CE_19_09 by Modiconlv

www.controleng.com

iÌ Þ ÕÀ ƂE w >Ì

alliedelec.com

Time-tested, industry-approved HMIs C-more HMIs are the go-to choice for low-cost system interfacing

CUSTOMER REVIEW:

As with most industrial control projects, cost is king, but you don’t have to sacrifice quality to keep your budget intact. C-more HMIs are built to last and provide many advanced capabilities, including object animations, logic and math operations, web server/mobile app access, and data logging, all for a surprisingly low price.

C-more HMIs starting at:

$477.00 (EA9-T7CL-R)

“This may well be the best HMI on the market when you consider functionality vs price...It is large and bright and the wide-screen appearance allows plenty of room for information and interaction...There are no better options available from any source.” Scott in DRAPER, UT

CUSTOMER REVIEW: “In a nutshell, these panels (and indeed, the entire EA9 line) offer great value, usability, and ease of use for the price...The programming is very straightforward and the panels have quite a lot of functionality...If you compare these to the AB Panelviews, I’m not sure what that extra $3000 buys you, but it’s nothing I need. As long as it’s up to me, I’ll save my employer that money, (and myself the frustration) of dealing with AB products...” Brian in TACOMA, WA

Research, price, buy at:

www.automationdirect.com/cmore

1-800-633-0405

input #1 at www.controleng.com/information

the #1 value in automation

Flexible Process Control for Less with ProSense® Universal Signal Conditioners starting at

$157.00 (SCU-3100)

YEAR

Universal Input Signal Conditioners / Isolators ProSense Universal Signal Conditioners provide excellent flexibility to convert, transmit, scale and/or isolate process signals to meet requirements of a wide variety of applications. Use the removable programming module to make parameter adjustments, display process and status data, and to download configurations from one module to others. Quality products, reliable operation, free two-day shipping (over $49), and free unmatchable tech support, all for everyday low prices from AutomationDirect.

Features: • Universal supply voltage, 21.6 to 253 VAC or 19.2 to 300 VDC, polarity insensitive • 3-way isolation (input, output, and power) • Easy-to-use detachable LCD programming/ display module (sold separately, required for programming) • Easy and quick conﬁguration settings transfer from one signal conditioner to another using programming module • Integral 35mm DIN rail mounting adapter

Also Available High Density Signal Conditioners

• Removable screw terminal blocks are keyed to ensure correct installation

Temperature Transmitters

Optical Isolators & Limit Alarms

• 5-year warranty

Research, price, buy at:

www.automationdirect.com/ signal-conditioners

1-800-633-0405

input #2 at www.controleng.com/information

the #1 value in automation

We build trust... that’s what we do. At Phoenix Contact, we stand behind our products. And now we are elevating that commitment with our Limited Lifetime Warranty. It’s our promise to you that the products you install in your control cabinets are free from defects and built to last. From all of us — we’ve got your back. Simply register and let us handle it.

www.phoenixcontact.com/warranty

input #3 at www.controleng.com/information

Vol. 66 Number 9

SEPTEMBER 2019

28 | Shift in control technologies, design

17-36 COVER: Leveraging mobile-enabled maintenance technologies allows teams to stay more connected to do their jobs more quickly and away from arc-flash zones. Courtesy: Fluke Corp. 38-46 INSET: Modern web browsers are leveraged for new mobile capabilities and other capabilities in Ignition 8 from Inductive Automation. Courtesy: Inductive Automation

INSIGHTS 5 | Research: Buying, specifying motor drives 6 | Technology Update: Collaborative robotics deliver faster ROI 12 | Career Update: Engineer retention 14 | Career Update: Control your career NEWS

16 | University technology roundup 17 | Think Again: Control Engineering 2020

ANSWERS

31 | Continuing education advances process control, instrumentation productivity 33 | Evolution of modern manufacturing:more data 35 | Digital twins, engineering future 36 | Improvement by association: engineers collaborate on best practices 38 | Selecting HMI remote access options 40 | New mobile HMI designs 42 | A mobile HMI strategy can lead to digital transformation 44 | Web browsers: HMI, SCADA applications 46 | It’s time the mobile HMI caught up 47 | NFPA 70E standard, electrical safety 51 | Engineering Leaders Under 40 60 | Five advanced process control, data analytics connections 62 | OOIP Part 3: interfaces and methods 64 | The basics of model-following control

18 | Smart Factory Testbed: From concept to reality

INSIDE PROCESS

24 | Future of industrial automation

P5 | Industry 4.0, automation: smelter

26 | 5 enduring developments in electronic motion control

P1 | RPC and model-based control P6 | Water, wastewater application uses IIoT energy management

CONTROL ENGINEERING (ISSN 0010-8049, Vol. 66, No. 9, 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

September 2019

•

Stressed out? Juggling too many motion control projects while trying to keep up with new technology can be overwhelming! Itâ&#x20AC;&#x2122;s time to contact an automation specialist at SEW-EURODRIVE for help. Using the latest innovation, we provide a complete package from start to finish, including expertise, project planning, components, software, commissioning, and worldwide support. So relax . . . we got this!

seweurodrive.com / 864-439-7537 input #4 at www.controleng.com/information

Number of hours worked per week 60 or more

Fewer than 30

INSIGHTS

RESEARCH

30 to 39

50 to 59

4% 12%

40 to 49

79%

Automation professionals, on average, work 44 hours per week, with 13% working 50 hours or more. Source: Control Engineering 2019 Career & Salary Study

Six in 10

end users use or expect to use function block diagrams over the next 12 months. Source: Control Engineering 2018 Programmable Controllers Study

45%

of end users seek the ability to try before they buy HMI software. Source: Control Engineering 2018 HMI Software & Hardware Study

87%

of end users prefer to order a standard off-the-shelf servo/stepper drive as opposed to custom-engineered. Source: Control Engineering 2019 Motor Drives Study

2019 MOTOR DRIVES STUDY

Buying, specifying motor drives

espondents to the Control Engineering 2019 Motor Drives study identified five key findings related to the purchase and specification of variable-speed, servo/ stepper and medium-voltage drives: 1. Usage: Eighty-eight percent of respondents use or expect to use variable speed drives (VSDs) within the next 12 months; 46% use/plan to use servo and/ or stepper drives and 17% use/plan to use medium voltage (MV) drives. 2. Applications (check all that apply): When specifying VSDs, 89% of applications are new, 74% are retrofit and 71% are replacement. The breakdown for servo/stepper drives is 87% new, 67% retrofit and 64% replacement. For MV drives: 89% new, 81% retrofit and 78% replacement. 3. Purchasing: Thirty-six percent of respondents prefer to buy motors and related VSDs separately; 22% prefer matched units. Regarding servo/stepper drives, only 12% prefer separate, and

60% look for matched units. For MV drives and Above NEMA motors: 30% prefer separate, and 19% favor matched units. 4. Expenditures: Over the past 12 months, respondents estimated an average of $139,000 having been spent on VSDs. For the same time frame, respondents also estimated average values of $94,000 for servo/stepper drives and $620,000 for MV drives. 5. Important factors: The most critical qualities respondents look for when choosing a motor drive are frequent start/stop tolerance for VSDs (83%), accurate positioning for servo/stepper drives (97%) and frequent start/stop tolerance for MV drives (83%). ce

M More RESEARCH

Access more motor drive trends at www.controleng.com/research. Amanda Pelliccione is the research director at CFE Media and Technology.

Top 10 motor drive evaluation criteria 74%

Drive reliability

65%

Price Simple setup/controls

54%

Programmability in software

53% 50%

Customer service and support

46%

Manufacturer's reputation

45%

Communication interface choices

42%

Maintenance

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

www.controleng.com

Downloadable parameters

38%

Convenient operator interface

37%

When evaluating any type of motor drive, automation professionals first look at reliability, followed by price, ease of setup/controls, programmability, customer service and support and the manufacturerâ&#x20AC;&#x2122;s reputation. Source: Control Engineering control engineering

September 2019

â&#x20AC;˘

INSIGHTS

TECHNOLOGY UPDATE Mark T. Hoske, Control Engineering

Collaborative robotics, faster ROI Collaborative robots used in industrial applications can be easier than traditional robotics for set up and redeployment, producing rapid return on investments (ROIs) in many diverse applications.

