals can also be individually conditioned this way on each rung. Faults can also be used in a permissive rung to prevent actuation of an axis. Fault bits are also used to activate messages on a touchscreen or human-machine interface (HMI), for instance, bit 10.0 might bring up a message that says, “Axis SV1.0 Failed to Extend; Correct Fault and Press Reset.” The Keywords: Ladder logic, fault message would be cleared when the detection fault is corrected and the fault reset In ladder logic, faults are used to capture abnormal circumstances within button pressed. a prescribed period of time. There are several ways to disFaults can display many ways on a play fault messages on an HMI. human-machine interface (HMI). Most HMI software allows the user online to make a list of faults and then call Read this story online at them by number to display in a banwww.controleng.com for more ner or other type of text display. information about ladder logic. Another option is to configure Consider this the trigger to display the message by How can better fault detection bit number. This also allows multiple programming help your processes? messages to be displayed on a timed
M More INNOVAtIONs INNOVAt
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cycle, unlike if the message were to be displayed by value or placing a number into the message register. The background color of the message can also be configured so that fault messages and warnings or other informational text can be displayed in the same banner. This is especially helpful if the HMI is small and doesn’t have room for more than one message display. Besides faults and messages, these displays can be used as multi-state indicators to show the mode of a machine or station status. Other properties of the message display can also be configured such as its visibility.
Bits versus values
There are advantages and disadvantages to using bits versus values. Using bits allows several “states” or messages to exist at the same time, whereas a value allows only one message to be called. If the HMI does not have the ability to cycle through messages with several bit triggers active at the same time, it will be necessary to write code in the programmable logic controller (PLC) that cycles through the messages. Another method that is sometimes used for message displays is to simply place a string display on the screen. While this is simple on the HMI end, it requires the PLC program to cycle through the strings and place them into the message register, which of course must be of the STRING data type. This technique has advantages and disadvantages. On the plus side, the PLC programmer can change string messages dynamically. As a matter of fact, the programmer can give access to the user of the touchscreen by placing links to the locations of the string registers on a screen. This allows the messages to be configured without using the HMI software. On the minus side, it is difficult to manage background or text colors using strings. The background would have to have a color register assigned to it, which would be managed separately. ce Frank Lamb is the founder of Automation Consulting LLC, and is a member of the Control Engineering Editorial Advisory Board. This article originally appeared on Automation Primer’s blog in two parts. Automation Primer is a CFE Media content partner. Edited by Chris Vavra, production editor, Control Engineering, cvavra@cfemedia.com. www.controleng.com
Defend Against the Bounce Pass
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