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Vol. 66 Number 1

JANUARy 2019

22 | Industrial network communications 24 | Industrial Ethernet, smarter machines

14-25

COVER IMAGE: Connect with network software, cover images: Through physical connections, networking software (communication protocols and middleware) connects devices and systems. Upper right, B&R Industrial Automation Corp.’s booth at IMTS 2018 included a live IEEE Time-Sensitive Networking (TSN) testbed. At the Rockwell Automation Fair 2018, Nov. 14 and 15 in Philadelphia, upper left, Spectrum Controls showed how industrial Ethernet devices can communicate with legacy network protocols. Lower left and right, also at Automation Fair, Panduit demonstrated network connectivity options for a variety of applications and environments. Images courtesy: Mark T. Hoske, Control Engineering. See six related articles in this issue, pages 14-25.

INSIGHTS 5 | PLC research results from Control Engineering 6 | Legalities: Negotiate better payment terms 8 | Technology Update: Digitalization and innovation NEWS

10 | Industrial internet groups to collaborate on cloud computing, IIoT research; Manufacturer to realign around digital industries; Online headlines 12 | Think Again: Hot topics in Control Engineering for 2018

25 | Software unlocks protocol diagnostics 27 | Industrial controller selection advice 30 | Automation programming advances enhance communication, programming 33 | Shaft encoders vs. bearingless encoders 34 | System integration in the automotive industry INSIDE PROCESS

P1 | Verifying primary and secondary flow measurement performance P7 | Lessons learned: Startup, shutdown incidents

INNOVATIONS NEW PRODUCTS fOR ENgINEERS | 58 Stepper motor for hazardous locations; Non-

contact magnetic measuring system; LVDTs; Three-phase ac motors; AI controller extends equipment life; CNC for machine tools; Cyber risk management

BACK TO BASICS

64 | Programming, collaborative robots

ANSWERS

ONLINE

14 | Industrial networking and the IIoT

• More networking software: OPC UA, MTConnect, EtherNet/IP from ODVA, and CC-Link.

16 | Future of IIoT software in manufacturing 20 | MQTT’s role as an IoT message transport

• Smarter robot grasping: sensors, software, cloud

CONTROL ENGINEERING (ISSN 0010-8049, Vol. 66, No. 1, 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 2019 by CFE Media, LLC. All rights reserved. CONTROL ENGINEERING is a registered trademark of CFE Media, LLC used under license. Perio dicals 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.

www.controleng.com

control engineering

January 2019

•

input #5 at www.controleng.com/information

To learn more about HART Isolators from Moore Industries Call 800-999-2900 or visit www.miinet.com/HART-Isolators

Attitude towards job Work is tolerable but open to other opportunities

Actively searching for another job 2% %

12%

40% Love going to work every day

Figure 1: 46% of end users enjoy their jobs and look forward to going to work every day; 40% are satisfied and pleased to be working. Source: Control Engineering 2018 Career & Salary Study

56%

of end users prefer to purchase servo and/or stepper drive controller products as matched units. Source: Control Engineering 2017 Motor Drives Study

Six in 10

end users are not bound to existing purchase agreements when selecting HMI/ SCADA software or hardware. Source: Control Engineering 2018 HMI Software & Hardware Study

46%

of end users take advantage of upgrades and patches provided by their industrial controller software provider. 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/research.

www.controleng.com

RESEARCH

2018 PROGRAMMABLE CONTROLLERS STUDY 46%

Work is okay, okay glad to have a job

INSIGHTS Industrial controller features

espondents to the Control Engineering 2018 Programmable Controller Software & Hardware Study provided their insights on important capabilities of industrial controllers: • Software functions: Programmable logic controller (PLC) programming tops the list of controller software features that end users need at 87%, followed by humanmachine interface (HMI) development (72%) and remote monitoring (70%). • Controller features: Seventy-seven percent of industrial controllers have proportional-integral-derivative (PID) control, and 61% can communicate with devices or systems outside of the control loop. • Networking: Thirty-seven percent of end users’ controllers interface with PLCs, 21% with a distributed control systems (DCS), 12% with programmable automation controllers (PACs), and 11% with industrial PCs; 18% stand alone. • Communications: The top communications protocols used by controllers are 4-20 mA/0-10 V dc (76%), Ethernet (73%), RS-232/RS-485 (61%), and Modbus TCP

(55%). Forty-five percent of end users’ controllers use the OPC Unified Architecture machine-to-machine communication protocol, and 25% use another communications software/method from OPC Foundation. Eight-two percent of end users employ Ethernet, TCP/IP in their controller hardware. • Programming: The majority of end users (84%) use or expect to use ladder diagrams over the next 12 months, while 63% use/expect to use function block diagrams and 38% use/expect to use sequential function charts and/or structured text. • Integration: Sixty-six percent of end users use controller software that is compatible with prior versions of the platform and 43% use a controller software that easily integrates data from other systems. ce

M More RESEARCH

View additional findings at www.controleng.com/2018-programmablecontrollers-study. Amanda Pelliccione is the research director at CFE Media, apelliccione@cfemedia.com.

Top 10 controller software programming, setup functions 78%

Ladder logic Function blocks

58% 48%

Full IEC 61131-3 language support Function/code libraries, object-oriented code

42%

Client-server capability

33%

Structured text

33%

Automated tagging Sequential function charts Simulation capabilities Custom programming tools

31% 29% 25% 23%

Figure 2: End users most often use controller software featuring ladder logic, function blocks, and full IEC 61131-3 language support. Source: Control Engineering control engineering January 2019 • 5

INSIGHTS

LEGALITIES FOR AUTOMATION AND INTEGRATION Brian Clifford, Faegre Baker Daniels

Negotiate better payment terms Payment cycle provisions are common in automation and integration contracts. Four strategies can help a company’s cash flow.

‘

Invoice the

costs for expensive third-party equipment

’

separately.

he right contract clauses can improve a company’s cash flow—whether you are making or receiving payments. “Payment cycle” provisions are common in automation and integration contracts. As you are likely seeing in the market, the historic “net 30” terms in commercial agreements are becoming harder to obtain. Companies making payments for completed services and deliverables are pushing for longer deadlines, as long as 90 or more days from invoicing. Like using a credit card (and paying it off monthly), companies are buying automation services and products and are essentially obtaining short-term, interest-free loans from vendors for projects. Sometimes, long payment cycles are an indication a purchaser is experiencing financial difficulties. Other times, such cycles are a function of burdensome internal approval processes or a company knowing it can use its leverage to obtain very favorable payment deadlines. Sometimes, it’s both scenarios. If you are the seller, four strategies can be used to get paid for completed work as quickly as possible:

1. Negotiate shorter payment deadlines

The most straightforward method to get paid faster, of course, is to shorten the payment deadlines. Often, customers are willing to consider reducing particularly long payment cycles if the issue is presented to them in the right way. You can explain that you are unable to KEYWORDS: Legalities, obtain corresponding payment cycle terms contract payment terms from your own vendors, meaning you would Contract payment terms have to “come out of pocket” for the project can improve how payments improve cash flow. for long periods of time. Many customers are Shorter payment deadlines sensitive to this cash-flow problem.

M More INSIGHTS

can improve cash flow. Expensive equipment might be invoiced separately.

CONSIDER THIS How is your automationindustry company aiming to improve cash flow?

ONLINE If reading from the digital edition, click on the headline for more resources. For other engineering-related legal issues, search “Faegre” at www.controleng.com.

•

January 2019

2. Carve-out portions

of the contract amount

If a customer is unwilling to shorten the payment deadline in general, you may want to consider “carving-out” certain portions of the contract amount for a shorter payment cycle. For example, if you are required to provide an expensive piece of third-party hardware or equipment for the project, you may be able to get a customer to agree to have the costs for the item separately invoiced on payment terms that are within the deadline established

control engineering

by your agreement with the third-party vendor. This can prevent you from being “caught in between” two large corporations using their market share to obtain unreasonably favorable payment cycles.

3. Insert a down payment or mobilization fee

If you know long payment cycles will be required, you may want to “front-load” your fees in the agreement. You can use this up-front payment to keep your out-of-pocket expenses to a minimum as work progresses. Such terms also decrease risk of non-payment for work already completed, but not yet billed or paid. However, you should be careful not to misrepresent such early payments.

4. Invoice more often

Another effective strategy in mitigating the risk of long payment cycles is to invoice more frequently. Instead of your usual monthly invoices, will a customer accept weekly or bi-weekly invoices? While the deadline for your receipt of payment on each of these invoices may still be set out far in advance, more frequent invoicing will increase cash flows for the project and decrease the amount of payments outstanding at any point in time.

If you are the purchaser, you can flip these strategies around. For example, you could propose a shorter payment cycle for services (in recognition of the employee salary payment cycle), but only permit invoicing for equipment once it has been delivered and passed a site acceptance test (SAT). It also might be possible to withhold a certain portion of the contract price until after final acceptance of the entire system and a successful start-up period. Invoicing also could be set on a longer cycle through the use of a milestone billing provision. Regardless of which side of the payment cycle you are on, you may be able to ensure a steadier cash flow for your next project by using these contract negotiation techniques. ce Brian Clifford is a partner in the automation and robotics practice of Faegre Baker Daniels, a law firm in the U.S., U.K. and China. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media, mhoske@cfemedia.com. www.controleng.com

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INSIGHTS

TECHNOLOGY UPDATE: INDUSTRIE 4.0 Jonathan Wilkins, EU Automation

Digitalization and innovation driving manufacturing’s future Manufacturing is in the midst of the fourth industrial revolution—known as Industrie 4.0— and constant plant-floor changes are forcing companies to keep up with the rapid pace or risk getting lost and falling behind.

he fourth industrial revolution, also called Industrie 4.0, is underway. It revolves around the rise of the Industrial Internet of Things (IIoT) and its ability to connect to seemingly everything, including innovations such as additive manufacturing, collaborative robots, artificial intelligence, and augmented and virtual reality (AR/VR). Industrial revolutions themselves are nothing new, but the pace at which they’re occurring is remarkable. The pace of change in ancient societies was on a scale of hundreds or thousands of years. In contrast, the industrial revolutions Book by EU Automa- of the 18th and 19th centuries shortened the time span tion has more about between successive revolutions to less than a hundred Industrie 4.0. Couryears. Depending on the source, the third industrial tesy: EU Automation revolution lasted from 1980 to the Great Recession. Despite innovations being more readily available than ever, countries are at different points on the journey to digitalize. There is a disparity between the rates of adoption of new technologies, awareness about what the fourth industrial revolution offers, and a cohesive leadership Keywords: Industrie 4.0, intended to drive change initiatives. This has digitalization, robots resulted in a fragmented system, with the conDigitalization is a key cept of industrial digitalization, or Industrie part of the fourth industrial 4.0, referred to by various names including revolution. Society 5.0, Smart Industry, Manufacturing In this new manufacturing USA, and Made in China 2025. environment, the robot’s role While the names and concepts differ, the has changed and become more collaborative. core principles are largely the same. Countries Digitalization offers a and companies seek to enhance connectivity great deal of potential, but on the manufacturing floor to provide better, companies have to recognize faster, and accurate data to make manufacturthat and enact policies to ing operations safer and more productive. realize it.

M More INSIGHTS

Consider this What other manufacturing developments will happen in Industrie 4.0?

online Learn more about Industrie 4.0 at www.controleng.com under the IIoT and Industrie 4.0 topic.

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January 2019

Robots and Industrie 4.0

Manufacturing has turned to robots to handle many of the dirty, dull, and dangerous (“the three Ds”) tasks on the plant floor. While robots used to be confined to a fixed area— preferably behind a mesh cage—they are starting to work alongside humans in day-to-day operations. Collaborative robots are among

control engineering

the manufacturing innovations. Nigel Smith, CEO of TM Robotics, has seen the challenges and the possibilities robots can bring in this new manufacturing environment. “Robots have dominated automotive applications for a long time,” he said. “In the last few years, however, we’ve seen robots being used in increasingly varied sectors, from food and pharmaceutical to medical and plastics manufacturing.” In addition to new applications, robots have become more reliable, Smith said, thanks to manufacturers shifting from hydraulics to electrical actuation. Remote monitoring helps users gain more insights to prevent potential mechanical or control issues. Interfacing and connectivity have improved. Connecting a peripheral device such as a vision system to a robot can be done easily, which makes processes such as inspection and conveyor tracking smoother. Even with these improvements, Smith pointed out there is still a big fundamental challenge manufacturers face at the beginning of the process. “A challenge that continues to affect many businesses is choosing the right robot,” he said. “Because robots are becoming easier to use and maintain, cheaper, more efficient and easily deployable, [there are more options.] This makes it even more important that engineers choose one with the right blend of features to match the needs of the application.” The manufacturing industry has progressed since the term Industrie 4.0 was introduced. Some technologies in operation were just ideas then. Robots were still in cages. Workers, while operating in a more interactive environment, didn’t have nearly as many choices as they do now with digitalization. Digitalization has the potential to transform the manufacturing industry, but companies need to embrace new technology to benefit. Even making small changes can have a huge impact on operations, staff and productivity. ce Jonathan Wilkins, marketing director, EU Automation. Edited by Chris Vavra, production editor, Control Engineering, CFE Media, cvavra@cfemedia.com. www.controleng.com

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INSIGHTS

NEWS

Industrial Internet groups to collaborate on cloud computing, IIoT research The Industrial Internet Consortium (IIC), a CFE Media content partner, and the OpenFog Consortium are merging to bring research and best practices promulgation around cloud and fog computing, 5G cellular communications, and artificial intelligence (AI) under one organization. The two groups announced Dec. 18, 2018, they would combine their organizations under the IIC name and would collaborate on a more holistic approach to furthering the use of the Industrial Internet of Things (IIoT). “The Industrial Internet Consortium, now incorporating OpenFog, will be the single largest organization focused on IIoT, AI, fog, and edge computing in the world. Between both of our organizations we have a remarkable global presence with members in more than 30 countries,” said IIC president Bill Hoffman. “This

agreement will help accelerate the adoption of the IIoT, fog, and edge computing.” Cloud computing transmits and stores information through data centers to provide greater computing capacity. Fog computing, also known as edge computing, allows for such calculations to be done at servers on a plant’s premises. “We’re excited by the growth and advancement of fog technologies—from a technology, standards, and general awareness standpoint—since our launch nearly three years ago,” said Matt Vasey, OpenFog chairman and president, and director, AI and IoT business development, Microsoft. “During that time, it has increasingly become apparent that we share so much synergy with the efforts of the IIC that it just made sense to bring the two consortia together. The resulting combination of memberships, resources, and shared

Manufacturer to realign around digital industries

BB announced the company will reorganize its global organization into four business units and sell its power grids business to Hitachi for $11 billion as part of the streamlining effort. The reorganization, scheduled to take effect April 1, will create four business units that company officials said would better position ABB to meet the customer needs in a changing digital landscape. “To support our customers in a world of unprecedented technological change and digitalization, we must focus, simplify, and shape our business for leadership. Today’s actions will create a new ABB, a leader focused in digital industries,” said ABB CEO Ulrich Spiesshofer. ABB will organize itself into four business units: electrification, industrial automation, robotics & discrete automation, and motion. “Our four newly shaped businesses, each a global leader, will be wellaligned to the way our customers operate and focus stronger on emerging technologies such as artificial intelligence,” said Spiesshofer. “The continued simplification of our business model and structure will be a catalyst for growth and efficiency.” By streamlining the organization, eliminating regional executive committees, and reallocating resources, ABB officials said the company expects to reduce costs by about $500 million annually and expects to grow to a $550 billion business by 2025, an increase of $140 billion from today’s revenues. ce Bob Vavra, content manager, CFE Media, bvavra@cfemedia.com.

•

January 2019

control engineering

knowledge will only further the growth of the technologies, including fog, that will support IIoT ecosystems.” In a press release announcing the merger, IIC officials quoted Christian Renaud, research vice president for Internet of Things (IoT) at 451 Research as saying, “Both organizations have been advancing the IIoT, fog, and edge computing, and their members represent the best and the brightest in their fields. It makes sense to merge their expertise and work streams to continue providing the IIoT, fog, and edge guidance that the industry needs.” The IIC’s overall goal is to help deliver a secure and connected infrastructure for manufacturers using the cloud computing technology to improve operations. ce Bob Vavra, content manager, CFE Media, bvavra@cfemedia.com.