C and

M More INSIGHTS

KEYWORDS: Collaborative

robots, manufacturing competitiveness, skills gap Robotics saves manufacturing jobs. Collaborative robots can be set up more quickly. Programming and training for collaborative robots.

CONSIDER THIS If you have traditional robots, or even if you don’t, what applications could benefit from a little extra help?

ONLINE Universal Robots July 31 webcast has supporting slides on benefits and case studies, a video of customer application ROIs, and a question-and-answer session. See related webcasts: www.controleng.com/ webcasts/past

ollaborative robots used in industrial applications can be easier than traditional robotics for specification, training, setup, integration with endeffectors and applications, operation redeployment. Collaborative robots also can help manufacturing workers fill in where skilled labor resources are scarce, adding productivity, saving manufacturing jobs and expanding manufacturing competitiveness and opportunities, according to Early Ewing, UR+ product manager for Universal Robots. In industrial implementations, collaborative robots can work in the same space with humans after an appropriate risk assessment. Compared to traditional industrial robots, Ewing said, collaborative robots can have faster setup, easier programming, more flexible deployment, limited space requirements, can work side by side with humans, and have a return on investment (ROI) of often a year or less, as explained in a July 31 webcast on return on investment (ROI) of collaborative robots, at www.controleng.com/webcasts/past through July 2020.

Manufacturing productivity

Collaborative robots’ ROI of one year or less, Ewing said, is strong compared to two years needed for many traditional robot applications. He also explained collaborative robots can help with manufacturing productivity in ways such as: The Universal Robots’ UR5 at Zippertubing eliminated product rejects. “We have no fears of ever sending bad parts to our customers now,” says Tim Mead, operations manager with Zippertubing. Courtesy: Universal Robots

•

September 2019

control engineering

• Humans working with machines can result in dynamic and adaptable production. • Robots help manufacturers grow even in this skill-labor-restricted current environment. • Skilled labor pressures in manufacturing are expected to continue with U.S. Baby Boomers reaching retirement age at a pace of 10,000 per day, resulting in an estimated 2.4 million open jobs between 2018 and 2028. • More than 68% of respondents to a National Association of Manufacturers survey in fourthquarter 2018 said attracting and retaining a quality workforce was the highest among “primary current business challenges.” • Average annual growth for collaborative robots exceeds 45% from 2018 to 2025, said “Global Collaborative Robots Market Report” from The Insight Partners. • Among eight collaborative robot customer application in a Universal Robots video, return on investment ranged from 1 to 14 months. Five were 6 months or less. • Implementations from customers, distributors, or system integrators can vary for more complex applications. • Human-robot collaboration is 85% more productive than humans or robots alone. • All Axis Machinery, which was turning away orders for lack of skilled labor, used four collaborative robots to automate six applications, increase spindle on-time from 8 to 20 hours per day with higher accuracy and quality for a 4-month ROI. • Zippertubing wrap-around cable tubing manufacturer achieved zero parts defect and was able to reassign 32% of labor force to other things the robot cannot do. Other case studies show other benefits such as eliminating backlog, increasing throughput, doing half of preliminary buffing so a skilled human can do the rest, eliminating downtime in a critical application, and providing enough help to enable a third shift to operate. ce Mark T. Hoske, content manager, Control Engineering, CFE Media, mhoske@cfemedia.com, wrote this with information from the Universal Robots July 31 “ROI of Collaborative Robots” webcast. www.controleng.com

SENSE Is it cold in here or did your boss just walk in?

We have a sensor for that.

Shop Allied. It makes sense. input #5 at www.controleng.com/information

1.800.433.5700

iÌ Þ ÕÀ ƂE w >Ì

alliedelec.com

input #6 at www.controleng.com/information

SEPTEMBER 2019

INNOVATIONS NEW PRODUCTS FOR ENGINEERS

76 | Information platform for processing applications, Electromagnetic filter series, Brushless servo motor series, Actuator series, On/off control valve series. See more New Products for Engineers at www.controleng.com/NPE.

BACK TO BASICS

79 | Robots need to understand and think more

NEWSLETTERS: Redesign this month

Control Engineering eBook series: Midstream Asset Management Summer Edition This helpful eBook will help readers learn about topics including orifice meters, oil terminal efficiency, and machine learning-based gas recognition. Learn more and register to download: www.controleng.com/ebooks

Starting this month, we have upgraded our newsletter to deliver a better overall experience for our subscribers. Go to www.controleng.com/newsletters to learn more.

ONLINE HEADLINES • Top 5 Control Engineering articles Aug. 19-25 • Hybridization as a disruptive, profitable energy strategy for manufacturers • Machine vision improves surveillance, public safety • Researchers use polymer to strengthen graphene oxide sheets • Regular hydraulic grab maintenance improves performance and reliability.

Learn more about upcoming events and awards at www.controleng.com/events-and-awards/2019-tradeshows-events/

CFE EDU: Catapult your career forward Earn learning units and discover exclusive content through videos, presentations and access to experts at CFE Edu, an on-demand education platform by CFE Media and Technology. Check out the course catalog today at cfeedu.cfemedia.com/catalog. • IIoT Series: Part 3: Edge, Fog, and Cloud • Data-Driven Maintenance • Introduction to Cybersecurity within CyberPhysical Systems • IIoT Series: Part 2, Current Issues and Applications

IIoT for Engineers In this issue: IIoT for Engineers is about the use of information, automation, and internet technologies to improve productivity, in discrete and process facilities. Featured articles include: Best practices for network security design, Control system connectivity, and Leveraging SCADA data in maintenance workflows. Read the digital edition at www.controleng.com/magazine.

controleng.com provides new, relevant automation, controls, and instrumentation content daily, access to databases for new products and system integrators, and online training.

www.controleng.com

control engineering

September 2019

•

AWARD WINNING SOFTWARE Software for Monitoring & Control

All the core SCADA • features you need in a single install that scales from 200 to 2 million 1/0.

ENTERPRISE SCADA Master SCADA Applications Centrally monitor multiple sub-systems. New Auto Tag Import Options Import Tags from Allen-Bradley® PLCs and OPC.

New High Performance Widgets.

Universal 1/0 & Calculation Tag Faster easier integration.

Master SCADA

■B

SCADA IN THE CLOUD

Local System A

Idea Studio on Internet Clients Configure displays from PCs without VTScada installed. Web-based Application Manager Manage apps from Internet Clients while running VTScada as a service. OPC-UA and MQTT Drivers for cloud-based connectivity.

Some integrated features licensed separately.© Trihedral Engineering Limited 2019 - V!Scada and Trihedral are trademarks of Trihedral Engineering Limited

INTRODUCING

VERSION 12 VTScada expands in all directions to help you effectively support small to world-wide installations.

ENHANCED REPORTING Excel® Plugin Create advanced reports outside VTScada. History Editing Overwrite bad or missing values. Improved Data Access New REST interface and enhanced ODBC. Excel Add m.xlsx - Excel

Review

View

Timestamp

2019-06-or •• ·- ••

Add-ins

Help

VTScada

My Alarms\Analog 1:Value:Average

2019-oo-o: VTScada Excel Reporting

•

2019-06-ol

2019-06-01

2019-06-0!

2019-06-0I 2019-06-0i

2019-06-rn 2019-06-0!

2019-06-1(

X Configure Data Query Name

2019-06-ll 2019-06-1:

Raw data

2019-06-1'.

2019-06-11 2019-06-1! ��::��

2019-06-11 2019-06-1!

2019-06-2l 2019-06-2: 2019-06-21

IMPROVED SITUATIONAL AWARENESS NEW High Performance Widgets Help operators focus on what matters most.

scada

�::ll

!&l!!J!s

ln5c

��E a,JF=)

�

fi)

lffll O F1,j Ce] 0e

!&il1"li!

*.jj\A

2018-11-05 13:34:10

<Jl!iA

1'!iA 1'1iA

Ji!l,&,t�

,1ljjlj

•

E',�li ti:?.<

E',�/ll

ll!!IE

}O;ic.

y "'1· "'® Y.,_ \1!lll

IA :::!

;;;;,

J/i�

100000

II Include timestamp column II Sort by timestamp descending

We are happy to provide a personalized webinar to introduce you to VTScada and the new features in version 12. Contact Us info@trihedral.com 1-800-463-2783

VTScada.co m/12

•ll!

Create translations for any number of languages.

E lminutev] [

Maximum records

ForYouorYourTeam

E',�li ,t,flj<

Time per record

BOOK A WEBINAR

Yt&

/jj�

•�ype_,

Download the plug-in from the Microsoft Store.

Enhanced Mapping New High Performance tiles and bulk import utility. Multi-Language Support Create SCADA solutions for a global market.

(Be

L) Get single value

2019-06-21

Enhanced mapping and application management.

<®>

:: " �r:-:::a�v

input #7 at www.controleng.com/information

INSIGHTS CAREER ADVICE

Angie Keller, Randstad Engineering

Improve engineer retention 3 ways Companies protecting top engineering talent from rivals should improve training, benefits and wages to make employees happier and more productive.

he new industrial age is in full swing. Automation, robotics, AI and the Internet of Things (IoT) are reshaping how businesses across nearly every industry operate. They’re helping organizations streamline processes, maximize productivity and reduce costs. With more businesses seeking the services of skilled engineers to help keep pace with the fast rate of change, engineering opportunities are being Manufacturers looking to retain their best engicreated faster neers should improve skill sets, benefits and than employers wages. Courtesy: Randstad Engineering can fill them. A Deloitte study said the skills gap could leave 2.4 million positions unfilled between 2018 and 2028 in the manufacturing sector. Consider these three tips to retain the best engineering talent.

M More INSIGHTS

KEYWORDS: engineers,

employee retention, employee benefits There is a major skills gap for engineers that companies are struggling to fill. Companies looking to shore up the skills gap should focus on retaining the top talent they have. Fair wages, better benefits and better training will make employees happier and more productive.

ONLINE Read this article at www.controleng.com for a link to the 2019 Control Engineering Career and Salary Survey for more information about engineering trends.

CONSIDER THIS What has your company done to retain talent and what have the results been like?

•

September 2019

1. Retrain to retain

Sixty-six percent of employers who responded to a McKinsey survey said addressing the skills gap was a top-ten priority, and nearly 30% put it in their top five — and retraining or upskilling existing workers emerged as a key component of their strategies for fighting it. Avoiding the tight talent market and retraining employees already on staff is the best way to confront the skills gap head-on and bring the workforce up to speed in all the areas where companies feel they may be lacking expertise. It also ensures companies don’t suffer even more vacancies by losing talent to competitors. As competition for talent accelerates, competing employers may become compelled to dangle lucrative offers in front of a company’s top performers to lure them away. If a company has prioritized training and development and increased upskilling efforts, they’ll be better protected from outside comcontrol engineering

petition. When asked about what they value most in an employer, training and development has consistently come out on top for many workers today. When companies demonstrate dedication to teams’ development and imbue them with new skills, better performance and greater loyalty will result.

2. Broaden the benefit spectrum

Competition for talent across all sectors has forced employers to think outside the box when it comes to the benefits and perks offered. If the current offering isn’t in line with competitors, companies run the risk of greater turnover. Fifty-five percent of employee respondents to Randstad’s Benefits and Perks in the Workplace study said they’d left jobs in the past because they received better benefits elsewhere. Keeping benefits and perks packages up to date with the latest worker expectations can help attract and retain top performers. So what should companies be offering to keep their best engineers? Randstad research found, as a general rule, almost all (94%) employees want benefits and perks that meaningfully impact their quality of life. What that looks varies. Companies should survey employees to discover the kind of benefits they value most. Other incentives that came out on top were perks like early Friday releases; flexible, remote work options; on-site amenities like gyms, dry cleaning and childcare; and unlimited vacation time.

3. Offer fair wages

Forty-four percent of respondents to a Randstad Employer Brand Research study said low compensation was the top reason they left their previous employer. For industries where demand for talent is especially high, the number could be even greater. After updating the benefits package, companies should set their sights on salary to make sure they’re doing all they can to retain engineers. Evaluate the cost of living in the area to make sure what’s being offered is reasonable. Companies also should study the local market to see what the current pay rates are for the positions they’re looking to protect to stay competitive. ce

Angie Keller, senior vice president, Randstad Engineering. Edited by Chris Vavra, production editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com. www.controleng.com

| EC11-16USA |

Many-core power, DIN rail form factor Powerful Embedded PC series offers up to 12 CPU cores with advanced Intel® Xeon® D processors

www.beckhoff.us/Many-Core-CX The Embedded PCs from the CX2000 series set new performance standards for DIN rail mounted controllers. With 4, 8 or up to 12 cores, task cycle times of 100 μs per core and an extended operating temperature range of -25 °C to +50 °C, these compact Embedded PCs offer a significant performance boost. The result: minimal hardware footprint and the highest controller performance available on DIN rail – ideal for high-performance automation and motion control applications. CPU variants CX2042: Intel® Xeon® D-1527 2.2 GHz, 4 cores CX2062: Intel® Xeon® D-1548 2.0 GHz, 8 cores CX2072: Intel® Xeon® D-1567 2.1 GHz, 12 cores Main memory: 8 GB DDR4 RAM up to max. 32 GB DDR4 RAM Graphic card: separate GPU, 2 GB GDDR5 Interfaces: 2 x Gbit Ethernet, 4 x USB 3.0, 1 x DVI-I, 1 x multi-option I/O: modularly extendable with Beckhoff Bus Terminals and EtherCAT Terminals input #8 at www.controleng.com/information

INSIGHTS CAREER UPDATE

Nelson C. Baker, Georgia Institute of Technology

Control a career: more mentors A personal board of directors is a broader version of a mentorship with many people assisting your engineering career journey from a variety of viewpoints. See four ways to begin.

ompared to the early days of your engineering-related career, accelerating technological advances, software updates, innovative heuristic strategies and new processes change “the way we do things” obsolete with astonishing regularity. In an environment of rapid technological development, acquiring new skills is a matter of professional survival. This is reflected in the changing demographics of public universities. At the Georgia Institute of Technology, half the students are adults taking professional development courses. Through programs like Georgia Tech Professional Education, professionals in fields such as cybersecurity, analytics, and electrical and computer engineering strive to remain relevant in their professions. They’ve adopted the attitude of a lifelong learner, and that may be the most valuable “skill” of all, learning to learn and seeking opportunities to do so. Engineers and other science, technology, engineering and math (STEM) professionals in particular can benefit from a lifelong learner mindset. Dealing directly with technology means dealing with constant change. To stand out to potential employers, electrical engineers need to have expertise that other candidates don’t offer. A personal board of directors is similar to a mentorship, but broader in its application. A personal board is a group of people who can help navigate your career and education, KEYWORDS: offering a mix of experience, talent and diverEngineering careers, mentoring sity that one individual can’t match. If you Engineering careers require want to survive in a shifting job market influconsistent learning. enced by shifting career needs, it’s necessary Diverse input from others to control of your own professional destiny.

M More INSIGHTS

can provide guidance. Track and update career goals.

ONLINE If reading from the digital edition, click on the headline for more resources. www.controleng.com/ magazine www.controleng.com/ contribute

CONSIDER THIS What are the last three things you’ve written to advance your career?

•

September 2019

Four ways to begin

Here are four considerations to begin: 1. Know your goal. Board membership should shift and change over time, just like your career goals. If you’re at an early stage of your career with your sights set on management, find someone who is at that level. If you’re not sure where you ought to go next, find someone who can help you figure that out. And if you don’t want to keep moving up, you at least need someone who ensures you stay current. Find board members who can help you take that next step. control engineering

2. Keep it formal. A personal board of directors is more explicit than traditional networking. Don’t be afraid to seek out specific expertise, even if you’ve never met potential board members in person. It doesn’t matter whether they are on a different continent or the other side of the country. The only requirement is they have the skills and the knowledge base you need and are willing to share insights. 3. Your board members’ benefits package: Why would anyone wish to serve on your personal board? Look at it like this: Each of us will be on someone’s else’s board. There is a very real sense of giving back. As for concrete benefits, you represent a potential source of talent to your board members. Board members also can become resources for one another. Connecting with other mentors and expanding personal networks is helpful at all stages of a career. 4. Build a diverse board. Innovation happens when fields of knowledge intersect. Whether your personal board has three or twenty members, stocking your board with a wide range of disciplinary expertise allows you to explore new paths and new passions. If you enjoy the policy aspects of your job, you may find your career pivoting toward policy work. You might go back and take policy-related education. With that new focus, your board of directors may acquire a city councilman in addition to engineers. By the same token, board members with legal and financial expertise are as relevant for a personal board of directors as they are for a traditional company board. You should consider at least one board member who can help you overcome self-doubt and provide the encouragement needed to take bold new steps. This person needs to know you are as a person and has seen you in day-to-day interactions. That might be within your community, your personal life, or any field outside your profession. Above all, a personal board of directors should help you follow your passions over a lifetime — even when passions change. By following your passions, you ensure you remain relevant. ce Nelson C. Baker, Ph.D., is the dean of Professional Education at the Georgia Institute of Technology and professor in the university’s School of Civil and Environmental Engineering. Edited by Chris Vavra, production editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com. www.controleng.com

You probably already use Tadiran batteries, but just donâ&#x20AC;&#x2122;t know it!