Headlines online Top 5 Control Engineering articles Dec. 3-9, 2018 Articles on process tuning, Engineers’ Choice finalists, process simulation, implementing a linear motion application, getting stronger process readings, and AR and VR were the most-viewed from Dec. 3-9, 2018. Researchers use thermal transistor to protect electronic devices from overheating A Stanford-led engineering team developed a way to manage heat produced by electronic devices with a thermal transistor. The next era of global manufacturing With technology and information, manufacturers change how they do business as globalization changes the nature of business. Hannover Fairs USA new trade event Digital Industry USA (DIG/IN USA) will highlight digital manufacturing Sept. 10-12, in Louisville. Engineer lights up the town Caleb Otto used his engineering background and love of holiday tradition to set up a musical light display. See video online. www.controleng.com

input #8 at www.controleng.com/information

INSIGHTS Think again

Hot topics in Control Engineering for 2018

3010 Highland Parkway, Suite 325, Downers Grove, IL 60515. 630-571-4070, Fax 630-214-4504

Content Specialists/Editorial Mark T. Hoske, Content Manager 630-571-4070, x2227, MHoske@CFEMedia.com Jack Smith, Content Manager 630-571-4070, x2230, JSmith@CFEMedia.com

Engineering salaries and career tips, neural network advances, ladder logic, cybersecurity, and autotuning were among top articles posted on the Control Engineering website in 2018.

Kevin Parker, Senior Contributing Editor, IIoT, OGE 630-571-4070, x2228, KParker@CFEMedia.com

ot Control Engineering topics 2. Processing a neural network’s mind posted in 2018 include engi- and its ability to process language; neering salaries and career tips, Jan. 7 neural network advances, ladMIT researchers have developed a techder logic future role in automation, indus- nique illuminates the inner workings of trial control system cybersecurity, and artificial intelligence systems that process proportional-integral-derivalanguage, which could improve tive (PID) controllers autotunoverall efficiency for machines. ing control, as identified by the 3. Ladder logic’s future role in most visited Control Engineering automation; July 3 articles during 2018. Review nine considerations Think again about upcomwhen selecting a programming ing topics at www.controleng. language. com/2019articles and contribute your expertise to next year’s Mark T. Hoske, hot topics. Especially of interest Content Manager 4. Understanding industrial control systems security basics; will be September, Control EngiApril 6 neering’s 65th anniversary, lookIt’s critical to implement an in-depth ing at how the past continues to influence cybersecurity plan to reduced risk to where we’re headed. industrial control systems (ICSs).

Chris Vavra, Production Editor CVavra@CFEMedia.com

Top 10 Control Engineering articles posted in 2018

The articles posted during 2018 at www. controleng.com with the most clicks during 2018 follow. This metric obviously favors those posted earlier in the year. At the bottom of this article online, link to the top article rankings for articles posted later in 2018.

1. Control Engineering Salary and Career Survey, 2018; May 15 Career Update 2018: Engineers are getting paid more and a greater percentage expect to get increases in 2018, but the technical challenge and a general feeling of accomplishment remains the highest factors for job satisfaction.

M More INSIGHTS INSIGHT •

January 2019

Part 1; June 1 PID controllers that can automatically select their own tuning parameters sound good but face challenges.

6. Ladder Logic: Fault detection and messages; Feb. 22 7. Comparing ladder logic and objectoriented programming; July 12 8. Implementing a cybersecurity strategy for cloud-based SCADA; Aug. 14

9. Three major VFD trends; Jan. 4 10. Process control sensor types and applications; Mar. 4. ce

If reading from the digital edition, www.controleng.com/magazine click on the headline top covers of 2018 and top 10 articles in 2018 posted prior to 2018, representing strong set of tutorials about Control Engineering topics. With this article online, link to each article referenced.

5. Pros and cons of autotuning control:

Traffic ranking based on www.controleng. com analytics performed by Chris Vavra, production editor, Control Engineering, cvavra@cfemedia.com.

control engineering

Emily Guenther, Associate Content Manager 630-571-4070, x2229, eguenther@CFEMedia.com Amanda Pelliccione, Director of Research 978-302-3463, APelliccione@CFEMedia.com

Contributing Content Specialists Suzanne Gill, Control Engineering Europe suzanne.gill@imlgroup.co.uk Ekaterina Kosareva, Control Engineering Russia ekaterina.kosareva@fsmedia.ru Seweryn Scibior, Control Engineering Poland seweryn.scibior@trademedia.us Lukáš Smelík, Control Engineering Czech Republic lukas.smelik@trademedia.us Aileen Jin, Control Engineering China aileenjin@cechina.cn

Editorial Advisory Board

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

CFE Media Contributor Guidelines Overview Content For Engineers. That’s what CFE Media stands for, and what CFE Media is all about – engineers sharing with their peers. We welcome content submissions for all interested parties in engineering. We will use those materials online, on our website, in print and in newsletters to keep engineers informed about the products, solutions and industry trends. www.controleng.com/contribute explains how to submit press releases, products, images and graphics, bylined feature articles, case studies, white papers, and other media. * Content should focus on helping engineers solve problems. Articles that are commercial or are critical of other products or organizations will be rejected. (Technology discussions and comparative tables may be accepted if non-promotional and if contributor corroborates information with sources cited.) * If the content meets criteria noted in guidelines, expect to see it first on our Websites. Content for our e-newsletters comes from content already available on our Websites. All content for print also will be online. All content that appears in our print magazines will appear as space permits, and we will indicate in print if more content from that article is available online. * Deadlines for feature articles intended for the print magazines are at least two months in advance of the publication date. Again, it is best to discuss all feature articles with the appropriate content manager prior to submission. Learn more at: www.controleng.com/contribute

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seweurodrive.com | 864-439-7537 input #9 at www.controleng.com/information

ANSWERS

Cover sTory: NeTWorKING soFTWAre Dr. Michael Hilgner, TE Connectivity Germany GmbH, IIC working groups

The significance of industrial networking for the IIoT The Industrial Internet Consortium (IIC) focuses on the role of the Industrial Internet of Things (IIoT) in industrial networking.

ndustrial networking connects devices and systems and is critical to the Industrial Internet of Things (IIoT). Application and deployment considerations—along with existing and emerging technology options—adds complexity to network planning and technology selection according to the Industrial Internet Consortium (IIC) white paper “Industrial Networking Enabling IIoT Communication.” When trying to understand and resolve networking issues, consider: 1. Future IIoT scenarios high-level descriptions of requirements and design considerations can vary by industry. 2. Various standards can apply and help.

3. The IIC is developing a technical document, the Industrial Internet Networking Framework (IINF). The core element of the document will be a conceptual toolbox designed to provide guidance KEYWORD: Industrial Internet of for selecting the appropriate network Things (IIoT) infrastructure.

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IIoT’s role in industrial networking. The Industrial Internet Consortium (IIC) is developing a technical document to provide guidance for selecting the appropriate network infrastructure. There is demand for streamlined semantics to help with operations technology/information technology (OT/IT) integration.

COnsiDER this Are you aware of the proper network architecture for an Industrial Internet Networking Framework (IINF)?

OnLinE See IIC’s white paper, “Industrial Networking Enabling IIoT Communication,” for more information.

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The Networking Task Group (NTG), a sub-group under the IIC’s Technology Working Group, is responsible for the three lower layers of the Industrial Internet Communication Stack as defined in the Industrial Internet Connectivity Framework (IICF), which are identical to the lower three layers of the OSI model: Physical layer, (data) link layer, and network layer. In industrial automation, these layers are impacted by the transition from traditional field buses to Ethernet-based protocols. Such industrial Ethernet technologies are defined by international user groups such as

control engineering

Profibus Profinet International, ODVA (EtherNet/ IP), the EtherCAT Technology Group, the Ethernet Powerlink Standardization Group and the CC-Link Partner Association (CLPA). Some technologies use standard Ethernet without modifications to layers 1 and 2 of the foundational IEEE 802.3 standard, whereas others define deviations in the data link layer. These Institute of Electrical and Electronics Engineers (IEEE) standards define the physical layer and data link layer’s media access control (MAC) of wired Ethernet. A set of common and technology-specific definitions is made available through the International Electrotechnical Commission (IEC) 61158 and IEC 61784-5 series. Companies implementing software stacks for these technologies or gateways to exchange data between them or between industrial Ethernet network and fieldbus segments need to follow the definitions by the user groups—especially those for the application layer. The emergence of the IIoT and the possibility to perform advanced analytics in higher-level IT systems have led the demand for interfaces providing access to additional data. Furthermore, for the sake of quick and reliable operational technology/information technology (OT/ IT) integration, there is a request for standardized semantics, which is often implemented through an additional “user layer” performing the conversion to a rich data model. ce Dr. Michael Hilgner, manager consortia and standards, TE Connectivity Germany GmbH, works on international standardization activities and industrial user groups in the areas of industrial networks, fieldbuses and cabling systems. For the Industrial Internet Consortium (IIC), a CFE Media content partner, he leads the smart manufacturing connectivity for Brown-field Sensors Testbed, and contributes to several Industrie 4.0 working groups. Edited by Emily Guenther, associate content manager, Control Engineering, CFE Media, eguenther@cfemedia.com. www.controleng.com

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input #10 at www.controleng.com/information

ANSWERS

COVER STORY: NETWORKING SOFTWARE Stan Schneider, PhD, Real-Time Innovations (RTI) and vice president, IIC

The future of IIoT software in manufacturing A guide to understanding and using data distribution service (DDS), time-sensitive networking (TSN), and OPC Unified Architecture (OPC UA) for advanced manufacturing applications

he top Industrial Internet of Things (IIoT) connectivity framework standards are OPC Foundation’s OPC Unified Architecture (OPC UA) and Object Management Group’s (OMG’s) Data Distribution Service (DDS). Both are gaining widespread adoption in industrial systems, though not in the same sectors. Each differ from many of today’s discrete automation systems, which use a simple architecture. A programmable logic controller (PLC) connects devices over a fieldbus. The PLC controls the devices and manages upstream connections to higher-level software such as human-machine interfaces (HMIs) and data historians. Factory-floor software is straightforward. It reads sensors, executes logic, and drives actuators, thereby implementing a repetitive operation. The factory has a series of workcells, each with a few dozen devices.

Why designs are changing The traditional PLC and HMI design served well for the last three decades. However, it may not survive the next one. Why? Processor speeds and easy interconnectivity offer more capable compute resources. The PLC-centric workcell design can build reliable systems that endlessly repeat an operation. They aren’t truly “smart,” though. They don’t adapt well to change. They can’t take advantage of the explosion in compute and networking capacity. In short, they don’t provide a path to intelligent, but more complex, software. The IIoT has the potential to transform industrial systems. To do that, it must share data across the workcell, factory, and front office. Of course, it’s not that simple. Pervasive data use requires a new architecture and new approach to connectivity. OPC UA and DDS solve different problems. Hardware engineers use OPC UA because it makes device connections simple. System architects use DDS because it spans system layers with a

Figure 1: Locally-connected pubsub device networks. OPC UA client/server uses a client/server pattern to connect workcells to human-machine interfaces (HMIs) and historians. When the OPC UA pubsub specification is used, devices and programmable logic controllers (PLCs) publish or subscribe to simple numeric data types and communicate over local connections, with time-sensitive networking (TSN) replacing a fieldbus in workcells. All graphics courtesy: Industrial Internet Consortium (IIC)

January 2019

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consistent model. DDS and OPC UA are different, but it’s not a matter of choosing the right one; they do not compete. In fact, there is growing appreciation for how they can work together to build a powerful industrial communication architecture in the future. The real challenge is deciding which problem needs to be solved. That makes it critical to understand what OPC UA and DDS can do. It’s important to identify when to use DDS alone, when to use OPC UA alone, and when to use a combination of both frameworks.

OPC UA and TSN connect

In the discrete manufacturing sector, OPC UA and time-sensitive networking (TSN) offer a potential path to resolving the “fieldbus wars.” OPC UA is useful for integrating dedicated devices, such as conveyor belts, sensors, repetitive robots, and drives into a workcell. It can connect workcells to software like HMIs and historians. It does this by modeling devices and allowing factory technicians and manufacturing engineers to coordinate these devices through a PLC controller (see Figure 1). Workcells aren’t so much programmed as they are configured. Manufacturing engineers or technicians use a palette of devices to implement a function in the cell. The devices come with standard models so the factory isn’t locked to one vendor. OPC UA systems are compositions of devices and existing modules such as data historians and HMIs. This design makes it easy to assemble workcells of devices with little software effort. OPC UA connects workcell data to systemwide data by changing the communication pattern from pubsub to client/server (request/reply). To receive data, an application or higher-level client has to discover and connect to the server. This architecture is not designed to enable programming teams. For instance, translating pubsub and client/server

presents an inconsistent programming model across levels. And it doesn’t let teams pre-define new software interfaces or shared data types. Without these, OPC UA doesn’t provide one source of “system truth” for systemwide software. OPC UA is optimal for integrating devices into a workcell, although OPC UA can frustrate teams trying to build complex system software.

DDS enables system software

DDS, on the other hand, targets teams building distributed software applications. The first DDS application was feedback control over Ethernet for intelligent robotics. DDS then spread into softwareintensive distributed applications such as autonomous vehicles and Navy combat system management. Its fundamental purpose is combining software applications into a complex system-of-systems with one consistent model. Most DDS systems combine “functional” artificial intelligence with 10 to 50 applications and devices, but some DDS systems are comprised of hundreds of thousands of devices and applications, which are written by thousands of programmers. The key to understanding DDS is to realize distributed systems are fundamentally parallel, and the system architecture must match that reality. This isn’t new; the heart of a current distributed control system (DCS) is a control execution engine that manages timeslices and control loops. All data is stored in “sandbox RAM” so processes can access any data without unwanted interaction. The DCS provides an environment to combine function blocks into parallel, deterministic feedback loops in one box. DDS takes that same concept and distributes it. DDS implements a data-centric shared “global data space.” This means all data appears as if it lives inside every device and algorithm. This is, of course, an illusion—all data can’t be everywhere.

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KEYWORDS: Data

Distribution Service (DDS), OPC Unified Architecture (UA) When to use OPC UA and DDS frameworks When to use a combination of both standard frameworks Defining how DDS and OPC UA can help.

COnSiDER thiS What framework would be the best fit for your manufacturing operations?

OnLinE For more information on OPC UA and DDS, go online at www.controleng.com. www.iiconsortium.org/ IICF.htm.

Figure 2: The IIC’s Industrial Internet Connectivity Framework (IICF) is the industry’s most comprehensive analysis of connectivity technologies. It includes detailed assessments for the most common IIoT technologies, including OPC UA and DDS. It also proposes an architecture for using them together. www.controleng.com

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ANSWERS

cover story: NetWorKING soFtWAre At 3:25 a.m. a problem occurred in your factory.

PlantRePlay saw it. And now, you can too.

PlantRePlay RePlay 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. • Module for Ignition SCADA • Run license $1000 • Available to all sites and Ignition Integrators • Proven installs in the US, Europe and Asia • Systems from 1000 to 500,000 tags

DDS works by keeping track of which application needs what data and when, and then delivers it. As a result, data an application needs is present in local memory on time. The essence of data centricity is instant local access to anything by every device and every algorithm, at every level, in the same way, at any time. It’s best to think of it as a distributed shared memory, similar to the DCS sandbox RAM. There are no servers or objects or special locations. It’s a parallel software architecture across the system. DDS is about data centricity, not patterns. While most standards use pubsub, the standard also specifies requests/replies and some vendors support queuing. Applications interact in many ways, but only with the shared distributed memory, not with each other directly. DDS also defines system interfaces (data types) and quality of service (QoS) flow control. It integrates modules with a transparent and consistent systemwide architecture that’s independent of patterns. This is the connectivity analog to data-centric system “truth” databases use to power the enterprise. However, DDS doesn’t model devices. Factory engineers and technicians can’t combine devices into workcells without writing code.

have to change. If, on the other hand, you see a future where the best software wins, you will need a different path to keep up (see Figure 2). A system may also need to be built from interoperable devices. Fortunately, this doesn’t have to be an all-or-nothing decision; DDS, OPC UA, and TSN can work together. The Object Management Group (OMG), the parent organization for the Industrial Internet Consortium (IIC), recently approved a standard to integrate DDS with OPC UA. OMG and OPC Foundation are working on standards to use TSN with DDS and OPC UA. DDS vendors are working on configuration tools. IIC developed an integrated architecture and has several testbeds using OPC UA in manufacturing applications and DDS in applications such as electric power and health care. Some use OPC UA and DDS. Combining the flexibility of interchangeable devices with a powerful software development environment is not too far off. Many people have difficulty defining what these technologies do. To stay competitive in the future, it’s vital to research and ask questions to ensure the right platform, or the right combination, is chosen. ce

Should you use OPC UA, or DDS, or both?

Stan Schneider, PhD, is vice chair of the Industrial Internet Consortium (IIC), a CFE Media content partner, and is CEO of Real-Time Innovations (RTI). Edited by Emily Guenther, associate content manager, Control Engineering, CFE Media, eguenther@cfemedia.com.

Manufacturing systems compete on the same basis they have for decades: reliability, production rates, or implementation cost. If you believe software can be bought and remain competitive, you don’t

Table: OPC UA and DDS

PlantRePlay RePlay the missing piece to ultimate SCADA

Visit PlantReplay.com for video demos and downloads. input #11 at www.controleng.com/information

Aspect

OPC UA

DDS

Integration users

Engineers/technicians

Software teams

Opposite

Abstraction

Object-Oriented

Data-Centric

Opposite

Primary markets

Manufacturing

Transportation, medical, power, robotics, defense, autonomy

Opposite

System data model

None (dynamic at runtime)

Fundamental integration point

Opposite

Vendor device support

Extensive

None

Opposite

Data model

Hierarchical

Relational

Opposite

Data sharing model

Variables

CRUD managed types

Opposite

Sends data

Yes

Similar

DDS and OPC UA are nearly opposites. DDS is widely deployed in industries that need sophisticated distributed software. OPC UA targets manufacturing, where device interoperability matters more.