PROVEN

40 YEAR OPERATING

LIFE

If you have a smart automatic water, gas, electricity, or heat meter in your home. If you have an electronic toll collection transponder, tire inflation sensor, or emergency E-CALL system in your car. If you have a GPS tracking device on your trailer, container, or cargo. If you have wireless sensors, controls, or monitors in your factories and plants. If you use electronics with real-time clock or memory back-up in your office.

If you have never heard of Tadiran Batteries, it is only because you have never had a problem with our products powering your products. Take no chances. Take Tadiran batteries that last a lifetime.

* Tadiran LiSOCL2 batteries feature the lowest annual self-discharge rate of any competitive battery, less than 1% per year, enabling these batteries to operate over 40 years depending on device operating usage. However, this is not an expressed or implied warranty, as each application differs in terms of annual energy consumption and/or operating environment.

input #9 at www.controleng.com/information

Tadiran Batteries 2001 Marcus Ave. Suite 125E Lake Success, NY 11042 1-800-537-1368 516-621-4980 www.tadiranbat.com

INSIGHTS

NEWS

Four university tech findings Below are some of the highlights happening in engineering. If reading the digital edition, click on the individual headlines to read the full story.

Smartphone apps may link to vulnerable cloud servers

Researchers from the Georgia Institute of Technology and The Ohio State University identified more than 1,600 vulnerabilities in the support ecosystem behind the top 5,000 free apps in the Google Play Store. Vulnerabilities in multiple app categories, could allow hackers to break into databases and perhaps into mobile devices. To help developers improve the security of mobile apps, the researchers have created an automated system called SkyWalker to vet the cloud servers and software library systems. SkyWalker can examine the security of the servers supporting mobile applications, which are often operated by cloud hosting services rather than individual app developers. Researchers discovered 983 known vulnerabilities and another 655 instances of zero-day vulnerabilities spanning software layers of cloud-based systems supporting the apps. Researchers are investigating if attackers could get into mobile devices connected to vulnerable servers.

Study to examine hurdles women face in STEM careers

Eduardo Salas, a Rice University researcher, examines women’s experiences in STEM careers. The project, titled “A Two-Part Project Examining Team Dis-

crimination by Gender in STEM Teams and a Way Forward,” will be funded with a $375,000 grant from the National Science Foundation (NSF). Many reasons for this problem have already been investigated, Salas said, including pay and promotion opportunities and family-related constraints. Workplace discrimination has been studied, with research showing women in STEM fields are more likely to face discrimination than women in non-STEM disciplines, he said. Few researchers have focused on day-today experiences of women in engineering. Salas and his research team will examine interpersonal discrimination and its impact on how individuals and teams do their jobs to determine the specific effects for women in STEM careers and what can be done to change this.

Machine learning for warehouse ergonomics

Researchers at the University of Washington have used machine learning to develop a new system that can monitor factory and warehouse workers and tell them how risky their behaviors are in real time. The algorithm divides up a series of activities into individual actions and then calculates a risk score associated with each action. They have developed a smartphone app that will allow workers and supervisors to monitor the risks of their daily actions in real time. The app will provide warnings for moderately risky actions and alerts for highrisk actions, with immediate feedback.

University grant for cybersecurity jobs

With the aid of a $1 million award from the National Science Foundation, The Lane Department of Computer Science and Electrical Engineering at West Virginia University hopes to prepare students to help meet the demand for these cybersecurity roles with the aid of as $1 million award from the NSF. West Virginia University Professor Katerina Goseva-Popstojanova said the NSF award will provide 120 annual scholarships of $5,000 to 40 undergraduate students over a five-year period. The project is called Attracting and Cultivating Cybersecurity Experts and Scholars through Scholarships (ACCESS). The ACCESS initiative also looks to encourage diversity and attract women to these positions. ce

- Edited from articles by Georgia Institute of Technology, Rice University, University of Washington, and West Virginia University by Chris Vavra, production editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com. CORRECTION: August story An incorrect image appeared in a Control Engineering August application article from Universal Robots, “Do-it-yourself collaborative robotic project,” pages 24 to 26. It should have appeared in the Omron article, “Collaborative robot applications,” pages 26 to 29. Images with the correct captions are shown, below left. Images appear correctly in the online articles. No robot is to blame for the error.

CORRECTION: July story The images provided for the print version of the Control Engineering July article, “Benefits of digitizing reality for workers in manufacturing,” were incorrect. The images appear correctly in the online article.

CORRECTION: July 2018

Collaborative robots use a variety of sensors to accurately deliver objects to the desired location. Courtesy: Omron Automation Americas

•

September 2019

Universal Robots’ distributor InPosition Technologies did a demonstration. Universal Robots Academy provides free training. Zippertubing installed an area scanner slowing the robot when a person enters the work envelope. Courtesy: Universal Robots

control engineering

A July 2018, Control Engineering article “Comparing ladder logic and object-oriented programming,” called object-oriented programming (OOP) a programming language. OOP is a structured programming methodology and discipline that produces readable code, easier for many to debug and troubleshoot than if OOP is not used. OOP also can foster reuse of previously written code, reducing development time and costs. Online text posted July 12, 2018, has been clarified.

www.controleng.com

The #1 Value in Automation www.AutomationDirect.com 1-800-633-0405

GET MORE THAN YOU PAY FOR . . .

Over 25,000 quality industrial control products at great everyday prices are available on our webstore 24/7/365, and each one comes with the customer service you deserve.

AutomationDirect: much more than just

AutomationDirect is a non-traditional industrial controls ideas from the consumer world to serve your automatio quality products fast for much less than traditional supp

You need quality products at g

AutomationDirect

Product

Our campus is located about 45 minutes north of Atlanta, GA, USA. We’re all here - our sales and technical support teams, purchasing, accounting, and of course our huge warehouses and speedy logistics team.

You want complete product information to make the right purchase decision. Whether you’re deciding on purchasing our products or learning our products after you buy, why jump through hoops or even pay for the information you need? That doesn’t make sense. We have exhaustive documentation, including overviews, technical specifications, manuals and CAD drawings online, and it’s all free to access with no limitations. We have over 1,000 videos online to get you up to speed quickly. When shopping online, if a product you’re looking at has video, it will be available right there for you to view. We even provide FREE online PLC training to anyone interested in learning about industrial controls. www.AutomationDirect.com/plc-training

Price/Part Number

Proximity sensor, 18 mm, 3-wire PNP DC shielded, with quick disconnect

$14.50 PBK-AP-1H

AC Drive, 5 hp, 460V

$424.00

NEMA 12 Enclosure, steel, wallmount (20” x 16” x 8”)

$284.00 N12201608

GS2-45P0

*All prices are U.S. published prices, subject to change without notice. Automa Hoffman prices are taken from www.alliedelec.com 4/30/2019. Allen-Bradley prices are ta Prices may vary by dealer. Many other part numbers are avai

For over two decades, we’ve been offering a controls by running our direct business effici on to you. No complex pricing structures or p low everyday prices on everything from fuse

Programming software for products can be c so we help you out by offering FREE softwar our most popular products, including all our PLC families and C-more Micro HMI. No licens upgrade fees to deal with! www.AutomationDirect.com/price

You don’t want to wait for you

We have same-day shipping, and it’s FRE if your order is over $49.*

AutomationDirect has always maintained a huge us to ship over 97% of orders complete the same d 6pm EST; certain items may have earlier order dea for details by part).

*Order over $49, and get free 2-day (transit) shipping withi (Certain restrictions apply; Canadian orders may take long

You insist on getting better service and you want it FREE. Our technical support has been voted best in service for 15 years in a row. And it won’t cost you a cent! Many independent industry magazine reader surveys have placed us at the top of their lists for service. In Control Design magazine alone, we were voted tops in service for multiple product categories fifteen years in a row.

www.AutomationDirect.com/support

a “.com”

company using the best on needs. We deliver pliers. See below . . .

great prices.

Competitor

Price/Part Number

$89.04 A-B 872C-D5NP18-D4

$477.51 Hoffman A-201608LP

ationDirect prices as of 6/26/2019. aken from www.wernerelectric.com 4/29/2019. ilable from vendors.

better value on industrial iently and passing the savings penalty for small orders, just es to motors.

inventory, allowing day (if ordered by adlines, see Webstore

Our team members here at AutomationDirect.com approach every day with one goal in mind - serve the customer. It’s a simple philosophy that many companies forget. If the answer to any decision is “Yes, this is good for our customers”, then we do it. It’s common sense.

“Should we have FREE tech support before, during, and after any sale instead of charging yearly fees for tech support? Yes, this is good for our customers.”

A-B 22B-D010N104

ur order.

For almost 25 years, our primary focus has been customer service. That takes many forms: quality products, great prices, fast delivery, and helpful assistance. But regardless of our product selection and other tangibles like pricing, the intangible value of customer service is something that cannot be faked, automated or glossed over.

“Should we have real upfront pricing online and realtime stock availability? Yes, this is good for our customers.”

$1,627.50

costly, re for r latest se or

This “.com” is powered by “.awesomepeople”!

“Should we offer FREE software on many products instead of charging licensing fees? Yes, this is good for our customers.”

“Should we have all our documentation online for FREE so people can access anytime, even before they choose to purchase? Yes, this is good for our customers.” “Should we offer more selection by consistently introducing more new quality products almost continually? Yes, this is good for our customers.” “Should we offer FREE shipping for orders over $49? Yes, this is good for our customers.”

All these are discussions we’ve had internally and all have made us wonder “can we do that?”, “that will be hard to accomplish”, “no one else is doing that, how can we?”. But if you bring it back to the simple answer, “Yes, this is good for our customers”, then the perceived obstacles really don’t matter. Our company has evolved dramatically since 1994, and it’s this type of decision making by all our team members over the years that keeps our customers coming back and new customers checking us out daily.

You want to be confident in our products and our commitment to you. We stand behind our products and guarantee your satisfaction. We want you to be pleased with every order. That’s why we offer a 30-day money-back guarantee on almost every stock product we sell, including our software. (See Terms and Conditions online for exclusions.)

in the U.S. and Puerto Rico. ger based on destination)

Check us out at: www.automationdirect.com

The best values in the world . . .

We’ve shopped around to bring you the most practical industrial control products that are in-stock, ready to ship and at the right prices! Reuben in Huntingdon Valley, PA: “Been shopping here for years and I don’t plan on stopping! Great products at a great price. Can’t beat the customer service!” Trent in Coolidge, AZ: “Always accurate with estimated delivery time, support responsive and helpful, product selection grows every time I visit the site.”

PROGRAMMABLE CONTROLLERS

FIELD I/O

SOFTWARE

OPERATOR INTERFACE

AC & DC DRIVES

MOTORS & MOTOR CONTROLS

MOTION CONTROL

POWER TRANSMISSION

PNEUMATICS

RELAYS & TIMERS

SENSORS

Jeff in Sherman, NY: “Love the products! Productivity PLC lines are awesome, Dura Pulse VFDs are awesome. Great prices on everything.” Murph in Chicago, IL: “Love this product, I specify materials for breweries and distilleries and all of the panels I design are exclusively AD. Love the fact that we can get replacements sent to anywhere in the US in 2 days. Tech support has been consistently excellent.”

PUSHBUTTONS, SWITCHES & LIGHTS

Terri in Clinton Township, MI: “Website is easy to navigate. I can always find what I need. Product has always been in stock and received in a timely manner.” William in Seymour, TN: “Products are good. Shipping is top notch. However, tech support keeps me coming back. They are patient and look for solutions not just answer questions. Good job!” Allen in Nashville, TN: “I have had nothing but excellent service from Automation Direct. The purchases that I have made have worked perfect and arrived quicker than I expected. A+A+A+” Gregory in Cincinnati, OH: “I was able to design and built a control system in weeks. Your website and technical information that was available allowed me to do this. In addition, the shipping was flawless. Great job.”

COMMUNICATIONS

TERMINAL BLOCKS & WIRING

POWER PRODUCTS

ENCLOSURES

CIRCUIT PROTECTION

PROCESS

SAFETY

TOOLS

A quality product line, with FREE #1 rated technical support and quick shipping! Call 1-800-633-0405 or visit us at: www.AutomationDirect.com

INSIGHTS ®

THINK AGAIN

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 Kevin Parker, Senior Contributing Editor, IIoT, OGE 630-571-4070, x2228, KParker@CFEMedia.com Emily Guenther, Director of Interactive Media 630-571-4070, x2229, eguenther@CFEMedia.com Amanda Pelliccione, Director of Research 978-302-3463, APelliccione@CFEMedia.com Chris Vavra, Production Editor CVavra@CFEMedia.com

Contributing Content Specialists Suzanne Gill, Control Engineering Europe suzanne.gill@imlgroup.co.uk Ekaterina Kosareva, Control Engineering Russia ekaterina.kosareva@fsmedia.ru Agata Abramczyk, Control Engineering Poland agata.abramczyk@trademedia.pl

Word cloud of Control Engineering 2020 editorial topics provides clear vision for what we can help each other learn. Courtesy: Control Engineering, CFE Media and Technology

Lukáš Smelík, Control Engineering Czech Republic lukas.smelik@trademedia.cz 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

www.controleng.com

Control Engineering 2020 Industrial Internet of Things (IIoT), process and machine control systems, automation and instrumentation are among the topics Control Engineering will advance in 2020, a year that suggests perfect vision and hindsight, as we mark 65 years in September 2019.

ontrol engineering seeks self-optimization by virtue of the control loop: measure, decide, actuate and repeat. In this 65th anniversary issue, we reflect what developments are shaping the future of control engineering, as we look ahead, with clarity of vision, to 2020, with help from subscribers and other industry experts. A word cloud of next year’s editorial calendar emphasizes key areas:

creating a brighter future by working with us to learn from and teach others. Our heartfelt thanks for all those the world over who have contributed these past 65 years. Learn how to shape the future at www.controleng.com/contribute and www.controleng.com/2020articles. ce Mark T. Hoske is content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com.

• Industrial Internet of Things (IIoT) • Process and machine control systems • Automation

ONLINE

• Instrumentation.

Learn; share knowledge

M More INSIGHTS

As we seek to learn from the past to optimize the present, think again about

www.controleng.com/webcasts www.controleng.com/CE-research www.controleng.com/eBooks CFE Edu online courses: http://cfeedu.cfemedia.com/catalog

control engineering

September 2019

•

ANSWERS

AUTOMATION FUTURE Kym Watson, Fraunhofer IOSB, Industrial Internet Consortium member

Smart Factory Web Testbed The Smart Factory Web Testbed aims to set up a web-based platform to allow factories to offer production capabilities and share resources to improve order fulfillment in a more flexible way than is possible with available technology.

he Smart Factory Web Testbed is designed to be a step towards establishing a marketplace for manufacturing where one can look for factories with specific capabilities and assets to meet production requirements. Factories offering those capabilities can then register to be located and participate in the marketplace. This requires up-todate information about the capabilities and status of assets in the factory. The characteristics of the products — availability, quality, price and so on — provides a basis for possible negotiation between competing offers. For this application to work, international standards such as OPC Unified Architecture (OPC UA) and AutomationML are needed to link factories into the testbed to provide information about the factories in a standardized way. This innovation enables production facilities to offer their services in a global market business and adapt their production in a very efficient way. The testbed also enables cross-site usage scenarios with secure plug and work functions and KEYWORDS: Industrial internet, data analytics. tested, Industrie 4.0 It reduces information technology (IT) The Smart Factory Web Testbed allows manufacturers system integration and installation costs, to look for factories with specific allowing for faster engineering and rampcapabilities and assets to meet up time of components, machines, plants production requirements. and IT systems—improving upon the utiliThe testbed also employs many zation of equipment. The core functionalstandards from groups such as ity is to describe the capabilities of factory Fraunhofer IPA and OPC UA. assets in a standardized way, to find assets ONLINE with the capabilities to access status data Read this article online at about these assets so they may be included www.controleng.com for more in the overall order management. information about the Smart Factory Web Testbed, its effects The testbed is directed mainly towards in manufacturing, testbed small-lot size environments rather than planning, standards, more large manufacturers; companies working results, collaboration, and a link with larger line orders usually have a supto planning. ply chain management system and do not www.smartfactoryweb.de need to be as flexible and responsive due CONSIDER THIS to order size. For smaller-scale production, What benefits could your there are more examples of where a modcompany gain from the Smart erate or smaller number of a part is to be Factory Web Testbed? produced, and machine capabilities need