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control engineering

CC-Link IE TSN - Accelerate smart factory construction with TSN technology CC-Link Partner Association (CLPA)

The CC-Link Partner Association (CLPA) has created a new industrial open network specification â&#x20AC;&#x153;CC Link IE TSNâ&#x20AC;? as the next generation CC-Link IE network. The first to offer a TSN network specification. CC-Link IE was introduced in 2007 as the first industrial open network in the industry based on 1 Gbps Ethernet. CC-Link IE is available in several different types. â&#x20AC;&#x153;CC-Link IE Controlâ&#x20AC;? is a trunk network that connects controllers within a factory, while â&#x20AC;&#x153;CC-Link IE Fieldâ&#x20AC;? covers general input/output control, connecting controllers with a wide variety of field devices. Functionality and scope have also been expanded with â&#x20AC;&#x153;CC-Link IE Field Motionâ&#x20AC;? (for motion control) and â&#x20AC;&#x153;CC-Link IE Safetyâ&#x20AC;? (for safety control). The newly established CC-Link IE TSN specification is the first to combine gigabit Ethernet bandwidth with Time Sensitive Networking (TSN). TSN is an addition to the IEEE Ethernet related standards and is starting to become popular for industrial networks. TSNâ&#x20AC;&#x2122;s key benefit is that it allows the combining of real-time control communication with non-real time information communication while maintaining deterministic performance. This is not possible with conventional general purpose industrial Ethernet. CC-Link IE TSN adds TSN to increase openness while further strengthening performance and functionality. It also supports more development methods, enabling easier implementation on a wider range of equipment and increasing the number of compatible products and is expected to accelerate the construction of smart factories using the IIoT. Download the paper at: am.cc-link.org/en/downloads/TSN_WP/TSN_WP.html

*OGP!$$-JOL"NFSJDB PSH t BN $$ -JOL PSH

input #12 at www.controleng.com/information

ANSWERS

Cover STory: NeTWorKING SoFTWAre Arlen Nipper, Cirrus Link Solutions

MQTT’s role as an IoT message transport Message queuing telemetry transport’s (MQTT) role as an Internet of Things (IoT) message transport began as an industrial communicator for a pipeline supervisory control and data acquisition (SCADA) system.

essage queuing telemetry transport (MQTT) has emerged as one of the dominant IoT message transports across multiple industries in the last five years. Considering that most cloud services provide native MQTT capabilities, more device manufacturers, software, and services are implementing MQTT-based products.

The genesis of MQTT

Adoption of MQTT by Facebook, cloud service providers, and many others in the information technology (IT) space might lead one to think that MQTT was invented targeting IT solutions, but the genesis of MQTT was driven by an industrial communication problem. In 1997, Phillips 66 had installed one of the first transmission control protocol/internet protocol (TCP/ IP)-based very-small-aperture-terminal (VSAT) systems in the market for use in its pipeline supervisory control and data acquisition (SCADA) system. Numerous challenges needed to be addressed to use

Messaging standards What messaging protocol(s) do you use for your IoT solution? MQTT HTTP Websockets HTTP/2 COAP AMQP (0.9 and/or 1.0) In-house / proprietary Other (please specify) Don’t know DDS XMPP Proprietary vendor protocol (specify below) None 10%

10%

20%

30%

40%

50%

60%

Figure 1: According to a survey by the Eclipse Foundation, message queuing telemetry transport (MQTT) is the most-used messaging protocol for an IoT solution. All graphics courtesy: Eclipse Foundation Inc.

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this network infrastructure effectively. Poll/response protocols were the norm for any SCADA system implementation until this system was implemented. However, due to the propagation delays inherent to VSAT communications, and the cost associated with continuously polling for process variables that may not have changed, Phillips was looking for a better way to optimize its network infrastructure. By this time, information technology (IT) departments used message-oriented middleware (MOM) software to decouple applications from each other. They were efficient infrastructures that used message brokers to ensure applications that “published” information could be connected to applications that “subscribed” to that information. Information could be published on an exception basis to any application that had interest and was subscribed to that information. The idea was to use this same type of infrastructure for a real-time SCADA system. The only problem was that MOM products on the market at that time weren’t appropriate for use in the SCADA environment. Based on these requirements, a project was started to develop a MOM specification that would be appropriate for use in these types of industrial environments. This ultimately led to the design of MQTT. The original design goals of MQTT were that it would be simple, efficient, stateful, and open. Simple. When MQTT first was being developed, the hardware platforms available on the market for remote edge computing were minimal; 8-bit microprocessors with 64 KB of memory were the norm. MQTT had to be simple to implement with minimal computing resources. Even in 2018, Arduino microcontrollers can provide complete MQTT communication stacks. Efficient. Early VSAT system providers charged for every byte of information sent and received. The MQTT transport had to provide minimal overhead on the network. Once an MQTT session is established, there is only a 2-byte overhead in messages being published. www.controleng.com

Figure 2: According to a survey by the Eclipse Foundation, MQTT is trending up since 2016 to over 62% use as a messaging standard.

Messaging standards - trends 70% 60%

2016 2017 2018

50% 40% 30% 20% 10%

on e N

PP XM

rie ta

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Stateful. If a user is providing infrastructure for mission critical, real-time infrastructure then the “state” of the MQTT TCP/IP connection is critical. MQTT provides a mechanism called “continuous session awareness” that informs all clients that care about the real-time state information of the MQTT connections. Open. In the late 1990’s SCADA/DCS/Telemetry products were based mainly on proprietary legacy Poll/Response protocols. For MQTT to be useful to the industry as a whole it was understood that when it was released, it needed to be an open specification that anyone could implement for free. Even with those criteria, it would be easy to assume a few important aspects are left out, including: Security. A lot of people note the MQTT specification does not define any security. This is because the MQTT specification in based on top of TCP/IP. It always was envisaged that the latest TCP/IP security practices would be applicable to an MQTT infrastructure. This ranges from private networks where security isn’t even required, to full transport layer security (TLS) certificates being used for connections. Since MQTT is a remote-originated connection, edge devices and clients don’t even have to have any TCP/ IP ports open, which is a huge reduction in the overall cybersecurity footprint. Payload data format. MQTT is data agnostic when it comes to the information contained in an MQTT payload. It can be a binary message from a programmable logic controller (PLC), a JPEG image, an extensible markup language (XML) document or a JavaScript object notation (JSON) string. MQTT leaves the encoding and interpretation of the payload to the software provider.

critical Industrial IoT (IIoT) implementations, the market needed a specification that would allow MQTT-based vendors easy interoperability. Although the MQTT specification does not dictate any message topic namespace or data representation, one was needed for the IIoT space. The Sparkplug specification does that for the IIoT market. The Sparkplug specification was developed to help define how best to get started using MQTT in a mission-critical, real-time application. The Sparkplug specification defines:

Industrial-strength MQTT

Arlen Nipper is president/CTO, Cirrus Link Solutions. Edited by Chris Vavra, production editor, Control Engineering, CFE Media, cvavra@cfemedia.com.

As Internet of Things (IoT) solutions using MQTT started to migrate to more mission-

www.controleng.com

1. A well-known MQTT topic namespace so publishers and subscribers of information can know the topic namespace in advance for interoperability.

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Keywords: Internet of

2. A binary payload optimized for industrial process variables. The Sparkplug specification acknowledges that industrial infrastructures don’t have unlimited bandwidth and must work well over VSAT, radio, and cellular infrastructures. 3. How the “state” management in MQTT works and how to effectively use it in SCADA, distributed control system (DCS), and industrial control system (ICS) solutions to know the state of all MQTT clients in real time. The Sparkplug specification and all of the reference implementation code written in C, Java, JavaScript, Python, and Node Red have been contributed to the Eclipse Foundation and to an open source project. ce

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Things, message queuing telemetry transport (MQTT) MQTT began as a communication protocol used by Phillips 66 to operate in tough industrial conditions. MQTT’s usefulness to engineers and manufacturers stems from ease of use. MQTT has been enhanced to work in the Industrial Internet of Things (IIoT) era.

Consider this For what applications do could you use MQTT?

online Read this story online at www.controleng.com for more information about the author and related stories about MQTT.

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cover Story: NetWorKING SoFtWAre Michael Bowne, PI North America

Improving industrial network communications Selecting a Profinet interface may enhance industrial network communication for devices.

ntegrating an industrial communication interface into an automation device begins with gathering information to determine the industrial network’s functionality along with familiarization about the task at hand. Development tends to be faster for new devices if the wheel isn’t reinvented each time. Depending on the functionality required (conformance class), it is essential to select the suitable type of implementation for each individual case. The available development capacity, company expertise, expected costs to produce the interface, and the time to market also play a large role. A variety of starter kits and evaluation boards are available for most implementations. These sets enable a quick introduction to development activities and often contain a complete development environment, as well. Sample programs and circuits and block diagrams can be especially helpful. The development packages also include the certifiable Profinet stack of the corresponding provider and detailed documentation. The plan of action and expenditure required for hardware and software design depend heavily on the selected implementation method. Here, a device manufacturer can carry out the development work independently or work collaboratively with KEYWORDS: Profinet, timea development or technology partner. sensitive networking (TSN) Independent development requires wellConformance classes for grounded Profinet expertise and one’s automation systems own hardware and software development How to implement Profinet resources. features To unburden an automation device The benefits of time-sensitive manufacturer’s development resourcnetworking (TSN) and Profinet. es, PI member companies can provide COnSiDER thiS complete development packages, readyHow can Profinet Ethernet to-install Profinet communication modenhance communications for ules, and a host of development services. your operation? These give the device manufacturer the OnLinE support needed from the design phase to Read more online about how to hardware and software development to implement Profinet features at certification. www.controleng.com.

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control engineering

Real-time requirements

IEEE 802.3-Standard for Ethernet is designed to ensure problem-free communication between Profinet automation devices and among Profinet automation devices and other standard Ethernet devices. For applications with stringent real-time requirements, Profinet offers mechanisms that enable standard and real-time communication to coexist in parallel. Communication with Profinet can be scaled using three performance levels that build on each other: 1. The transmission of engineering data and non-time-critical data occurs over transmission control protocol/internet protocol (TCP/ IP). This standard communication is possible between all automation devices. 2. The real-time (RT) channel is available for the transmission of process data. 3. For isochronous applications like motion control, isochronous real-time (IRT) communication is used. This enables a clock rate of < 1 ms and a jitter of < 1 μs.

The IRT capability is based on hardware support in the device, which means special application-specific integrated circuit (ASICs), microcontrollers, and field programmable gate arrays (FPGAs) must be used for this purpose. Commercial-switch ASICs without IRT hardware support are suitable for implementing an automation device with RT capabilities only. Devices with RT communication can be developed based on standard Ethernet components and a Profinet software stack.

Profinet conformance classes

To meet the different requirements of automation systems, three conformance classes that build upon one another are defined for Profinet. Each class has a functional scope determined for the typical area of application. The device manufacturer must consider www.controleng.com

TSN services integrate seamlessly into the Profinet architecture. They reside at Layer 2 of the ISO/ OSI Model, maintaining existing upper level PROFINET functionality. Courtesy: PI North America

the required conformance class before selecting an implementation option for the Profinet device interface because the type of interface implementation affects the conformance class that can be achieved. The key functions of the three conformance classes and their advantages are described below: • CC-A: Using the infrastructure of an existing Ethernet network, including integration of basic Profinet functions. All information technology (IT) services can be used without restriction. Typical application examples are found in building automation and process automation. • CC-B: The functional scope of CC-B comprises the functions of CC-A, plus it supports user-friendly device replacement without needing an engineering tool. Simple network management protocol (SNMP) supports extended device diagnostics of network functions such as port status messages. To increase data reliability, a performance-adapted media redundancy protocol is available as an option. All IT services can be used without restriction. Typical applications can be found in automation systems with higher-level machine control with a deterministic, but not isochronous, data cycle. The vast majority of Profinet devices fall into this category. • CC-C: The functional scope of CC-C comprises all the functions of CC-B. It also supports high-precision and deterministic data transmission, including isochronous applications. The integrated optional media redundancy enables smooth switchover of the I/O data traffic if a fault occurs. All IT services can be used without restriction. Typical applications are in the field of motion control. Once a device manufacturer has decided what Profinet features they need to implement on a product, the next question is how to implement those features. There are three options: • Drop an ASIC onto the printed circuit board (PCB) to handle Profinet communications. If the real estate is available on the PCB for a chip, this might be feasible. • Plug a module into a slot on the device PCB. Unlike ASICs, a module can deliver the network requirements with physical cable connectors, magnetics, PHYs (physical layer circuits for the physical layer of the OSI model), an integrated Ethernet switch, and a chip to handle the Profinet stack. There is a range of backplane connections available–everything from dual-port memory to SPI to the compact flash (CF) card interface. www.controleng.com

• Buy a software stack and implement it on the application processor. Software stacks are one of the most common Profinet implementations–they’re the most cost-effective way to implement the protocol in volume. However, they’re also the most complex way to implement Profinet. Stacks touch a lot of peripheral software pieces such as the operating system, the IP stack, the nonvolatile RAM, and so on.

TSN and Profinet

Time-sensitive networking (TSN) is a promising technology and offers a lot of potential for Profinet. TSN aims to combine the wide range of IT networks with the robustness and determinism of automation networks. In short: hard real-time via standard IT networks. This doesn’t signal a revolution for Profinet. Rather, it represents a visionary architecture upon which Profinet is building. TSN offers Profinet a new layer 2 in the ISO/OSI model. It corresponds to today’s RT and IRT technologies. This makes it clear TSN will not replace RT or IRT in the coming years. It’s an additional option with a number of potential benefits. Today’s manufacturers that are providing solutions with RT and IRT will be able to continue providing them in the future. Users employing RT or IRT to operate their systems can be sure that they are using a sustainable technology. TSN offers the possibility to also achieve this with standard chip-sets because TSN is based on open standards, which is supported by many semiconductor vendors. Everything else about Profinet remains unchanged–especially services such as diagnosis, configuration, alarms, etc. This will make it easy for users and device manufacturers to use TSN in the future. They can build on existing knowledge and continue using the applications they have developed. ce Michael Bowne, executive director, PI North America. Edited by Emily Guenther, associate content manager, Control Engineering, CFE Media, eguenther@cfemedia.com. control engineeering

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ANSWERS

covEr story: NEtWorK soFtWArE APPLIcAtIoN cov Michael Bowne, PI North America

Smarter machines

Machine builder uses industrial Ethernet for remote monitoring and diagnostic services. “Our primary goal was to maximize uptime and customer satisfaction, as well as to identify opportunities for continuous improvement for current and future equipment,” Zarembski said. He wrote the algorithms that evaluate machine performance and guide the company’s service technicians in troubleshooting and technical assistance work.

First installation with services

ndustrial Internet of Things (IIoT) concepts are inspiring new business models for manufacturing. Manufacturers are asking equipment makers to find new ways to help them improve machine reliability and production uptime. Ecoclean Inc., a maker of industrial and automotive cleaning machines, now provides remote monitoring and diagnostics services on dashboards by using Profinet networks. Ecoclean machines are a part of the quality control for manufacturers. Reliability is critical. “Often a washer can be fed from many production lines, making that process crucial in overall plant production,” said Aaron Zarembski, controls engineer for Ecoclean. KEYWORDS: Ecoclean’s technical support involves Industrial Ethernet, Profinet three tiers of service, beginning with remote Machine builders want to expand services. diagnostics of the programmable logic conIndustrial Ethernet networks trollers (PLCs), human-machine interfaces such as Profinet can help. (HMIs), robots, drives, and other compoMonitoring and diagnostics nents that control the cleaning machines. improve uptime. Online troubleshooting, modifying paramCONSIDER THIS eters for process control, software upgrades, Is your plant-floor network and adjustments to the PLC code can be hindering productivity? handled remotely. Statistical data from the machines also can be logged onto a server ONLINE and then used to identify trends and make If reading from the digital edition, click on the headline preventive decisions for maintenance prior for more, including a to any equipment failure. A third service level discussion of “local versus enables compiled information to be displayed cloud” or find it online. for the customer in real time on a dashboard IIoT webcasts are available interface showing pertinent machine data www.controleng.com/ webcasts. graphically.