M More ANSWERS

•

September 2019

control engineering

to be configured. Spare production resources may be offered to improve utilization. The testbed’s primary use cases involve manufacturers seeking a factory to produce certain parts. The manufacturer accesses the database to find a factory with the right capabilities, and a potential target is identified. After negotiating with the target factory about delivery route, schedules, price and other factors, an order can be placed. The target factory may need to adapt its production to meet the requested product specifications, and it wants to do this as efficiently as possible. Once the production order is finished, the factory provides the finished or partial product to the original manufacturer or to another element in the overall supply chain. This usage scenario, Order Driven Adaptive Production, is a combination of the application scenarios “order controlled production” and “adaptable factory” as defined by Plattform Industrie 4.0 (PI4.0)[1]. This scenario is split into six sub-scenarios: Sub-Scenario 1.1 Publish: Registration of Smart Factories: Realized in Phase 1: “Geospatial Mapping and Factory Information” with the help of AutomationML to describe factory capabilities and assets. Sub-scenario 1.2 Find: Discovering Smart Factories: Realized in Phase 1: “Geospatial Mapping and Factory Information” to find smart factories registered in the Smart Factory Web with the desired capabilities best matching the order requirements. Sub-scenario 1.3 Order: Management and execution of orders in the Smart Factory Web: The workflows to broker, orchestrate and process production orders in the testbed constitute this sub-scenario, but they are not yet part of experimentation in this testbed. A proof-of-concept implementation in the Smart Factory Web Testbed will handle the ordering workflows and modeling of supply chains. Sub-Scenario 1.4 Adapt: Adapting the Factory Production: Realized in Phase 2: “Plug & Work” to flexibly and efficiently adapt a production facility to meet order requirements. Sub-Scenario 1.5 Bind: Smart Factory Web Asset Connectivity and Monitoring: Realized in Phase 3: “Data & Service Integration” to provide current information on product and asset status (including www.controleng.com

availability of free capacity) for exploitation in the Smart Factory Web, especially to support the discovery process and linking of supply chains through secure data exchange. The Smart Factory Web information model will be updated dynamically. Sub-Scenario 1.6 Collaborate: Collaborative Engineering: To be realized in Phase 4: “Collaboration” to enhance the efficient adaptation of factory production with shared engineering workflows and software plug and work.

Technologies for the testbed

There are three primary technologies involved in the testbed. The first is the IEC 62541 standardOPC UA, used to implement data communication between factories in the testbed. Second, the IEC 62714 standard-AutomationML is used to describe the necessary information models — the semantics of the data transport from the factory to the testbed. The other fundamental technology is the testbed portal, a web-based information management system and application development environment which provides full support for access rights, work flows and ontology-based information models. The testbed is driving standards by providing feedback to standards bodies — OPC UA, AutomationML, and standards work within the IIC and PI4.0. Other organizations are working on asset administration. The testbed is designed to tackle the whole combination of technologies involved.

Testbed results

There are five phases in the testbed: 1. Geospatial mapping and factory information; 2. Plug and work; 3. Data and service integration; 4. Collaboration; and 5. Ecosystem development. The testbed’s architecture and experiences gained in the testbed over all phases will be documented in a technical design report to be published as a whitepaper in 2019. The testbed team plans to extend the report to describe the work being done in the Digital Twin/PI4.0 Component testbed, a project under the IIC-PI4.0 Joint Task Group and on data sovereignty following the concepts of the International Data Spaces Architecture. The first three phases have been completed up through the data and service integration. Phase 4 involves the collaborative software engineering of these systems and overlaps with Phase 5 covering cooperative projects with other initiatives. On-going work on the system architecture will include new developments with the Asset Administration Shell, as well as extensions of the testbed to support the Negotiation Automation Platform from NEC. The collaborative software engineering phase is ongoing — intensifying the work on the Asset Administration Shell, on the extension of the Smart Factory Web platform for other testbeds, and for IDSA work. The technical report highlights the description of assets in AutomationML, covering: • Their capabilities based on an ontology (to diswww.controleng.com

Figure 1: Smart Factory Web as a marketplace for manufacturing. All images courtesy: IIC, Fraunhofer IOSB and KETI

Figure 2: Phases of the Smart Factory Web Testbed

cover and integrate them as resources in a factory or supply chain), • The definition of data to be sent to Smart Factory Web and Microsoft Azure through OPC UA or SensorThings API and • The visualization of asset data in Smart Factory Web and Microsoft Azure. Phase 4 focuses is on collaborating to achieve the necessary software engineering to integrate factories, the engineers of the various factories and assets in the factories are needed to provide data and semantics of their assets in a way that can be integrated into a cloud — Smart Factory Web or Microsoft Azure. A notable level of interest in the testbed from the industry has resulted customer engagement. Fraunhofer is working to form advanced, leading-edge models and move them into the industry. To enable this entrance into the field, the testbed has had ongoing discussions with industrial companies to transfer research and development results from the experimental environment. Fraunhofer IOSB is transferring general knowledge and training as part of its mission, and the testbed has conducted training exercises on OPC UA and AutomationML for the industry. Fraunhofer IOSB has transferred this knowledge to its testbed partner KETI, which is conducting similar training sessions for Korean companies. Another example of customer engagement is consultancy work control engineering

September 2019

•

| PC11-50USA |

Ultra-compact Industrial PCs: huge performance in a small footprint

C6015

C6017

C6030

www.beckhoff.us/C60xx Beckhoff raises the bar for PC Control with this generation of extremely compact and flexible Industrial PCs, from the C6015 entry-level model to the top of the line C6032 with extended interfaces. Which ultra-compact model suits your application? Ultra-compact: C6015, C6017 processor: Intel Atom®, 1, 2 or 4 cores C6015 interfaces: 2 Ethernet, 2 USB, 1 DisplayPort C6017 interfaces: 4 Ethernet, 4 USB, 1 DisplayPort main memory: up to 4 GB DDR3L RAM Ultra-high-performance: C6030, C6032 processor: up to Intel® Core™ i7 with four 3.6 GHz cores C6030 interfaces: 4 Ethernet, 4 USB, 2 DisplayPort C6032 interfaces: 4 Ethernet, 4 USB, 2 DisplayPort, 2 PCIe compact module slots main memory: up to 32 GB DDR4 RAM input #10 at www.controleng.com/information

C6032

ANSWERS

AUTOMATION FUTURE

Figure 3: Timeline of the Smart Factory Web Testbed has five stages.

on how to design factories of the future and how to set them up to include new emerging technologies. This area represents a challenge because there are so many new technologies arising, and it is difficult for anyone to assess if these technologies will have a real impact and can be relied on for 15 years. In addition, the testbed must be able to transfer these technologies to client applications, help set up the necessary software environments and concepts, and take a multitude of steps to implement the Smart Factory Web Testbed or aspects of the testbed in the clients’ own workflows. It is crucial to increase the level of understanding and skills about certain technologies — trust in those technologies needs to be established so there is a sufficient level of proven experimentation and best practices on how to apply the technologies. This level of trust is necessary before using these technologies in critical manufacturing applications where large production costs and employee well being is at stake. One of the major lessons learned is open interfaces based on standards are essential to realizing a system architecture that can be adapted to changing requirements and technologies with a reasonable effort. The technical design report will contain best practices and how to set up the overall system architecture. It will be a blueprint comprised of advice on how to accomplish this integration sustainably. The testbed derives different forms of business value from participating in the IIC Testbed Program. The testbed has procured new projects in the Industrial Internet of Things (IIoT) domain based on the experiences gained, as well as IIC’s marketing support. The Smart Factory Web Testbed offers three pieces of advice to other testbeds and companies considering an IIoT implementation: www.controleng.com

• Follow open standards as far as possible on both the communication and data modelling level • Develop a sustainable, robust and flexible implementation architecture where one can make adaptations and demonstrate new technologies. • Ensure there are sufficient accompanying projects to maintain synergy, funding and stakeholder commitment — this will bring the testbed from concept to reality and help maintain it over a period of several years. ce Kym Watson, Fraunhofer IOSB and Industrial Internet Consortium member, on behalf of the Smart Factory Web Testbed team comprising Fraunhofer IOSB, KETI and Microsoft. Smart Factory Web is an IIC testbed. The IIC is a CFE Media content partner. Edited by Chris Vavra, production editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com. control engineering

Figure 4: 3-tier architecture for factory integration. Abbreviations AML: AutomationML, CEP: Complex Event Processing, OGC: Open Geospatial Consortium, FROST: Fraunhofer Open Source SensorThings API Server

September 2019

•

YOU SEE OUR LEGACY

WE SEE WHAT’S NEXT We’re changing the game … again. See the next generation of condition monitoring technology at the Turbomachinery & Pump Symposia, Sept. 9–12, 2019, in Houston.