Hugo Benzing LLC uses Ecoclean’s new remote support capability at a fastener plant, with Profinet and a TosiBox VPN router. Courtesy: PI North America

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Hugo Benzing LLC manufactures fasteners for the automobile, aerospace, fine mechanical, and electrical industries. The first installation of Ecoclean’s new remote support capability was at the Hugo Benzing manufacturing facility in New Hudson, Mich. The plant has a Profinet network, which allowed Ecoclean technicians to remotely connect to the network and clean machines using a self-contained and secure virtual private network (VPN) router. “This was a perfect example of streamlined integration for remote diagnostics,” Zarembski said. “With the Profinet architecture and [the router manufacturer], we had a secure VPN connected to the network in minutes, and it required minimal interaction with the customer’s information technology (IT) department. It uses a non-IP protocol on top of the Profinet Ethernet layer, making the remote connection implementation easy and secure.” Although it would have been possible to connect to the Internet in other ways to provide support, according to Zarembski, using the Profinet protocol helped with processing of safety signals. The installed devices had embedded hardware configurations, dedicated diagnostic signals, and priority settings for safety. Such options are crucial when making a safe, fast, and reliable system. Systems built on this framework are easily upsized without impacting functionality. For older machines with Profibus protocol, a proxy translates Profibus into Profinet, allowing remote service capability. This also works with other protocols that can interface with Profinet via proxy. Zarembski said Ecoclean intends to embed this remote service capability, making the hardware standard and the service contract an option for customers that require high uptime through preventive maintenance and statistical analysis. ce Michael Bowne is executive director, PI North America, the organization for Profinet, Profibus, and other networking technologies. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media, mhoske@cfemedia.com. www.controleng.com

ANSWERS

CovEr sTory: NETWorKING soFTWArE Robert Trask, PE, EtherCAT Technology Group

Software unlocks EtherCAT Ethernet protocol diagnostics Through a vendor-independent diagnosis interface, an EtherCAT master can provide detailed slave diagnostic information and network health status via human-machine interfaces (HMIs) or third-party tools.

pecification of a vendor-independent diagnosis interface for the EtherCAT Ethernet protocol was among the announcements the EtherCAT Technology Group (ETG) made at SPS IPC Drives 2018. This interface will help EtherCAT vendors gather and analyze data to determine internal or external issues affecting components throughout an EtherCAT network. This specification, known as ETG.1510, “Profile for Master Diagnosis Interface,” will provide an accessible upgrade to allow easy access to the network’s health status. EtherCAT can support 65,535 devices in real time on one network. It also has a range of cyclic and acyclic diagnostic information for rapid reactions to errors and in-depth analysis for intermittent issues. The interface will provide a master-based software so all network users can use this data. As a result, plants can expect to improve machine performance and increase uptime through the diagnostic interface without having to implement any changes to the slave or EtherCAT slave controller (ESC) hardware. To understand the value of a diagnostic interface, it is important to know what kinds of built-in diagnostics EtherCAT offers.

New diagnosis interface plan

More than 200 approved EtherCAT masters range from traditional programmable logic controllers (PLCs) to PC-based software. Many call the diagnostic information quite easily, but not all. One consideration is EtherCAT network diagnostics are found in three locations: the slave registers, the DS402 CAN protocol over EtherCAT (CoE) and in the cyclic process data with the working counter (WKC) concept. The issue is not the amount of network data available; EtherCAT is already very good at locating errors with precision such as including loose connectors, incorrect cabling order, damaged cables, unintended effects on slaves, EMC interference and bit errors, among others. The new diagnostic interface will not change this existing capacity, but will instead act like a dragnet,

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integrating all information. The interface will gather errors created by hardware and software to assess the network’s health status. It will also maintain a minimal file size so it can be used on any EtherCAT controller—even compact embedded devices with limited memory. The diagnostic interface’s access mechanism will provide diagnostic information from the EtherCAT slaves based on the existing EtherCAT master object dictionary and mailbox gateway functionality. The interface runs in the background and enables the master to cast a wide net to pull in all of the diagnostic data stored in the subordinate devices. The vendor-independent design will also allow any master implementation to use third-party analysis tools in conjunction with ETG.1510.

Different network diagnostic variants

Figure 1: The new ETG diagnosis interface enables vendorindependent access to EtherCAT diagnostic data. It allows users to troubleshoot or improve machine performance whether they are using a PCbased controller or traditional programmable logic controller (PLC) as the EtherCAT master. All graphics courtesy: EtherCAT Technology Group

With the interface in place, engineers will have access to a range of diagnostics. These rely heavily on the WKC, which is a 16-bit field at the end of each datagram. The EtherCAT slaves increment the read and/or write commands for each WKC. The master then compares the datagram against the expected value, discarding any bad frames and forwarding all good frames to the control application. control engineeering

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cover story: NetWorKING soFtWAre EtherCAT slave’s internal state differs from the state commanded by the master. • Product vision serial number errors: These often happen when the network topology does not match with the one expected by the master or when slave devices were connected in an incorrect order.

Figure 2: Both hardware and software diagnostics are available through EtherCAT, including cyclic and acyclic information. The new diagnosis interface software gathers disparate information in one location.

These mechanisms add analysis and comparison capabilities, such as examining invalid frame against lost link counters and vice versa, for cyclic and acyclic diagnostics. While cyclic synchronous diagnosis for hardware and software relies on WKCs, acyclic hardware diagnosis involves link lost counters and invalid frame counters. Acyclic software diagnosis also involves state machine errors. EtherCAT slaves incorporate all diagnostic mechanisms at the chip level, and as a result, they will remain available on legacy and future components.

Masters, network architectures

Figure 3: When the working counter (WKC) value returning to the EtherCAT master does not match the expected value, all input data in the datagram are discarded, and a counter is incremented.

Other variants of EtherCAT network diagnostics reported by the interface include: • Lost link errors: When a component that is physically attached to a slave disappears, the slave signifies internally that it has lost a physical connection to the next slave. • Invalid frame errors (CRC): Each frame is mathematically checked and bad frames are counted and discarded. • Physical layer errors: Similarly, this detects frame corruption and increments a counter. Physical layer errors are different from CRC errors, and the ratio of the errors is important in diagnosing intermittent errors from noise. • State machine errors: This occurs when an

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control engineering

The diagnostic interface unlocks a wealth of EtherCAT topology information, providing significant advantages for end users, vendors of master components, and diagnostic tool suppliers. With this data, engineers will be able to conduct rapid troubleshooting and pinpoint where errors occurred. For example, a slave that might have seemed to operate without issue could require service, repair, or replacement because it is storing 400 link lost counters. Without the ETG.1510 specification, masters that were not equipped to gather this information would require new code. However, the specification also will enhance masters that could access the data by automatically locating it on the master. It also will make it easier to access data with third-party diagnostic tools and HMIs. In general, the software interface will benefit all EtherCAT system architectures and master implementations. ce

Robert Trask, PE, North American representative, EtherCAT Technology Group. Edited by Emily Guenther, associate content manager, Control Engineering, CFE Media, eguenther@cfemedia.com.

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KEYWORDs: EtherCAT, industrial Ethernet The benefits of the ETG.1510 specification The range of diagnostics with ETG.1510.

COnsiDER this How will you benefit from the new data/diagnostics due to the new specification?

OnLinE Read more about the ETG.1510 specification online at www.controleng.com. www.controleng.com

ANSWERS

FACTORY AUTOMATION CONTROLLERS Winn Paulk, AutomationDirect

Industrial controller selection: Look beyond the basics When specifying controllers for industrial automation applications, consider capabilities such as data handling, communications, and high-speed control.

ost industrial controllers, such as programmable logic controllers (PLCs) and programmable automation controllers (PACs), can handle basic functions like realtime control of discrete and analog input/output (I/O) connections. In fact, this type of functionality is a given with most controllers, with the main concern being the capacity to handle the required number of I/O points, which is normally easy to ascertain. When specifying industrial controllers, concerns often turn to other capabilities such as data handling, communications, and high-speed control. Identifying functions required to select and implement controllers and knowledge of how functions improve designs can help.

Data handling functionality

Modern controllers with advanced tag namebased programming have a variety of data handling capabilities including built-in data logging. Some advanced controllers also can also interact with standard databases in enterprise-level systems such as an enterprise resource planning (ERP) system. Logging data directly to a USB storage device connected to the controller is an important feature and often a requirement in many applications. Controllers with data logger features often support a formatted USB pen drive or MicroSD card, each with up to 32 GB of storage. Data logging is typically event-based or scheduled. Events are triggered by status changes such as an edge transition of a Boolean tag. Scheduled data logging is configured to occur at regular intervals such as every minute, hour, day, or month. The number of tags that can be logged is often limited, but at least 50 tag values should be stored for every scheduled or triggered event. System errors should also be stored with the time and date of the error or event included. The log file name should be configurable or automatically generated depending on user preference. www.controleng.com

Beyond local data logging, some controllers can communicate with information technology (IT) enterprise systems. One example is an OPC server connected to the controller. This allows a server to collect real-time data from controllers on the plant floor and retrieve, add, delete, and update data records in a standard database. This is done by supporting connections to a database compatible with Microsoft Access, a structured query language (SQL) server, or an open database connectivity (ODBC). Several software tools on the market allow a user to set up a connection between an IT enterprise system and a PLC to allow data to be collected from the PLC and saved in a database. Configuration effort for these servers is often minimal, and the user can choose to collect only the data they need for their process. These database capabilities provide practical applications for tracking material movements and production metrics. The controller performing the actual production tasks can track plant-floor

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KeyWORD: Factory automation controllers Controller selection requires specific knowledge Controllers help with data handling, communications High-speed motion control is a factory controller function. CONSIDeR THIS

Existing controllers may work fine, but what competitiveness is lost without modern functionality?

ONLINe See research and a Digital Report on PLCs at www.controleng.com/ research, www.controleng. com/DigitalReports

Figure 1: Productivity relies on data collection. The communication and data handling capabilities of this AutomationDirect Productivity Series controller enables connection to many different devices. All figures courtesy: AutomationDirect control engineeering

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FACTORY AUTOMATION CONTROLLERS

progress to make sure manufacturing time is optimized. It also can track consumption of materials. This information can be used to adjust inventory to ensure materials are available when needed. These capabilities also can be used to track the status of the product from start to finish by logging production data as the part or product is manufactured. The status of the final product is saved, and the database’s built-in date/time stamping features can be used to satisfy quality assurance or audit requirements.

communication ports should be available to provide easy integration with human-machine interfaces (HMIs), motor drives, and other devices (Figure 1). These high-speed Ethernet ports also can be used for peer-to-peer (P2P) or business system networking. This is where support for the EtherNet/IP (ODVA) and Modbus TCP/IP Ethernet protocols is important. Other communication ports should be provided for USB in/USB out, Mini USB, MicroSD, Remote I/O, RS-232, and RS-485 connectivity. These connections enable simple programming access, connection to high-speed devices such as drives, and HMI integration for operator monitoring. They also enable outgoing email, scanner/client, and adapter/server connections—along with other communication functions for remote access. Remote monitoring apps are available to allow users to connect to controllers using Wi-Fi (IEEE 802.11x wireless) or cellular network connections. The remote user can monitor the local controller via user tags configured for remote access inside the tag database. Modern controllers should have built in security whereby remote functions must be enabled in the hardware configuration related to remote access, with each tag in the database selected to enable remote access to it. Also, as is true for any device that can be accessed from the internet, it is highly recommended a firewall be used for security purposes. Even though the remote access feature for a controller can and should be configured with password protection, a secure and encrypted VPN connection is best practice due to internet security risks (Figure 2). Another protection feature related to remote controller access is the separation of accounts and IP addresses configured to allow the upload, download, or edit of a program by users given a remote access connection. One account should not permit both remote monitoring and program modifications. The controller should support remote monitoring apps and include the necessary security. Authorized users should be able to connect their smartphone or tablet to the controller for remote monitoring in real time with a Wi-Fi or cellular connection. Additional web server functionality in a controller allows remote troubleshooting of issues through system tags, error logs, and event history—and allows remote users to examine data files logged to a controller’s thumb drive or MicroSD card.

Communications capabilities

High-speed control

Another important feature to consider when selecting an automation controller is communication capability. Multiple Ethernet and serial

Another feature driving the selection of a modern controller is the ability to control motion and other high-speed applications. High-speed I/O is

Figure 2: Get remote data from the controller. Some modern controllers, such as this Productivity3000 from AutomationDirect, include up to seven built-in communication ports, a critical capability for connection to both devices on the plant floor and to enterprise level business networks.

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www.controleng.com

Figure 3: Controller capabilities are expanding, such as those with this Productivity2000 from AutomationDirect. Features such as data handling, communication, and high-speed control should be considered during the selection process to improve designs.

needed to perform these functions, along with a powerful processor and the ability to prioritize high-speed tasks. While some controllers offer coordination among many motion axes, even coordinated motion between two axes typically requires special hardware and built-in controller functionality. To start, a high-speed output (HSO) module and high-speed input (HSI) module are required. The HSO module generates pulse and direction commands to command servo drives operating two or more servo motors. These pulse and direction commands can control a variety of applications such as cut-to-length, stitching and coordinated x-y axis moves. A registration function also may be available for move commands generated by an HSO module. The registration function can trigger several internal and external position-based events using the moduleâ&#x20AC;&#x2122;s built-in I/O. An input from a sensor via an HSI module can be used to trigger the starting or stopping of a move, capture encoder feedback position, or to turn on/off or pulse an output. A programmable drum switch (PDS) and programmable limit switch (PLS) offer additional high-speed control capabilities. The PDS enables monitoring of several devices, such as encoders, at rates up to 1 MHz. These input signals are

used to coordinate and control outputs at rates of up tens of thousands of times a second. This type of hardware configuration provides precise and accurate motion control independent of controller scan time, which can vary depending on processor load. A PLS instruction works like a mechanical rotating cam with limit switches, but the virtual shape of the cams can be controlled in real time. Since this function often runs in conjunction with an HSI, itâ&#x20AC;&#x2122;s completely independent of the processor load and related scan time, resulting in accurate and repeatable timing for high-speed applications.

Data logging, communications, motion

When selecting PLCs, PACs, and other industrial controllers, users need to think beyond basic control and I/O requirements. For many applications, controllers (Figure 3) also need extensive data logging and communication capabilities, along with control of high-speed applications such as coordinated motion. ce

Winn Paulk is automation controls group product manager, AutomationDirect. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media, mhoske@cfemedia.com.

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ANSWERS

CONTROLLER PROGRAMMING John Kowal, B&R Industrial Automation Corp.

Controller programming Automation software and hardware advances reduce programming tasks and provide more built-in configurability, scalability, background communication among software components, simulation/digital twin capability, and usability.

oday’s automation hardware and software can integrate much more than stand-alone machine controls. There is a need to provide an integrated development and programming environment that presents itself in an approachable, cohesive way. It’s not enough to pick a programming language and go–that’s only viable for straightforward machine applications. Today, machine automation requirements integrate HTML5 human-machine interfaces (HMIs), input/output (I/O), sequential logic, motion and networked safety, robotic and collaborative robot kinematics, vision, safe robotics and motion, condition and energy monitoring, machine-to-machine communications, coordination with multiple production modules and intelligent track systems, edge and cloud communications, and interfaces. Requirements span more than direct control capabilities. There is an increasing need to integrate reporting, database management, and machine simulation for initial design and ongoing optimization through digital-twin capabilities. These capabilities require a holistic, ground-up approach to automation software platforms that is scalable, modular, documented, reusable, and based

on the IEC 61131-3 programming languages standard. Today, automation technology companies provide a comprehensive range of capabilities including single- and multi-axis motion, computer numerical control (CNC), recipe and alarm functions, user management and audit trail, industry standards (such as PackML from OMAC Packaging Workgroup), and web diagnostics. Many capabilities highlighted used to be available only as third-party software, but now are considered standard in many packages and are helping change automation implementations.

HMI animations Dynamic HMI content makes it easier to visualize complex manufacturing processes. One approach uses a widget to allow users to animate XML-based scalable vector graphics (SVG) images they already have or to convert them from 2-D CAD with runtime data. The user drags and drops a widget onto the desired page in the HMI application and configures it there. At runtime, the image’s animation can be controlled from the application program. Rotations, transitions, and movements can be animated from one SVG image, which saves the time and cost needed to create sequences of multiple images. Since SVG images are based on vector graphics, they retain their high resolution without loss of quality even when zoomed in.

Managing machine variants

Figure 1: Dynamic human-machine interface (HMI) content such as scalable vector graphics helps to visualize complex manufacturing processes. All images courtesy: B&R Industrial Automation

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CONTROL ENGINEERING

Modular applications can be implemented to add I/O modules to existing programs at any time without touching the machine code. This can happen before a machine is delivered or even at runtime, which simplifies managing machinery and equipment variants. I/O variant configurations can be generated from enterprise resource planning (ERP) or an order management system. No engineering tools are required even if third-party drives or modules are added. Additional variants and options may be configured directly on the machine using the appropriate configuration tools. Some development environments include a tool that allows the programming of options in ladder logic without affecting the machine’s primary application. The machine can be commissioned without having to modify the original www.controleng.com

machine software, giving the end user needed flexibility while preserving the integrity of the original equipment manufacturer (OEM) solution.

Integrated vision

Another trend is integrating vision cameras into the machine control program, including intelligent cameras, lighting, and advanced image processing algorithms. This allows microsecond synchronization between the machine vision and other automation components with one engineering tool and one application to manage.