Booth 2701

Visit bently.com to learn more input #11 at www.controleng.com/information

ANSWERS

AUTOMATION FUTURE Dr. Keshab Panda, L&T Technology Services

Future of automation: discern the possibilities, potential Industrial automation is on the threshold of a new revolution, moving through rapid technology changes, adoption of new systems and networking architectures and looking toward interoperability of devices and systems.

he industrial automation space has traditionally been resistant to innovation or early adoption of high-end technologies. More often than not, enterprises in this segment have preferred to leverage proven technologies and standards to ensure safe, secure and consistent operations over time. However, things have started to change radically with the advent of Industry 4.0. The industrial space has been impacted with incremental technology changes, rapid adoption of new systems and augmented networking architectures over the last decade. Many experts believe that while Industry 4.0 is gradually percolating through many industrial revolutions, we are already at the cusp of Industry 5.0. Industrial automation is poised to deliver almost $209 billion in revenue by 2020 with new instrumentation and control products driving the growth. Industrial technologies such as robotics, cloud, the Industrial Internet of Things (IIoT) and artificial intelligence (AI) are becoming increasingly pervasive. Where will industrial automation go from here, and how will it shape the future of manufacturing?

M More ANSWERS

KEYWORDS: Automation future, Industry 4.0, Industry 5.0 Industrial automation is accelerating. New technologies, systems, networks and architectures make automation more efficient. Next is interoperability of devices and systems. CONSIDER THIS Implementing Industry 4.0 advances will lead to interoperable devices and systems.

ONLINE www.controleng.com/ iiot-Industry-4-0/

â&#x20AC;˘

September 2019

Beyond Industry 4.0

The convergence of advanced information, communication and networking technologies is driving automation and its industrial applications. This symbiosis of technologies has enabled integration and collaboration of people and machines across the factory floor and the supply chain. This trend has had a major impact on industrial controllers. Traditionally, automation systems have had a proprietary design because of the need for close-knit process structures that operate in real-time. This helped suppliers forge close partnerships with the end-user. The model also cre-

control engineering

ated vendor lock-ins that allowed manufacturers to source control systems from one supplier. This also eliminated the ability to implement state-of-theart applications and technologies from other vendors. Unfortunately, in the long run, this inhibited a manufacturerâ&#x20AC;&#x2122;s ability to innovate and harness technology for the betterment of its processes. Today, as digitization enables manufacturers to use data in a variety of ways, there is a collective need to implement scalable control systems that allow a manufacturing process to scale according to business needs. Given the proliferation of large-scale, continuous and parameterized industrial devices digitization has fostered, this need will turn into an obligation.

Vertical, horizontal integration

Manufacturers looking to successfully converge have to vertically and horizontally integrate advanced control systems with lower field sensing and data acquisition layer and enterprise management systems. This means, apart from integrating control platform properties, such as motion control, sequence control, logic control, programming and human-machine interface (HMI) configurations, manufacturers also will have to stress integrating control system functionalities such as remote access, condition monitoring, remote diagnostics, etc. One integrated control platform will enable companies to enhance efficiency and productivity and achieve plant-wide process optimization and enhanced user experience. The evolution of programmable logic controllers (PLCs) will play a key role in driving the industryâ&#x20AC;&#x2122;s revolution into this new era. With greater programming flexibility and convenience, scalability, more memory, smaller form factor, high-speed (Gigabit) Ethernet and embedded wireless functionalities, future PLCs will adapt technology improvements in software, communications and hardware. A significant part of this evolution will include the integration of PLCs and programmable automation controllers (PACs), which facilitates communication between www.controleng.com

Control system trends drive the future of automation by easier integration, connectivity, and advanced intelligences. Courtesy: L&T Technology Services

the plant floor and other processes. To achieve this, controller manufacturers will have to find a PLC to control an application and provide the necessary tools to collate, analyze and present process data to a user as and when required. This could include providing data access through mobile apps or web browsers. It’s important to note managing a network of high-end controllers spells significant capital expenditure in the form of hardware and infrastructure investments for companies. In addition, proprietary hardware stacks hinder operational flexibility while adding cost and complexity in controller deployments. Virtualization can help companies create a difference here.

Virtualized controllers

Unlike commercial off-the-shelf (COTS) options, virtualized control systems such as PLCs, distributed control systems (DCSs), HMIs and supervisory control and data acquisition (SCADA) systems require fewer physical servers. Virtualized control functions can also be consolidated and embedded into one platform rather than deploying each function as a separate application. This flexibility of an open, software-based control architecture allows companies to upgrade control processes, optimize them and expedite the deployment of new functions. Recently, a provider of engineering services and aerospace systems launched a platform that let control system manufacturers design and develop applications in less time, at a lower cost and with modular and simple builds. Operating in a virtualized environment, the software transforms how control systems are maintained over their life cycles. Shifting day-to-day server management to a dedicated, centralized data center where specific protocols manage the application performance enables plant engineers to focus on control system optimization. As automation and the control systems evolve, instrumentation will simultaneously develop to

www.controleng.com

‘

Proprietary automation systems created vendor lock-ins and eliminated the option to implement state-of-the-art applications and technologies from other vendors and

’

inhibited process innovation.

accommodate the changes. So, how will future of instrumentation shape up? Easy-to-read dashboards will continue creating an impact in the future, allowing for instrumentation that is more interactive and approachable to plant operators. Networked instrumentation has already been adopted in manufacturing plants across the world. Instead of allowing operators assess instrumentation near the process where it’s installed, networked systems can transmit data to one hub where it’s compiled and analyzed for use.

Incremental upgrades: Industry 5.0

The convergence of technologies creates an avenue for manufacturers to take that next leap towards the fifth industrial revolution where disparate industrial automation systems will share resources and act in synergy. To stay ahead of the curve, companies will have to capitalize on the technologies already out there, accelerate technology implementation and unlock new sources of value. After all, the move to the next phase of automation is more of an incremental upgrade with technology still serving as a primary driver for innovation. ce

Dr. Keshab Panda is CEO and managing director, L&T Technology Services. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com. control engineering

September 2019

•

ANSWERS

AUTOMATION FUTURE Frank J. Bartos, P.E., Control Engineering, retired

5 enduring developments in electronic motion control Motor drives, power-switching transistors and microprocessors, sophisticated control algorithms, software influences, and mechatronic integration are among the standout electronic motion control developments.

erhaps the pace of developments has slowed over the past six-plus decades, yet innovations continue in the maturing technologies of electronic motion control. Five developments in electronic motion control are anticipated to continue to drive advancements.