PDF reports

Communication platforms can be built into the control system, and they automatically can generate PDF reports. Reporting functionalities collect statistical machine data and information from any software components provided by the control platform. The data, layout, and design of the reports can be customized, and the user can define the language and units used. Report design options make it possible to customize reports to the usersâ&#x20AC;&#x2122; needs. Graphical elements such as images and tables can be included in the reports. To protect against unauthorized access, it is possible to encrypt the files. The reports can be sent automatically via e-mail at a defined time or triggered by a specific event. In addition, reports can be saved to external storage media such as a USB flash drive or sent directly from the machine to network printers.

Data management

Implementing databases in applications is easier with a database integration toolbox. Data may be archived from the field level to a database, regardless of whether that database is located on-site or in the cloud. This simplifies managing large volumes of data, which is key to Industrial Internet of Things (IIoT) data acquisition and analytics requirements. Manufacturing machinery can generate huge volumes of data, which must be visualized, archived, or passed on to higher-level systems for processing to be useful. Giving the control system a database interface makes it possible to send data directly from the controller to the database. Common database functions such as stored procedures allow key performance indicators (KPIs) to be generated as needed, resulting in more optimized manufacturing processes.

Machine simulation, digital twins

Automation programming is no longer limited to isolated machine programs. It now includes integrated production systems such as the next generation of intelligent track technologies that define the adaptive machine. Consider the automation software challenge of independently controlling individual products traveling on shuttles in coordination with dozens or even hundreds of other shuttles on a track system. www.controleng.com

Figure 2: Input/output (I/O) machine variant configurations can be generated directly from an enterprise resource planning (ERP) or order management system and no engineering tools are required. Figure 3: Communication platforms can be built into the control system, and they can automatically generate PDF reports. There are options available to customize reports to the specific needs of different users.

Each workstation represents a machine module, and all the machine control and ancillary functions apply for each product, production module, and the overall system. Built-in simulation software is a valuable tool to visualize and optimize intelligent track system requirements. It facilitates engineering and reduces time to market for new track systems and for running new products on existing systems. Integrated simulation software is based on process-oriented programming. These simulation tools help ensure shuttles do not collide, cross virtual barriers, or violate configurable speed limits. FDA-compliant tracking also can be implemented. The software can link the product data with the respective shuttles and make the manufacturing process traceable. When track system applications are created using process-oriented programming, a software engineer defines rules for how the shuttles should behave on the track. The rules become active when shuttles pass virtual trigger points. This makes motion sequence implementation more efficient and reduces the amount of programming required for the individual shuttles. control engineeering

Figure 4: With a database integration toolbox, it is possible to archive data directly from the field level to a database, which helps simplify managing large volumes of data.

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COver stOry: CONtrOLLer PrOGrAMMING With integrated simulation options, a track system developer can run tests to identify the optimum number and speed to maximize shuttle productivity. The same system software is used in the simulation and the real plant, which makes it possible to switch between simulation and real operation at any time. How the shuttles interact with

mechanical elements, such as robots, also can be visualized.

Integrated automation platform

These examples available to the machine automation programmer demonstrate how far beyond stand-alone machine operation today’s software considerations—and tools—extend. It’s no longer a

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

Figure 5: Automation programming now includes integrated production systems such as the next generation of intelligent track technologies that define the adaptive machine.

question of choosing ladder logic versus C programming. It’s about selecting an integrated automation platform that delivers a configurable software suite to manage— not just control—machines. For an architect to develop these functions on a one-off machine project basis would be daunting at best, and impractical in reality. At the same time, these kinds of new software functions are essential to realize the connected machine, let alone manufacturing IIoT, and are designed to deliver machinery to support the new digital business models. ce John Kowal is director, business development, B&R Industrial Automation Corp. Edited by Chris Vavra, production editor, Control Engineering, CFE Media, cvavra@cfemedia.com.

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Keywords: Automation software, human-machine interface, programming Automation hardware and software are no longer stand-alone functions and encompass most of the manufacturing floor. Advances include integrated vision, automated data reports, managing machine variants, and improved simulation. Automation software advances are essential for delivering the new digital business models for today’s interconnected manufacturing environment. online Read this online at www.controleng.com for more about automation programming.

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Consider this What advances in automation programming could benefit manufacturers? Instrument Class® Signal Solutions dataforth.com • 800-444-7644

input #14 at www.controleng.com/information

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international: DiSCrete SenSorS, enCoDerS Mark Howard, Zettlex, U.K.

Shaft encoders versus bearingless encoders Where should encoder technologies be used and why?

hen design engineers imagine an encoder, they usually think about shaft encoders. Typically, these look like a small can with a shaft poking from one end–turn the shaft and the encoder outputs an electrical signal according to the angle or change of angle. Inside most shaft encoders, an opto-sensor and a grating attach to the shaft. As the shaft rotates, the grating interrupts the sensor’s light path and an electrical pulse is produced. This is pretty straightforward, especially when measuring modest accuracies in benign conditions. When measuring angles to <1o accuracy in a tough or outdoors environment, these encoders may not be the best choice. Optical sensors are not robust and do not like temperature extremes. Foreign matter and impact or shock also can pose problems.

Sensors used inside encoders

An option is to use a shaft encoder based on different sensing technologies. Options include capacitive, magnetic, or inductive techniques. Capacitive sensors are as unreliable in harsh environments as optical devices. Magnetic sensors can work well in tough conditions, but have limited measurement performance and are susceptible to dc fields. Inductive encoders (incoders) are a more recent phenomenon but are increasingly being used as an alternative to traditional inductive devices such as resolvers or rotationally variable differential transformers (RVDTs). Resolvers and RVDTs have been used in heavy industry, aerospace, defense, and medical applications. Incoders use the same basic physics as resolvers and offer similar levels of reliability and performance. Inductive shaft encoders are tougher and more compact than optical encoders and offer shorter axial length. Inside, the shaft rotates in a bearing arrangement. The bearings usually are small and not designed for significant load. The shaft to which the encoder connects must be aligned along its axis so it doesn’t fight against the encoder’s own bearings. Encoder bearings won’t last long in a misalignment. If installation tolerances are loose for an application, a flexible shaft coupling can minimize the misalignment effect. Flexible couplings are not recommended when measuring angle to high accuracy. Angular displacement of the main shaft does not necwww.controleng.com

essarily result in the same angular displacement of the encoder’s shaft, resulting in “lost Zettlex supplies motion” (hysteresis) and inaccuracy. Use of a bearingless encoder also can help avoid inductive sensors alignment problems. This relies on the host system’s for servo controls bearings rather than the encoder’s. Bearingless encod- and motor encoders typically come in two parts: a stator and a rotor. ers for the medical, Typically, the stator has an electrical connection (for industrial, defense, power supply and data output) and so the stator is aerospace, and petusually fastened to the host system’s main chassis with rochemical sectors. Courtesy: Zettlex, the rotor fastened to the rotating element. Optical is the most common sensing technologies Control Engineerused. There can be problems with bearingless optical ing Europe encoders—more often called ring encoders—if the operating environment isn’t clean and stable. Typically, an optical ring encoder features a stationary read head and a rotating optical disc. If measurement accuracies are <1°, then the installation tolerances of the optical disc relative to the read head needs careful consideration. With high-accuracy ring encoders, headline measurement performance tolerances are stated in the data sheet’s small print. Installation eccentricities of <0.025 mm are not uncommon for some optical ring encoders. Other approaches include inductive ring encoders, which work reliably in extreme temperatures and dirty areas. They are more tolerant to misalignment since they use the planar faces of the stator and rotor rather than the point measurement of one optical read head. KeyWORDs: Encoders, sensors Inductive ring encoders increasingly are Bearingless and shaft encoders are preferred over “pancake” or “slab” resolvers. suited to different designs. Size and shape are the biggest reasons Shaft encoders are compact and to use a bearingless encoder. Shaft encod- easy to deploy. ers are compact and available in through Bearingless encoders remove the shaft (or hollow shaft) designs but are rare need for bearing alignment. (expensive) when the through bore is big- CONsIDeR THIs ger than 50 mm. Bearingless encoders are Higher reliability application well-suited for low axial height and/or a may require a different encoder large bore. The large bore enables cables, technology to avoid premature maintenance. piping, or mechanical elements to pass ONLINe through the middle of the encoder. ce

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Mark Howard is general manager at Zettlex, U.K. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media, mhoske@cfemedia.com, from a Control Engineering Europe, article.

If reading from the digital edition, click on the headline for more resources, including links to related articles. www.controleng.com/magazine See other international coverage at www.controleng.com/international.

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SYSTEM INTEGRATION Mark T. Hoske, Control Engineering

Automotive upgrades Competitive challenges with automationrelated upgrades drive some of the technologies being integrated.

xamples from four system integrators show how the automation industry is improving its competitiveness with industrial automation. Below are some of the trends and technologies being applied in automotive industry manufacturing applications by JMP Solutions, Leidos, Polytron, and Wood. See more online.

Productivity, quality

JMP Solutions: The automotive sector seeks to improve productivity, increase product quality and deliver projects on time and on budget. Smarter implementations can improve production performance, quality, safety, and profitability. Automotive manufacturers, in a highly competitive market, seek consistent project delivery across multiple sites, quick adoption of technology, plant-to-plant best practice sharing, and project leadership and execution. Automotive projects often require payback in fewer than 18 months. Projects require training so the team in place can understand and maintain the system. New systems should be easy to maintain and complement existing systems and engineering standards with high reliability and safety, reduced downtime, and consistent communication about project status, scope, and budgets during implementation.

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KEYWORDS: System

Flexibility, tighter control

integration, automotive automation Industrial automation can improve automotive industry quality, productivity, flexibility, efficiency, and optimization. System integration in automotive applications can include automation, machine vision, robotics, safety, and other technologies.

ONLINE See more with this article at www.controleng.com. Learn more about each integrator in the Global System Integrator Database www.controleng.com/ Global-SI-Database

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Leidos: Flexible manufacturing systems enable agility and standardization of business processes. Integration of business systems with the plant floor connects people with technology to make more timely decisions. Software can allow customer to configure change without programming to meet flexible manufacturing challenges. Using an assembly management system embeds visibility, standardization, and control throughout the manufacturing enterprise. Areas of focus include connecting enterprise assets to the plant floor.

Efficiency, optimization

Polytron: Competitive markets require delivering more with less and the highest possible quality.

control engineering

A sports utility vehicle received a lift by a Fanuc robot in an IMTS 2018 automotive application demonstration at the Fanuc booth. The lifting robot is integrated with motion of the Otto Motors mobile robot that serves as a mobile base for a second Fanuc robot. Courtesy: Mark T. Hoske, Control Engineering, CFE Media

Enabling tools include manufacturing intelligence, smart manufacturing, greater machine efficiency, increased automation, workforce optimization, and product tracking for quality assurance. Implementation help can include concepts, and manufacturing training to help maximize operational efficiency. Other automation-related tools include automation, track-and-trace systems, and industrial networking and security.

Robotics, safety

Wood: To increase competitiveness and lower costs globally, the automotive industry is integrating robotic and other automated systems into manufacturing, often combining safety with automation. Related services range from facility siting through commissioning, maintenance, and upgrades, engineering, procurement, and construction (EPC) capability, and discrete services, with attention to safety, technologies, and environment. Technologies can include robotics and vision, and automated material-handling systems to improve production, lower costs, and increase product reliability. ce

Edited by Mark T. Hoske, content manager, Control Engineering, www.controleng.com, CFE Media, mhoske@cfemedia.com. www.controleng.com

ANSWERS

INSIDE ProcESS

Joseph Amalraj and Babar Shehzad, Syncrude Canada Ltd.

Verifying flow measurement A novel method analyzes the performance of the primary and secondary flow measurements by separating repeatability and accuracy (bias shift) without having to assume the primary flow measurement is accurate and repeatable.

t is a common industry practice to use a secondary flow measurement (verification meter) to verify the performance of a primary flow measurement (PM, such as in a custody transfer meter) when the PM is used to bill a transacted product. It also is common industry practice to use highly accurate and repeatable instruments for the PM and use less accurate, but repeatable, instruments for the secondary flow measurement. The novel method discussed in this article is designed to help understand the performance of the PM and the secondary flow measurement (SM) without having to assume the PM is always accurate and repeatable and identifies whether the issue is with the PM or with the SM. It eliminates the need to calibrate the SM whenever a difference is noted between the PM and the SM.

Background about measuring flow

For PM, industries use accurate and repeatable flowmeters, which are compensated by pressure, temperature, density/gas chromatograph, etc., to obtain the flow measurement in standard units. Most PMs undergo periodic proving of the flowmeter and calibration of other instruments used to compensate the flowmeter readings to obtain the flow measurement in standard units. For the secondary flow measurement, industries use less accurate but repeatable flowmeters, which may be compensated by pressure, temperature, density/gas chromatographs, etc., to obtain flow measurement in standard units. The purpose of the secondary flow measurement is not to have a highly accurate flowmeter. Therefore, secondary flow measurements typically do not have periodic flowmeter proving and the instruments used to compensate the secondary flowmeter are calibrated less frequently. It should be noted an instrument’s accuracy depends on the measurement principle, design, installation, and maintenance of the instrument. Repeatability, however, of an instrument is an inherent feature of the measurement technology used. Repeatability is defined for an absolute constant flow. However, in process industries, variable flow is common. www.controleng.com

If accuracy (bias shift) changes for a secondary flow measurement, there is no need to replace, recalibrate, or reprove the secondary flow measurement as a multiplier can bring the SM reading closer to the true value. However, if repeatability has changed, the secondary flow measurement needs to be replaced, as this indicates a degradation of the SM instrument. It is common industry practice to accept 1% repeatability for secondary flow measurements for liquids and 2% repeatability for secondary flow measurements for gases.

Current flow measurement methodologies

Process industries often use two methodologies to verify flow measurements performance: time-stamped comparison and selected constant flow samples. In both methodologies, it is assumed the PM is accurate KEYWORDS: flow measurement, and repeatable and the secondary flow flowmeter measurement accuracy and repeatabilFor the primary flow measurement ity are being verified. This goes against (PM), industries use highly accurate the original intent of installing a secondand repeatable flowmeters, which ary flow measurement, which is installed are typically compensated by pressure, temperature, and density/ to verify the PM and not the other way gas chromatograph. around. For the secondary flow The verification process using the curmeasurement, industries use less rent methodologies is described below:

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Time-stamped comparison: • The difference between the PM and SM is calculated from the time stamped measured values. • Repeatability of SM is calculated as the standard deviation from the difference between the PM and the SM divided by the SM average. This method works well when the flow is maintained at an absolute constant or the flow variation is negligible. However, as flows in the process industries can have moderate to significant variation, this methodology often points

accurate but repeatable flowmeters. Accuracy of an instrument depends on the measurement principle, design, installation, and maintenance of the instrument, whereas, repeatability of an instrument is an inherent feature of the measurement technology used.

CONSIDER THIS How are flow measurements in your plant verified?

ONlINE Full version of this article appears online www.controleng.com; if reading the digital edition, click through the headline to view. The second half of this article is expected to appear in March.

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January 2019

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• The SM average and standard deviation is calculated for this bin. • The repeatability of the SM is the standard deviation divided by the SM average. Red = primary flow measurement Green = secondary flow measurement

Figure 1: The graph shows primary and secondary flow measurement trends for fairly constant flow. All graphics courtesy: Syncrude Canada Ltd.

Time-stamped deviation method results

Repeatability of secondary flow measurements

Average from secondary flow measurements

3,115

Standard deviation from primary flow minus secondary flo w measurements

Standard deviation from primary flow minus secondary flow measurements divided by average from secondary flow measurements

1.28%

Table 1: Time stamped comparison for fairly constant flow.

Selected constant flow samples method results Minimum from primary flow measurement

3,029

Maximum from primary flow measurement

3,420

Smaller flow ranges (bins) assumed

Repeatability of secondary flow measurements

200

Smaller flow range size (bin size)

Maximum count in a bin size from primary flow measurement

Secondary flow measurement average for the same bin

3,144

Secondary flow measurement standard deviation for the same bin

Standard deviation from secondary flow measurement divided by average from secondary flow measurement for the same bin

0.64%

Table 2: Selected constant flow samples for fairly constant flow.

to the SM not performing well. This methodology will not identify PM failures, and any failures are erroneously identified as SM failures. Selected constant flow samples: • Minimum and maximum flows are obtained from the PM time-stamped values. • The PM minimum to maximum flow data is further subdivided into smaller flow ranges (bins). • Determine the number of counts in each bin. • The bin with the maximum count is selected as this bin represents a constant flow period. Hourly data for a monthly billing cycle—a total of 720 samples (24 hours x 30 calendar days)—is available. • The SM values are extracted for this bin for the same time stamps.

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control engineering

The pitfall with this method is the repeatability verification may be done using a much smaller sample size and may not reflect the repeatability of the secondary flow measurement for the whole billing cycle. This methodology will not identify the failures in the PM, and any failures are identified as SM failures (minimum flow, maximum flow, smaller flow range, and maximum count) are all based on PM values. The following sections demonstrate how these two current methodologies report the flow measurement performances for constant flow, moderate flow variation, and significant flow variation billing cycles. It should be noted both methodologies can provide the same result for constant flow, but the selected constant flow samples methodology will have a smaller sample size. For moderate flow variation and significant flow variation, the results arrived from the two methodologies could be conflicting to each other.

Constant flow

Figure 1 shows the primary and secondary flow measurements for a typical monthly billing cycle. After adjusting the display ranges, the following could be observed: • Fairly constant flow. • Difference between the primary and secondary flow measurements is consistent most of the time. • Excluding the bias differences, the primary and secondary flow measurements are tracking each other.

Table 1 shows the measurement verification using the time stamped comparison method for the same period shown in Figure 1. Measurement verification using the time-stamped comparison method indicates that the repeatability of the secondary flow measurement is 1.28%. Based on this result, it could be concluded the repeatability of the secondary flow measurement is within the industryaccepted repeatability of 2% for gas measurement. Table 2 shows the measurement verification using the selected constant flow samples method for the same period shown in Figure 1. Measurement verification using the selected constant flow samples method indicates the repeatability of the secondary flow measurement is 0.64%. Based on this result it could be concluded the repeatability of the secondary flow measurement is within the industry-accepted repeatability of 2% for gas measurement. www.controleng.com

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This demonstrates the following: • The time-stamped comparison methodology works for constant flows or for flows with negligible variation. • The selected constant flow samples methodology used 28 out of 720 samples. • It is assumed the PM is performing well.

Moderate flow variation

Figure 2 shows the primary and secondary flow measurements for a typical monthly billing cycle. After adjusting the display ranges (to account for different engineering units), the following could be observed: • Moderate flow variation.

Red = primary flow measurement Green = secondary flow measurement

Figure 2: The graph shows primary and secondary flow measurement trends for moderate flow variation.

Time-stamped deviation method results

Repeatability of secondary flow measurements

Average from secondary flow measurements

2,028

Standard deviation from primary flow minus secondary flow measurements

Standard deviation from primary flow minus secondary flow measurements divided by average from secondary flow measurements

2.91%

Table 3: Time-stamped comparison (moderate flow variation).

Selected constant flow samples method results

Repeatability of secondary flow measurements

Minimum from primary flow measurement

1,219

Maximum from primary flow measurement

3,785

Smaller flow ranges (bins) assumed

200

Smaller flow range size (bin size)

Maximum count in a bin size from primary flow measurement

Secondary flow measurement average for the same bin

1,258

Secondary flow measurement standard deviation for the same bin

Standard deviation from secondary flow measurement divided by average from secondary flow measurement for the same bin

1.11%

Table 4: Selected constant flow samples for moderate flow variation.

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control engineering

• The difference between the primary and secondary flow measurements was consistent most of the time. • Excluding the bias differences, the primary and secondary flow measurements are closely tracking each other. Table 3 shows the measurement verification using time-stamped comparison method for the same period shown in Figure 2. Measurement verification using the time-stamped comparison method indicates the repeatability of the secondary flow measurement is 2.91%. Based on this result, some companies may initiate maintenance to the secondary flow measurement as the repeatability is greater than the industry-accepted repeatability of 2% for gas measurement. Table 4 shows the measurement verification using the selected constant flow samples method for the same period shown in Figure 2. Measurement verification using the selected constant flow samples method indicates the repeatability of the secondary flow measurement is 1.11%. Based on this result, it could be concluded the repeatability of the secondary flow measurement is within the industry-accepted repeatability of 2% for gas measurement. This demonstrates the following: • The two methods had conflicting results. The time-stamped comparison methodology indicated that the performance of the SM is not within the industry accepted 2%, while the selected constant flow samples methodology indicated that the performance of the SM is within the industry accepted 2%, based on 18 out of 720 samples. • It is assumed the PM is performing well.

Significant flow variation

Figure 3 shows the primary and secondary flow measurements for a typical monthly billing cycle. After adjusting the display ranges, the following could be observed: • Significant flow variation. • Difference between the primary and secondary flow measurements is consistent most of the time. • Excluding the bias differences, the primary and secondary flow measurements are tracking each other most of the time. Table 5 shows the measurement verification using the time-stamped comparison method for the same period shown in Figure 3. Measurement verification using the time-stamped comparison method indicates the repeatability of the secondary flow measurement is 6.65%. Based on this result, some companies may initiate maintenance to the secondary flow measurement since the repeatability is www.controleng.com

greater than the industry-accepted repeatability of 2% for gas measurement. Table 6 shows the measurement verification using the selected constant flow samples method for the same period shown in Figure 3. Measurement verification using the selected constant flow samples method indicates the repeatability of the secondary flow measurement is 4.55%. Based on this result some companies may initiate maintenance to the secondary flow measurement since the repeatability is greater than the industry-accepted repeatability of 2% for gas measurement. This demonstrates the following: • Though the PM and SM are tracking each other, the time-stamped comparison methodology indicated that the performance of the SM is not within the industry-accepted 2%. In addition, the selected constant flow samples methodology, using 15 out of 720 samples, concluded that the SM repeatability is not within the industry-accepted 2%. • Two methodologies are not robust enough for applications where flow significantly varies. • It is assumed the PM is performing well.

of secondary flow measurement being used to verify the primary flow measurement. There is a perception that since the primary flow measurement is more accurate because it undergoes periodic flowmeter proving and calibration of other compensating instruments. As such, we end up verifying the secondary flow measurement.

Assuming the PM is performing well and verifying only the SM is contrary to the original intent

Figure 3: The graph shows primary and secondary flow measurement trends for significant flow variation.

The challenge

In addition to significant flow variation application, the challenges are: • The primary and the secondary flow measurements may use different technologies to measure the product.

Red = primary flow measurement Green = secondary flow measurement

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Time-stamped deviation method results

Repeatability of secondary flow measurements

Average from secondary flow measurements

2,795

Standard deviation from primary flow minus secondary flow measurements

186

Standard deviation from primary flow minus secondary flow measurements divided by average from secondary flow measurements

6.65%

• The primary and the secondary flow measurements are managed by different companies. • The primary and the secondary flow measurements could be located at considerable distance from each other. • Methodology commonly used in the industry to verify the performance for consistence over the eyeballing of the trends necessitated frequent maintenance of the secondary flow measurement. • Time and resources were spent on analyzing the data of the primary and secondary flow measurements, defending that the secondary flow measurement was as good as the primary flow measurement and/or the actual issue is with the primary flow measurement. ce

Table 5: Time-stamped comparison for significant flow variation.

Selected constant flow samples method results

Repeatability of secondary flow measurements

Minimum from primary flow measurement

1,740

Maximum from primary flow measurement

3,837

Smaller flow ranges (bins) assumed

200

Smaller flow range size (bin size)

Maximum count in a bin size from primary flow measurement

Secondary flow measurement average for the same bin

2746

Secondary flow measurement standard deviation for the same bin

125

Standard deviation from secondary flow measurement divided by average from secondary flow measurement for the same bin

4.55%

Joseph Amalraj is a senior technical specialist, and Babar Shehzad is a systems advisor. Both work for Syncrude Canada Ltd. Edited by Jack Smith, content manager, Control Engineering, CFE Media, jsmith@cfemedia.com.

Table 6: Selected constant flow samples for significant flow variation.

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Lessons learned: Startup, shutdown incidents Effective communication; providing workers with appropriate training; having strong, up-to-date policies and procedures for hazardous startup and shutdown operations in place; and effective process safety management can prevent incidents from occurring.

rocess unit startups and shutdowns are more hazardous than normal oil refinery or chemical facility operations. A startup is a planned series of steps to take a process from an idle, at rest, state to normal operation; a shutdown is the reverse sequence. The Center for Chemical Process Safety (CCPS), an industry-sponsored membership organization that identifies and addresses process safety needs within the chemical, pharmaceutical, and petroleum industries, determined a majority of process safety incidents occur during a plant startup, even though it represents a small portion of the operating life of a plant. Process safety incidents occur five times more often during startup than during normal operations, according to the CCPS. Indeed, a 2010 study of incidents in the refining industry found 50% of process safety events occur during startups, shutdowns, and other cases that infrequently occur. This is because startup and shutdown periods involve many nonroutine procedures; these periods can result in unexpected and unusual situations. To prevent these types of incidents from occurring, facilities should employ effective communication, provide workers with appropriate training, and have in place strong and up-to-date policies and procedures in place for hazardous operations such as startups and shutdowns. The following released from the Chemical Safety Board (CSB) highlights three incidents that occurred during a startup or shutdown, and provides lessons learned in hopes of preventing future startup and shutdown incidents:

1. BP Amoco thermal decomposition

incident that occurred March 13, 2001, in Augusta, Ga., where three people died. Workers were attempting to open a cover on a process vessel containing hot plastic when the cover unexpectedly blew off, www.controleng.com

expelling the hot plastic and killing three workers. A vapor cloud subsequently formed and ignited. The vessel, known as a polymer catch tank, was designed to receive partially reacted waste plastic that had been diverted from a chemical reactor when there were mechanical difficulties with other equipment during periods of startup and shutdowns. The CSB investigation found 12 hours prior to the incident, an attempt was made to start up the production unit. During that time, workers experienced mechanical problems downstream of the reactor, and an unusually large amount of partially KEYWORDS: Process safety, reacted material was sent to the polymer startup, shutdown catch tank. Process safety incidents occur five times more often during startup than Decomposition reactions of this mateduring normal operations, according rial produced gases, which caused the to the Center for Chemical Process plastic in the vessel to foam and expand Safety (CCPS). and travel to connecting pipes, where it Startup and shutdown periods then solidified and plugged the inlet to involve many nonroutine procedures, and these periods can result in the vent line. This prevented gases from unexpected and unusual situations. escaping, which caused the polymer catch Facilities should employ effective tank to become pressurized. communication, provide workers Among other things, the CSB found with appropriate training, and have in process hazard analyses concerning the place strong and up-to-date policies polymer catch tank were inadequate, and procedures for hazardous operations such as startups and and process safety information inadeshutdowns. quately described the design basis and operating principles for the tank. CONSIDER THIS

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First Chemical Corp. reactive explosion and fire occurred Oct. 13, 2002 in Pascagoula, Miss., where three people suffered injuries. Steam leaking through manual valves heated mononitrotoluene (MNT), a raw material used to produce dyes, rubber, and agricultural chemicals, inside a 145-ft-tall chemical distillation column. The column had

Does your organization have strong, up-to-date policies and procedures for hazardous startup and shutdown operations in place?

ONlINE Read this story online at www.controleng.com for additional information as well as 11 best practices, featured in the October 2018 issue, to prevent a process safety incident.

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been shut down five weeks prior to the incident and was thought to be isolated and in standby mode. During the shutdown, 1,200 gallons of MNT were left inside the tower and continued to be heated by leaking steam pipes. During the days leading up to the explosion, the hot MNT began to

decompose, forming unstable chemicals. This resulted in a runaway reaction and explosion that injured three workers, damaged plant equipment, and ignited several fires. The CSB found the facility lacked an effective system for evaluating hazards and for sharing safety information between different facility operations.

‘

Process safety incidents occur five times more often during startup than during normal operations, according to the Center for Chemical

’

Process Safety.

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3. Bayer CropScience pesticide chemical runaway reaction and pressure vessel explosion occurred Aug. 28, 2008, where two people were killed. At the Bayer CropScience facility in Institute, W.Va., a runaway chemical reaction occurred inside a 4,500-gal. pressure vessel known as a residue treater, causing a vessel in the methomyl unit to explode. The methomyl unit used the toxic chemical, methyl isocyanate (MIC), in a series of complex chemical reactions to produce methomyl, a dry chemical used to make the pesticide Larvin. The incident occurred during the restart of the methomyl unit after an extended outage to upgrade the control system and replace the original residue treater vessel. The CSB investigation found the standard Pre-Startup Safety Review (PSSR) and turnover practices were not applied to the methomyl control system redesign project. The CSB also found the equipment was not tested and calibrated before the unit was restarted. Finally, the CSB found operators were inadequately trained to operate the methomyl unit with the new distributed control system (DCS). Lessons learned from these events— including effective process safety management—could have prevented these incidents. ce Gregory Hale is the editor and founder of Industrial Safety and Security Source (ISSSource), a news and information website covering safety and security issues in the manufacturing automation sector. This content originally appeared on www.ISSSource.com. ISSSource is a CFE Media content partner. Edited by Jack Smith, content manager, Control Engineering, CFE Media, jsmith@cfemedia.com.

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January 2019

he voice of the engineering community speaks loud and clear in the following pages featuring corporate profiles of

those companies participating in the Executive Voice program presented by Control Engineering magazine. Our thanks to the following participants: Allied Moulded Products, Inc. Applied Motion AutomationDirect Beckhoff Automation Dataforth Digi-Key Corporation EZAutomation Festo HEluKABEl uSA, Inc. Maple Systems Moore Industries Newark Electronics Nexans Opto 22 SEW Eurodrive Inc. WAGO Corporation

llied Moulded Products, Inc. is a leading manufacturer of nonmetallic electrical boxes and enclosures in today’s residential, commercial and industrial markets. Leveraging more than half-a-century of experience, Allied Moulded has grown to become the benchmark of quality within the electrical industry. Its full-service molding operation includes expertise in compression and injection molding, using thermoset and thermoplastic materials, as well as a unique resin transfer molding process.

Allied Moulded’s industrial enclosures can be found all over the world in many different control applications such as industrial and manufacturing plants, waste water treatment, wind turbines, security, SCADA, solar, marinas, data & telecommunications, mining, and more. The extensive line of NEMA type 4X/IP66 fiberglass reinforced polyester (FRP) enclosures, made with its proprietary ULTRAGUARD® resin formulation, outperforms competitors in the areas of yellowing, gloss retention, discoloration and change in texture.

Utilizing a modern, automated assembly process, Allied Moulded provides customer with a superior product at a competitive price. Unrelenting focus on service, delivery, value, innovation and technology in everything Allied Moulded makes and does, has made it what it is today.

With a wide range of sizes, accessories and customizations available, Allied Moulded offers a complete solution to your industrial enclosure needs. In addition to fiberglass, Allied Moulded also offers the POLYLINE® series, a line of polycarbonate, injection-molded enclosures.

Matt McIntosh Vice President of Global Sales and Marketing

According to Matt McIntosh, Vice President of Global Sales and Marketing, “Allied Moulded’s nonmetallic enclosures are found in many diverse industries around the world. The design features combined with their resistance to corrosion provide a solution to many application problems, such as exposure to UV rays and extreme weather conditions. Allied Moulded’s enclosures are easy to customize and have a large variety of accessories available to suit any application need.”

“Allied Moulded’s enclosures are easy to customize and have a large variety of accessories available to suit any application need.” Allied Moulded’s products are marketed in the U.S. primarily through an extensive network of professional manufacturer’s reps, all specialists and experts in electrical enclosures. Allied Moulded has expanded its global reach, with the addition of Allied Moulded Enclosure Products (India) Pvt Ltd., serving India and the Middle East markets. Corporate Headquarters in Bryan, Ohio

Tel: 800-722-2679 • Fax: 800-237-7269 sales@alliedmoulded.com www.alliedmoulded.com

utomationDirect takes the best ideas from the consumer world to serve the industrial market. As a direct seller of industrial automation products for more than 20 years, AutomationDirect is a leader in the industry that offers many customer services not typical with traditional distributors. The company created a print catalog, and later an online store that provides complete product information and pricing so customers can make informed decisions on their automation purchases quickly and independently. AutomationDirect’ s products are practical, easy to use and offer a low cost of ownership. The company offers quality products at prices up to 50 percent lower than those of more traditional distributors. Most product programming software is free, requiring no initial or upgrade costs and no software maintenance contracts. Product offerings include programmable logic controllers (PLCs), alternating-current (AC) drives/motors, operator interface panels/human machine interface (HMI), power supplies, direct-current (DC) motors, sensors, push buttons, National Electrical Manufacturers Association (NEMA) enclosures, pneumatic supplies and more.

See videos on AutomationDirect’s YouTube channel: https://www.youtube.com/user/automationdirect

Customers can also obtain return authorizations online for quick and easy product returns or exchanges. AutomationDirect’s phone technical support staff has garnered top honors in service from industry magazine readers 15 years in a row. And, with tens of thousands of active customers, the company’s online technical forum taps into that knowledge base by encouraging peers to help each other with applications and other questions. Other online help includes frequently asked questions, application examples and product selection guides.

They Guarantee It AutomationDirect’s corporate headquarters near Atlanta, Georgia

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AutomationDirect has always maintained a huge inventory, allowing them to ship 99.7 percent of orders complete the same day. They were among the first to offer free two-day shipping, available for any order over $49. Shipment confirmations and any backorder status and estimated delivery information are communicated electronically to keep you informed. Their online store is one of the most exhaustive in the industry – all technical documentation can be downloaded free of charge, as well as software and firmware updates. Hundreds of instructional videos are available without registration. Online access to your account allows viewing and changing account information, viewing order history and making payments.

AutomationDirect wants you to be pleased with every order. That is why they offer 30-day moneyback guarantee on almost every product they sell, including software (see Terms and Conditions for certain exclusions).

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

eckhoff Automation is a global provider of open automation systems based on advanced PC Control technology. The “New Automation Technology” philosophy at Beckhoff represents universal and open automation solutions used in a wide spectrum of high-tech applications around the world. These applications range from control of machines and robots used in manufacturing, to Internet of Things (IoT) systems, intelligent building automation and much more. The world headquarters of Beckhoff Automation is in Verl, Germany while the US headquarters is in Savage, Minn. (Minneapolis area).

US headquarters in Savage, Minnesota

System-Integrated Solutions for Automation and IoT The comprehensive Beckhoff system architecture for machine and plant automation promotes control hardware consolidation by advancing powerful PC-based control technology. This approach takes the best from automation technology (AT) and IT, making the most powerful tools available to engineering teams in one universal environment. All the benefits from the early days of this effort remain from the integration of PLC, motion control and HMI, while adding other highvalue functions for robotics, safety, high-end measurement, condition monitoring, and of course, cloud connectivity and IoT. Beckhoff has machine builders and manufacturers covered whether they need to gather and store process data in the cloud, integrate condition monitoring or implement track-and-trace functions in machinery. With TwinCAT IoT and TwinCAT Analytics software, machines directly benefit from Industrie 4.0 and IoT functionality. Engineering efficiency is greatly increased because the software packages share the same universal platform as all other machine programming tools from Beckhoff.

Aurelio Banda CEO and President, Beckhoff Automation

The “New Automation Technology” philosophy at Beckhoff represents universal and open automation solutions used in a wide spectrum of high-tech applications around the world. Another significant innovation from Beckhoff is AMP8000 distributed servo drive technology. The space-saving AMP8000 integrates a servo drive directly into a servomotor. By relocating the power electronics directly into the machine, it is possible to supply power to multiple servo drives with a single cable via a machine-mounted distribution module. For more information: www.beckhoffautomation.com

igi-Key Electronics, a global Internet-based distributor of electronic components, is an authorized distributor of more than 8.4 million components, including over 1.6 million in stock, from more than 750 trusted suppliers. The company’s reputation extends worldwide through the continuous choice of Digi-Key’s customers as the provider of the widest range of electronic components in the industry, ready for immediate delivery. With this wide range of products available in both design and production quantities, Digi-Key is the best resource for designers and buyers alike.

New products are added every day, in a continuous effort to offer the full range of electronic components required by the customer. Whether semiconductor, passive, interconnect, electromechanical, wireless or lighting components, Digi-Key is a one-stopshop for the solutions to all your application and design needs. Digi-Key is the preferred supplier for Industrial Automation, Control and Safety products. They carry a broad line of products from advanced controls such as PLC, HMI and temperature controllers to accessories such as wire duct, safety switches and safety light curtains. With excellent technical resources and same-day shipping, Digi-Key will get you the parts you need when you need them.

Headquarters in Thief River Falls, MN

Product availability is one of the distinguishing features of Digi-Key from other electronic component distributors. They stock over 1.6 million products at its distribution center in Thief River Falls, MN.

The company offers a vast selection of online resources including a range of EDA and design tools, reference design library, on-demand multimedia library, a comprehensive article library, and community forums, among others. Digi-Key also offers numerous Supply Chain solutions such as bonded inventory and just-in-time shipping, as well as a newly updated BOM manager.

Dave Doherty President and COO

The Best Possible Service Digi-Key prides itself on the ability to provide the best possible service to customers. A customer can request electronic components or reach the talented team of technicians and application engineers 24 hours a day, seven days a week, 365 days a year, either by phone, fax, e-mail or through the website.

With a wide range of products available in both design and production quantities, Digi-Key is the best resource for designers and buyers alike. From prototype to production, Digi-Key has the resources and products to take your design to the next level! Find out more about www.digikey.com.

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ZAutomation, a division of the AVG Group, is a manufacturer and direct online seller of innovative low cost automation products made in America. The AVG Group has been in business serving the automation industry since 1968! In fact, Struthers Dunn, a division of AVG which later changed its name to Uticor, first invented the PLC for welding controls in the automotive industry. EZAutomation was originally launched in 2001 when it first released the most innovative, cost-effective, and EZ to program HMI/Operator Interface, “EZTouch” used by over 40,000 companies today. Over the past 17 years, EZAutomation has designed hundreds of industrial automation products, becoming a one stop shop, of affordable automation innovations, while proudly maintaining the “Made in America” campaign.

EZAutomation.net: American Industrial Automation Product Shopping Made Easy and Cost-Effective. EZAutomation, is a manufacturer of industrial automation products including, HMI/ Operator Interfaces , Programmable Logic Controllers (PLCs), Din-Rail Mount Power Supplies, Industrial Panel PCs, Inductive Proximity Sensors, Rotary Shaft Encoders, all-in-one HMI-PLC combo units, Time Delay Relays, Control Transformers and much more.

EZAutomation, a division of AVG, that has been serving the automation industry since 1968, first introduced itself into the market with its award winning EZTouch® in 2001. EZAutomation is proud to be one of the only remaining automation suppliers that continues to manufacture in the USA!!

Innovation by Design - IIoT Ready! We are always at the fore-front of technology innovating new concepts based on industry needs. With IIoT and Edge-Gateway computing being the wave of the future for preventative maintenance and productivity monitoring, EZAutomation is proud to be the first PLC Manufacturer that supports Industry standard MQTT Protocol. The EZRack PLC that is IIoT ready also acts as an Edge-Gateway device for current plant automation equipment running on EtherNet/IP and Modbus RTU & TCP/IP.

Vaidhyanath “Doc” Nanjundaiah Director, Marketing & Customer Success

The Most Competitive Prices in the Market. With all the most innovative technology reducing programming time and maintaining uptime, we guarantee that our customers will have the lowest cost of ownership in the industry when using EZAutomation.

“Innovative, low-cost automation products that’ll put a smile on your face” Customer Service and Free Technical Support: At EZAutomation we focus on providing the best quality service that will put a smile on your face. With customer service and same day shipping available from 6:00 am to 7:00 pm (CST), we have the East to West Coasts covered. Free Technical Support is available from 6:00 am to 12:00 (midnight), including weekend emergency support. EZAutomation also offers an “Online Chat” function to interact live with one of our experienced staff to get immediate answers. It is our mission to make sure the customer is always up and running!

EZAutomation www.EZAutomation.net sales@ezautomation.net

utomation is widely used in manufacturing, be it packaging, food & beverage processing, automotive, or other production lines. With new automation technology, comes new cable challenges.

With almost 40 years in the cable business, we have designed our products to provide uninterrupted power and data transmission to todayâ&#x20AC;&#x2122;s automated manufacturing systems, regardless of working conditions. HELUKABELâ&#x20AC;&#x2122;s high-quality cables and accessories have been tested to withstand multi-million flexing cycles, and are guaranteed to handle the high mechanical stress and repetitive, automated movements found in todayâ&#x20AC;&#x2122;s industrial environments. This makes the automated manufacturing process more efficient by reducing downtime and increasing productivity.

Helukabel USA headquarters â&#x20AC;&#x201D; a 75,000-square-foot facility in West Dundee, Illinois

Our cable engineering expertise allows us to meet and exceed customer expectations as industry technology becomes more advanced. We are continuously providing new cable solutions to our customers, which allows them to maintain their position at the forefront of the market. In addition to providing bulk cable and accessories, HELUKABEL offers pre-assembled servo, motor, feedback cables for the worldâ&#x20AC;&#x2122;s leading drive system manufacturers, as well as pre-assembled data, network and bus cables for plug-and-play installation, maintenance and repair. We also develop entire cable protection systems for companies that incorporate robots into their manufacturing operations. HELUKABEL USA, based near Chicago IL, is a global manufacturer and supplier of cables, wires and cable accessories. Our extensive in-stock product portfolio includes flexible and continuous-flex control cables, data/network/bus cables, VFD/servo motor cables, torsion cables for wind turbines, single-conductors, and multi-norm cables with domestic and international electrical approvals.

â&#x20AC;&#x153;We are continuously providing new cable solutions to our customers, which allows them to maintain their position at the forefront of the market.â&#x20AC;? With access to a product portfolio of over 33,000+ line items at our fully automated logistics center in Germany, we are able to serve the North American market on a just-in-time basis to deliver the cable products you need, when you need them. Our combination of excellent cable quality, innovation and technical expertise, along with a vast product portfolio and smooth logistics operations truly makes HELUKABEL your one-stop shop cable solution provider, or as we like to call it â&#x20AC;&#x201C; The Worry-Free Cable Experience!

TBMFT!IFMVLBCFM DPN r www.helukabel.com

oore Industries, a world leader in the design and manufacture of rail, panel and field instruments for industrial process control and monitoring, system integration and factory automation, continues its investment in developing rugged and field hardened instrumentation for the process control and automation industry. Bridging the gap between the plant floor and higher-level information and control systems requires products that can endure extreme ambient temperatures and noisy (RFI/EMI) plant environments.

HES HART to Ethernet Gateway System

The introduction of industrial Ethernet networks in process manufacturing plants and automation facilities has meant that data exchange in a facility and across global corporate networks is becoming commonplace. This free flow of information has introduced new possibilities for using the copious amounts of data in existing field devices in an IIoT (Industrial Internet of Things) context or Smart Factory (Industry 4.0) setting. The typical process control model that involves decision making at the local

or centralized level by PLCs (Programmable Logic Controller) or BPCS (Basic Process Control System) is quickly changing. These systems were never intended to deal with the amount of data they would have access to in the near future. There are newer ERP, MES and asset management systems that collect some of this data now, but the more critical challenge that facilities face is manpower and tight project budgets. So the challenge remains: how do existing and new manufacturing facilities find a cost effective way to get critical plant floor data up to higher level information systems?

â&#x20AC;&#x153;Making HART data easily available over Ethernet infrastructures enables our customers to get the most out of their new and existing installations.â&#x20AC;? The answer is to take advantage of the digital HART data already installed but either didnâ&#x20AC;&#x2122;t know was there or couldnâ&#x20AC;&#x2122;t afford the equipment upgrades to gain access to it. The HART digital signal found in most smart field instruments often contains additional process variables that may include instrument status, diagnostic data, alarms, calibration values and alert messages. A simple and cost-effective solution for gathering HART information is to use a HART interface device that supports Ethernet.

Scott Saunders Chief Executive Officer, Moore Industries-International, Inc.

Standalone gateways like the HES HART to Ethernet Gateway System provide an economical pathway to extracting HART data from field devices. r Multiplex up to 64 HART instruments to each HES and share instrument diagnostics and data with your control and information systems over Ethernet r The HES communicates with all HART 5, 6 and 7 devices including smart valves, multivariable flowmeters, pressure, pH, level, and temperature transmitters and more. r The HES supports enhanced techniques to mitigate cybersecurity breeches by preventing unauthorized configuration access with hardware solderless jumpers and software communication socket restrictions.

JOGP!NJJOFU DPN r

upporting your journey at every stage

Newark element14 is a high-service distributor of technology products, services, and solutions for electronic system design, maintenance, and repair. We bring together the latest products, services, and development software, all connected with an innovative online engineering community where purchasers and engineers have access to peers and experts, a wide range of independent technical information, and helpful resources.

Making it easier to get the products you need, when you need them r Fast access to the latest technology r Local personal service r Buying tools to simplify your work process r Complete design solutions r Engineering expertise and free technical support Chris Breslin Global access, with service President of Premier Farnell that’s close to home Newark element14 has operations in the US, Canada, and Mexico, serviced from our regional distribution hub in Gaffney, South Carolina. We are committed to supporting local language, currency, product, and shipment needs across North America and around the world. Additionally, as part of Premier Farnell and Avnet, our global reach provides greater access to stock and stronger relationships with suppliers, ultimately allowing us to better serve your needs with the latest technologies and a wider range of products.

Newark element14’s corporate office in Chicago, IL

“Our global reach provides greater access to stock and stronger relationships with suppliers.”

A commitment to innovation that powers change Along with Premier Farnell, Newark element14 has a history of innovation. We’ve developed many industry firsts that save precious time, like the first online community for engineers, customizable online catalogue, and the element14 TV engineering video library. This leadership can also be found in our Trust Agenda – a unique focus on driving sustainability through our planet, our people, and our principles. As a result of our sustainability effort, Premier Farnell has been listed on the FTSE4Good Index and also the Dow Jones Sustainability Europe Index. We continue to work to provide a sustainable future through leadership in packaging, exceeding green standards, providing support for environmental legislation, and more.

www.newark.com 1 800-463-9275

ounded in 1974 by engineers who designed a better solid-state relay, Opto 22 still manufactures SSRs that are known worldwide for their reliability— plus controllers, I/O, automation software, and groov EPIC®, a completely new system for automation and IIoT applications.

groov EPIC Opto 22’s groov EPIC Edge Programmable Industrial Controller merges a secure, industrial control platform with an array of software to meet today’s control and business needs: r Place groov EPIC almost anywhere—it’s UL and ATEX compliant, and operates in -20 to 70°. r Program monitoring and control using IEC 61131-3, field-tested PAC Control™, Node-RED™, or Linux® secure shell access. r Collect, process, and exchange data where it’s produced—at the edge of your network—for a single, reliable data source.

All products are based on open standards and manufactured and supported in the U.S.A. Famous for their quality, SSRs and I/O are individually tested and most are guaranteed for life.

Mark Engman Opto 22 President and CEO

Company philosophy President and CEO Mark Engman, the son of founders Bob and Mary Jane Engman, joined Opto 22 in 1983 after obtaining his engineering degree at the University of California, Irvine. Mark learned all aspects of the business from the ground up, working in research and development, product support, and manufacturing operations. In 1996, he was awarded the prestigious Leonardo Medal for outstanding Technical Innovations in Manufacturing.

r Securely share data among databases, cloud services, PLC systems, and other components.

In a sea of constant change in automation, Opto 22 is still family owned, still manufactures all products in Southern California, and is still based on the fundamental tenets of its founders’ business philosophy:

r Easily build your own HMI with the data and controls your users need.

r It’s more fun to work in a small company than a big corporation.

r Let authorized users view your HMI locally on EPIC’s high-resolution color touchscreen, on an HDMI monitor, and on any mobile device.

r Treat people well—employees and customers—and they’ll stick with you. r Design and build good products that last a long time. r Utilize new technologies and open standards: that’s automation’s future.

Reliable hardware, easy-to-use software, and people you can talk to: that’s the Opto 22 difference.

sales@opto22.com 800-321-6786 www.opto22.com Opto 22 factory and headquarters in Temecula, California

s a world leader in drive technology and a pioneer in drivebased automation, SEW-EURODRIVE has established a reputation for quickly solving the most difficult power transmission and motion control challenges. We introduced the gearmotor in 1931. Since then, we have been bringing the best in drive technology to our customers worldwide.

Our five regional assembly centers in the U.S. stock millions of dollars of our modular inventory for quick delivery of drive solutions and spare parts.

SEW-EURODRIVE offers much more than just components. We also provide the expertise, project planning, software, commissioning, and service from start to finish. Being a single source partner radically sets us apart from others. No one knows how our products work together better than we do because we designed them! Our team of automation experts can solve even the most complex motion control challenges. Your engineers will appreciate our value when they are able to be home with their family at night and on weekends, instead of troubleshooting an application.

Your engineers will appreciate our value when they are able to be home with their family at night and on weekends. Innovation In addition to engineering excellence, SEW-EURODRIVE is also known for innovative new products.

PT Pilot simplifies the choices and identifies a custom solution for each application

Support Our PT Pilot® online drive selection tool quickly selects the perfect drive for your specific needs. PT Pilot simplifies the choices and identifies a custom solution for each application within minutes.

MOVIGEAR® is an all-in-one mechatronic drive solution for horizontal material handling. It combines the gear unit, motor, and electronics in one highly efficient and hygienically designed unit. MOVIGEAR® also eliminates excess inventory since it allows the use of a single ratio to replace several different ratios. MOVIGEAR has been proven to reduce total start-up costs and annual operating costs in your material handling system by 20-30%!

This powerful program includes technical documentation, net pricing, CAD files, and an application calculator. Visit ptpilot.com.

Flexibility Our products are based on a unique system of modular components that can be assembled in literally millions of different configurations so every drive solution is custom built to our customer’s exact specifications.

SEW-Eurodrive…Driving the World

Our customer service personnel, engineers, product specialists, and service technicians are available to answer questions and troubleshoot problems. SEW-EURODRIVE also offers on-call technical support around the clock for emergency breakdown situations.

864-439-7537 www.seweurodrive.com

AGO has been connecting the world since our founding in Minden Germany in 1951. As the world leader in spring pressure wire termination technology, we opened our US subsidiary in Milwaukee, WI in 1979. In 1999, we moved into a new state-of-the-art facility in Germantown, WI and have since increased our operational capacity to include over 110,000 ft2 of office and manufacturing space.

US headquarters in Germantown, WI

As we continue to improve processes and drive innovation, we are always looking to provide simplicity and inspiration for our customers. This year we have accomplished just that with the expansion of our TOPJOB©S Series of rail mount terminal blocks to include push-button and leveractuated variants alongside the original open slot version. This gives the user a variety of operating options to suit their individual wiring needs. All three operating versions have the same profile to allow them to be mixed and matched on the same

DIN rail, as well as share accessories such as jumpers, marking strips and test adapters. Looking into the future, IIoT is becoming more and more prevalent in industry. WAGO has been helping people collect and analyze information from their plant floor for years, and we continue to enhance our technologies with exciting new tools for this digital transformation age. For example, we have embedded the MQTT Protocol in our PLC enabling secure data exchange between the plant floor and Cloud services (Microsoft Azure, IBM Cloud, SAP Cloud and others). These same PLCs also support the OPC UA standard for seamless data exchange with SCADA applications. Our focus on cybersecurity tools helps users transfer this data in a secure manner. WAGO controllers become IIoT controllers that safely and efficiently send data from the field level to the cloud. There they can be aggregated and used for analyses. This creates real added value for our customers– whether to increase efficiency in their own production, for energy management, predictive maintenance or for the development of other end-customer services.

Toby Thomann President of WAGO Corporation

“WAGO has been helping people collect and analyze information from their plant floor for years, and we continue to enhance our technologies with exciting new tools for this digital transformation age.” The underlying concept of all of our products, services and technologies is safety and reliability. The result is the most extensive line of spring pressure termination technology products and the momentum to keep current with customer needs. Our vision and mission is for “WAGO to be the backbone of a smart connected world.”

We empower connections!

Info.us@wago.com (800) DIN-RAIL www.wago.us

his year is the 40th anniversary of the founding of Applied Motion Products. Our early years were focused on providing stepper motors to the rapidly growing computer peripheral industry in Silicon Valley California. We rapidly became the dominant supplier to this industry through leading product technology and customer service excellence. It was also a time where we became a truly international company with manufacturing in Japan and operations in Singapore and Europe.

Our vision, â&#x20AC;&#x153;We make life easier by connecting people to motionâ&#x20AC;?, reflects a core idea that the development of manufacturing technology has lifted people out of manual based tasks, freeing individuals to unleash creativity and enjoy their work. By connecting people to motion our products make it easy to create automated systems with little prior experience in automated motion systems.

To survive in a technology business, organizations must remain agile and capable of adapting to rapid change. To put this in perspective: the industries that originally adopted our products have improved their product performance by something close to 9 orders of magnitude, 1 billion X.

Our mission to be â&#x20AC;&#x153;the leader in automation products through exceptional customer focus, innovation and continuous improvementâ&#x20AC;? reflects key elements of our growth strategy. When I returned to Applied Motion Products seven years ago, we adopted a three-pronged approach to growth: address new markets with new products, serve new customers with a wider sales channel, and provide products of exceptional value to our customers. By expanding our sales force and channel partner relationships, and continually increasing the breadth and functionality of our product line, we are well on the way to success in an increasingly connected manufacturing environment.

CEO/President, Applied Motion Products

sales@applied-motion.com 1-800-525-1609 www.applied-motion.com

As we move toward 2019 and beyond, Applied Motion Products finds itself thriving in this environment, taking advantage of rapid change and working towards providing customers with motion control solutions in an ever more complex operational environment. Today with operations in California, Shanghai and Frankfurt we are part of a billion-dollar global organization focused on industrial and factory automation.

Don Macleod

ounded in 1984, Dataforth is a recognized global leader in the design and manufacture of signal conditioning modules and industrial data acquisition & control systems. â&#x20AC;&#x153;Our mission is to set the highest standards of product quality, performance, and customer service,â&#x20AC;? says Corporate Headquarters, Tucson, Arizona Georg Haubner, VP of Sales and Marketing. â&#x20AC;&#x153;We know that signal integrity is critical and so our products are all designed to ensure the most reliable, cost-effective isolation and protection for customersâ&#x20AC;&#x2122; measurement and control signals and connected equipment.â&#x20AC;?

Unparalleled Data Acquisition & Control r MAQÂŽ20: Dataforthâ&#x20AC;&#x2122;s 3rd generation DAQ system, based on 30+ years of experience in the industrial test and measurement and control industry, offers the industryâ&#x20AC;&#x2122;s lowest cost per channel, 1500Vrms channelto-bus isolation, Âą0.035% system accuracy, and two dedicated software packages with integral PID control.

Two new modules have just been added to the system and two more are on the way. The MAQ20 is ideal for factory, process, and machine automation; military and aerospace, power and energy, oil and gas, and environmental monitoring applications. r 8B isoLynxÂŽ SLX300: Builds on proven reliability of the SLX200 and miniature 8B signal conditioners. r SCM5B isoLynxÂŽ SLX200: Implements industry standard Modbus RTU and TCP protocols.

MAQ20 DAQ System with 5B, 7B, and 8B Signal Conditioners

Unrivaled Signal Conditioning â&#x20AC;&#x153;Our signal conditioner families ensure outstanding accuracy, isolation, and protection,â&#x20AC;? Haubner states, adding that custom modules are available upon request. Modules provide1500Vrms transformer isolation, up to 240Vrms field-side protection, Âą0.03% to Âą0.05% accuracy, and wide operating temperature range. r r r r

SCM5B Analog Modules Ideal for temperature, pressure, flow SCM7B Process Control Modules A compact, low-cost solution SensorLexÂŽ 8B Analog Modules Miniature size for embedded & portable apps DSCA DIN Modules DIN rail mount for temperature, pressure, flow

All 1200+ Dataforth products are manufactured in Tucson, AZ. The Quality Management System is ISO9001:2008 registered.

sales@dataforth.com r EBUBGPSUI DPN

o win, manufacturers need partners they can trust to help them build better products. To streamline production. And of course, to continuously cut costs. Itâ&#x20AC;&#x2122;s all about innovation. For over 40 years in the US and 80 years globally, Festo has been a positive force for manufacturers. Our passion is automation â&#x20AC;&#x201D; intelligent automation solutions that transform the way people work â&#x20AC;&#x201D; and the way companies compete. Ultimately, itâ&#x20AC;&#x2122;s about continuously stimulating progress. In big ways and in small ways.

Our aim is to help our customers make their products faster, smarter and more precisely. Thatâ&#x20AC;&#x2122;s how they thrive instead of just survive. And when our customers win, we win. We are Festo. And our purpose is to help people turn the power of intelligent automation into a catalyst for transformation.

The automation system CPX-E is designed as a central control system for handling technology, with an EtherCATÂŽ master controller and a motion controller with protection to IP20.

We are driven by a desire to always be helpful. We observe. We analyze. We inspire. We engineer with an intense focus on every last detail.

Full Range of Standard and Customized Products

We operate with a simple, yet powerful manifesto: That intelligent automation isnâ&#x20AC;&#x2122;t just about movement - itâ&#x20AC;&#x2122;s movement with purpose. And itâ&#x20AC;&#x2122;s not just about innovative products. Itâ&#x20AC;&#x2122;s about products that come with expert advice and differentiated customer support.

r r r r r r r r

United States Headquarters in Islandia, NY

With a comprehensive line of more than 30,000 automation products, Festo can support the most complex automation requirements. Pneumatic Drives Servo Pneumatic Technology Handling & Vacuum Technology Air Preparation, Pneumatic Connections and Tubing Valve and Valve Manifolds Sensors and Machine Vision Control Technology Electromechanical Components

XXX GFTUP DPN r DVTUPNFS TFSWJDF VT!GFTUP DPN Phone: 800-99-FESTO

aple Systems began in 1983 as a manufacturing company building controller boards and embedded control systems. Since then, Maple has become a global leader in the operator interface industry, offering solutions for every type of industrial application.

Recently Maple has expanded and with that, brought on new product lines. In addition to the HMIâ&#x20AC;&#x2122;s weâ&#x20AC;&#x2122;re known for, we now proudly offer: t 4NBSU ).*T GPS UIF **P5 t 4NBSU (BUFXBZT 4FSWFST GPS UIF **P5 t $MBTT * %JW ).* 1-$ DPNCJOBUJPO VOJUT t $MBTT * %JW 1-$T BWBJMBCMF XJUI 'JYFE &YQBOEBCMF * 0 t *OEVTUSJBM 8JOEPXTÂĽ #BTFE 1BOFM 1$T

Over 300 Protocols Supported Maple Systems Inc., Everett, Washington

Our commitment to our customers has always been to offer quality, reliability and affordability.

Maple Systems products integrate with hundreds of different programmable controllers from the biggest names in PLCs including Allen Bradley, Schneider Electric, GE, Siemens, Mitsubishi, and Omron to the lesser-known

legacy protocols like SIXNET, GE Series One, TI505, Idec, and ASCII. This support allows for customers to still use what they know without having to compromise on functionality in choosing their controller.

Connecting Up with the IIoT Every manufacturer has specific needs and elects to connect their business to the IIoT at different paces. The versatility of Maple Systems products allows for this upgrade at any time, often without having to remove or replace a unit. Existing upgrade paths like this allow customers to feel more comfortable in purchasing Maple products today, knowing that they will be able to tap into the additional capabilities of tomorrow, when they are ready.

Larry St. Peter CEO Maple Systems

What can we help you control? Learn more today: www.maplesystems.com

Sales@maplesystems.com www.maplesystems.com Phone: 425.745.3229

ndustrial Ethernet is the technology of the future on the factory floor. It enables convergence to the office and to the internet, which is impossible over traditional, often piecemealed bus technologies. Nexansâ&#x20AC;&#x2122; industrial Ethernet solutions help improve productivity and profitability by avoiding, eliminating, and minimizing risk, and ultimately achieving 100% uptime.

The Fourth Industrial Revolution - We are in the midst of the fourth industrial revolution,

characterized by the introduction of cyber-physical systems. A cyber-physical system is a mechanism controlled or monitored by computer-based algorithms tightly integrated with the internet and its users. Reliable connections between the machines, the people, and the internet are, in a word, everything. However, one bad connection can mean the flow of information is disrupted, which could have devastating results on your operation and your bottom line.

Mike Bayda Industrial Product Manager, Nexans

Nexans gives you the confidence to make the connection. Superior Product Performance - In the field of industrial cabling solutions, Nexans offers a complete range of products that provide improved reliability and reduced cost of ownership.

Nexansâ&#x20AC;&#x2122; solutions are run through a battery of vigorous mechanical testing, followed by data transmission testing to ensure your IP traffic will be protected. Nexans Industrial Solutions are built to withstand even the most demanding harsh conditions. Our comprehensive solutions include bulk copper and fiber cables in a variety of constructions, field installable connectors, cordsets and fiber assemblies. Learn more at www.nexans.us/industrial.

ce201901_execVhalf_NEXANS.indd 1

717-354-6200 nexans.us/industrial industrial.support@nexans.com

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INNOVATIONS

NEW PRODUCTS FOR ENGINEERS Stepper motor for hazardous locations, where flammable gases are

Applied Motion’s HX56-100 hazardous location stepper motor is designed for motion control in challenging environments of oil, gas, printing, and paint finishing applications. It is certified for ATEX and IECEx for Class 1, Zone 1 locations and UL-Listed for Class 1, Division 1, Group C and D locations. Class I hazardous locations are areas where flammable gases, vapors or liquids are, or may be, present in the air to cause a potential hazard. Zone 1 defines a hazardous location in which flammable gases, vapors or liquids exist all of the time or some of the time. It can run stored programs created with Applied Motion’s Q programming language, and can connect to multiple external devices or sensors. Applied Motion, www.applied-motion.com

Non-contact magnetic measuring system

Elesa’s MPI-15 magnetic measuring system is designed to allow precise alignment and positioning of workpieces thus reducing time of machinery processes to a minimum, saving costs, and speeding the whole production cycle. Combined with a magnetic band, it is easy to install and features an easy-to-read digital display, enabling operators to accurately read linear or angular displacements. It is made of an LCD multifunction display with a builtin magnetic position sensor. When combined with the magnetic band M-Band-10, it provides a complete system to measure linear and angular displacement (with a minimum radius of 65 mm). Elesa (UK) Ltd., www.elesa.com

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Hermetically-sealed, spring-loaded LVDTs

NewTek Sensor Solutions’ series of spring-loaded linear variable differential transformers (LVDTs) are designed to provide accurate dimensional feedback for many position measurement and quality assurance applications including go/no-go measurements, quality testing, position/thickness control and material testing. Designed with a stainless-steel probe assembly and ¾”-in. diameter hermetically-sealed housing, the sensors operate in dirt, water, vibration, and temperature ranges of -65 to 220°F with maximum linearity of +0.25% of full-scale output. NewTek Sensor Solutions, www.newteksensors.com Input #202 at www.controleng.com/information

Rugged Stainless Steel Enclosures Extensive stainless steel offering has been expanded. New HWSSHK Series: • • • •

Durable 14 gauge 304 or 316L stainless steel construction Heavy duty 316 SS piano hinges and padlockable handles UL/CSA Type 4X approved Painted steel version available

Trust your next project to Hammond enclosures.

Quality Products. Service Excellence.

Visit hammondmfg.com to learn more.

hammondmfg.com | (716)630-7030 | sales@hammfg.com input #20 at www.controleng.com/information

See more New Products for Engineers. www.controleng.com/NP4E

Cast-iron three-phase ac motors

AutomationDirect’s IronHorse MTCP2 industrial duty motors are offered in T-Frame (1 to 300 hp) and TC-Frame/C-Face (1 to 30 hp). C-face kits are available for motors over 30hp. These motors are available in 1200, 1800, and 3600 RPM and have totally enclosed fan cooled (TEFC) enclosures with a cast iron frame and ribbed design for maximum cooling. The motors feature full length, cast iron mounting feet, a steel fan cover, and a cast iron junction box with a rubber gasket and rubber dust cover. MTCP2 motors have premium quality ball bearings (1 to 75 hp) or roller bearings (100 to 300 hp) with maintenance-free bearings on 10 hp and below. V-ring shaft seals are used on the drive end and opposite drive end. The motors are electrically reversible and have Class F winding insulation. AutomationDirect, www.automationdirect.com

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AI controller uses machine learning to extend equipment life

Omron Automation Americas’ Sysmac AI Controller handles several key steps in the data-driven decision process for predictive maintenance, thereby freeing up industrial professionals from tedious calculations, analyses, and infrastructure upgrades. It is designed to help manufacturers reduce the risk of bad parts or equipment damage by detecting issues early and prompting immediate action to resolve them. Customers will be able to take advantage of Omron’s advanced technology and its team of data scientists to facilitate predictive maintenance rather than figuring everything out on their own. The machine learning functionality can identify abnormal machine behavior without being explicitly programmed to do so. Omron Automation Americas, www.omron.com

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January 2019

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INNOVATIONS

NEW PRODUCTS FOR ENGINEERS

See more New Products for Engineers. www.controleng.com/NP4E

CNC system for machine tool applications

Bosch Rexroth’s CNC system MTX with new hardware is designed to achieve even shorter cycle times and better machining quality. With the new XM42 embedded controller, systems with an extremely large number of axes and stations can now be automated efficiently with one central controller. This simplifies project planning and reduces costs and complexity. With the elimination of communication in multicontrol solutions, performance increases. The CNC system MTX uses open standards and protocols throughout and, with its Open Core Interface, offers machine manufacturers the opportunity to implement their know-how independently and securely. With an interpolation cycle of 250 μs, the MTX from Rexroth sets standards for CNC machining. The cores of the multi-core processor, assigned to the respective tasks, process the CNC, PLC, and communication tasks independently of each other. Bosch Rexroth, www.boschrexroth.com Input #205 at www.controleng.com/information

Cyber risk management platform, roadmap to improve operations

Axio’s NIST-CSF risk management platform is designed to establish a baseline for cyber readiness, and provides companies a risk reduction roadmap for ongoing improvement. Axio’s platform enables risk officers and chief information security officers (CISOs) to achieve and sustain full visibility into their overall cyber program maturity through model-driven, on-demand assessments. It also helps companies develop a clear action plan and roadmap for improvements. It also can help prioritize actions and investments based on the impact to their business, and monitor and report on cyber program maturity as it changes over time. Axio Global, www.axio.com

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January 2019

Media ShowcaSe for engineers Your place for new products, literature, Apps, Videos, Case Studies and White Papers.

ANALOG &

DIGITAL I/O

DC-POWERED SERVO DRIVES

RS232

Supply voltages from 24 to 60 volts DC. Up to 40 in-lb peak output torque. Auto-tuning and Safe Torque Oﬀ (STO). Pair with J Series Servo Motors. www.applied-motion.com

603 622 0452 Made in USA Since 1986

VOLTAGE CURRENT TC, RTD BRIDGE FREQUENCY DIGITAL

www.dghcorp.com/rs232 Input #100 at controlengineering.hotims.com

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