1. Electric motor drives

Electric drives power myriad manufacturing and process lines worldwide. Variable frequency drives (VFDs), delivering reliable speed and torque control of the industrial workhorse ac induction motor, represent one of the biggest developments over time. The ability of newer-model VFDs to control permanentmagnet ac synchronous motors adds to their versatility. Servo and stepper drives have made remarkable performance advances in torque and position control of various types of servo and stepper motors. They complement the scene at their respective lower power ranges. Hardware and software innovations were the enablers for these electric drives. KEYWORDS: Motion control, Prime hardware developments include motor control, VFDs power-switching transistors and microFive trends in motion control processors. The second category comshaped the past and guide the prises new software tools that allowed future. execution of sophisticated control algoMotor drives and powerswitching transistors and rithms not possible in the past. With microprocessors wider availability, software also made Motion control algorithms, electric motor drives more user friendly. software influences, and Dramatic size and weight reductions mechatronic integration. have especially been realized in VFDs. CONSIDER THIS Bulky cabinets gave way to compact elecWhich key motion tronic housings that could be located near developments do you need motors to suit specific manufacturing plant to advance motion control layouts — even mounted on the motor, optimization? depending on power needs of the appliONLINE cation. In the 1990s, a class of so-called If reading from the digital “microdrives” sprang up, which included edition, click on the headline to a 0.19 kW model able to fit into a technilink to 15 references with links and much more on each point. cian’s shirt pocket. This is an impractical www.controleng.com/magazine application, yes, but a vivid illustration of

M More ANSWERS

•

September 2019

control engineering

possibilities. Servo and stepper drives have benefitted from ongoing electronic controls miniaturization.

2. Power-switching devices, microprocessors

Power-switching transistors that shape input current/voltage waveforms for motor control are at the heart of electric drives. The silicon-controlled rectifier (a type of solid-state switch) and the gate turnoff thyristor (a power semiconductor) served the power-switching role in the early drives. They represent matured technology and see limited application, mainly in some large-power drive applications. With the proliferation of computers and digital technology, motor drives moved to digital microprocessor (MPU)-based designs that continue to dominate the scene. A newer class of semiconductor, the insulated-gate bipolar transistor (IGBT) came along, which has become the prime powerswitching device for present-day electric motor drives. IGBTs combine best features of a metaloxide semiconductor field-effect transistor (MOSFET) input and a bipolar transistor output. They provide fast switching and lower losses due to the

Figure 1: Computer simulations via appropriate software can perform virtual prototype tests to evaluate different motion control system designs before committing to build hardware. Source: Yaskawa Electric www.controleng.com

Figure 2: A prime example of mechatronic integration is the combining of motor and drive components into one package. Exploded view of an integrated step motor shows the technique, which is applicable to other electric motor types as well. Courtesy: Applied Motion

insulated gate, among other features. IGBT advances, for example, include faster switching speeds and the ability to operate at higher voltages. Microprocessors and digital signal processors (DSPs) also are continually increasing their capabilities. Higher computation speeds allow faster response to load dynamics and near real-time communication with other parts of the motion system. Memory can squeeze more capacity into microchips. More sophisticated motion control algorithms can be implemented in software and hardware.

3. Control sophistication

Versatile ac variable-frequency drives offer three principal motor control methods. Open-loop control (also called Volts per Hertz (V/hZ) or scalar) was the first and simplest method to come along. It provides reasonable speed regulation and runs without a feedback device. Flux-vector control (FVC) is at the highest level of VFD performance and has several variations. Field-oriented FVC models characteristics of the dc motor to ac motors, via independent control of flux-producing (magnetizing) and torque-producing current components to derive optimal control of motor torque and power. FVC uses a feedback device (usually an encoder) to obtain motor shaft position and speed information. Control algorithms rely on sophisticated motor models and implement separate speed and torque loops. Full vector control can deliver high torque at low speeds — even near zero rpm. Between the above extremes lies sensorless vector control (SVC) — also called open-loop vector control — still another alternative to improve low-speed torque, speed regulation, and starting torque capability over V/Hz drives. While SVC drives work without a feedback device, they can estimate — using motor current and voltage signals — torque current, magnetizing current, and the vector relationship between them necessary for precise motor control. They also rely on an accurate motor model. Newer VFDs offer all control types noted above, even V/Hz, because of its usefulness in certain applications.

4. Software influences

The equations and motor models were available early on, but their implementation into software for dynamic motion control programs and algorithms had to wait until computers became commonplace. In parallel, continual performance improvement

www.controleng.com

occurred in MPUs, digital signal processors, and microchips for executing programs in motion controllers and motor drives. Higher execution speeds and huge memory growth were made possible. One result was the ability and the economic rationale to incorporate multiple motor-control topologies noted above in the same electronic drive. A simple software parameter change could thereby change control modes. Another aspect of motion control software is assistance in the set-up of an electronic drive/motor combination — especially for servo drives. Simulation is a further area of software innovation. It allows “virtual prototyping” of motion control systems in software before building hardware.

5. Mechatronic integration

Mechanical and electronic systems traditionally worked as physically separated units. The motion control arena experienced a huge change in this regard in the mid-1990s when electric motor and control integration came on the scene in a big way. A flurry of products was introduced by many manufacturers — first as combinations of ac induction motors with VFDs in one package, so-called integrated motors. Then similar combined units became available for servo and stepper motors and their respective controllers. Various benefits can be attributed to having control electronics onboard motors — for example, lower installation costs without long cabling between motors and drives and associated conduit trays, fewer system components, easier diagnostics and maintenance, and simpler control architecture. However, integrated motors have experienced less success than expected, mainly in the induction motor and drive sector. Perhaps this is due to fewer favorable applications or user ambivalence. Still, these induction motor/drive combinations remain in the market for sizes up to 22 kW, serving appropriate applications and in hybrid control architectures. Today, the road ahead remains open to continued developments in these five areas of electronic motion control. ce control engineering

Frank J Bartos, P.E, retired, is a former Control Engineering executive editor and consulting editor. braunbart@sbcglobal. net. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com.

September 2019

•

ANSWERS

AUTOMATION FUTURE Jason Urso, Honeywell Process Solutions

Shift in control system design Project execution using a process control system highly integrated virtual environment melds software and networking to uncouple control applications from physical equipment, and controllers from physical I/O. This reduces capital cost, creates standardization and eliminates some non-value-added work.

he world is changing at an unprecedented pace, and process control technologies have responded by adapting Lean project execution principles, software, and networking to decouple control applications from physical equipment, and controllers from physical input/output (I/O). Modular designs allow multiple controllers to form one virtual controller. Such technologies used in the connected global economy help business decisions to be agile and accurate. Processes must execute with speed and efficiency. Projects must be completed on time and within budget. Workers must react to changing circumstances with confidence based on available and precise data. Technology must enable success, not hinder it. Few technology environments are more complex than those required for industrial control systems (ICSs). These environments must incorporate critical functions including cybersecurity, redundancy, highspeed networking and deterministic operations. This helps customers control safety-critical process manufacturing facilities with the highest levels of reliability. Process control systems (PCSs) have served the process industries more than 30 years. Many opportunities to harness the power of new technologies and make a step change in benefits remain. The process industry continues to have an opportunity to KEYWORDS: Virtual process drive down capital cost by shifting from controllers, modular I/O customization to standardization and Lean project execution helps control system design. eliminating significant amounts of nonHigh-speed Ethernet field value-added work. With installed systems, I/O network enables smarter improved operations continue by convertdesigns, cybersecurity. ing data into knowledge and transforming Design the controls, assign to a knowledge into more precise action. controller, and it finds its relevant Ultimately, the process industry has I/O. more opportunity to execute projects in CONSIDER THIS less time with lower risk while improving Streamlined control designs will throughput, quality and operational relienable benefits more quickly. ability. Decades of implementations and ONLINE customer collaborations provide first-hand If reading from the digital knowledge of the pain points impeding edition, click on the headline for more on faster commissioning. project efficiencies and limiting customers www.controleng.com/magazine from achieving and sustaining best opera-

M More ANSWERS

â&#x20AC;˘

September 2019

control engineering

tions. Helping customers overcome these roadblocks has resulted in a new approach to deploying and operating ICSs by integrating a virtual environment. Automation can be implemented effectively by applying Lean execution methods for automation projects. Such a strategy removes the traditional dependencies that used to force project flows to be sequential by combining universal I/O devices, virtualization, virtual engineering and automated commissioning. Doing so separates physical from functional design, breaks down task dependencies, uses standardized designs, and enables engineering to be done from anywhere in the world, resulting in significant risk and cost reductions.

Less complexity, modular design

New generations of control system technologies use Lean project execution principles, software and networking to unchain control applications from physical equipment and controllers from physical I/O. This enables control systems to be engineered and implemented in less time, at lower cost and risk, and with simpler, modular builds. This transforms how control systems are maintained, shifting day-today management of servers to a centralized data center, where experts and established protocols mitigate cybersecurity risk, allowing plant engineers to focus more proactively on control system optimization. Eliminating complexity, decoupling control from the physical platform and reducing information technology (IT) costs can remove roadblocks preventing simplified control system design, implementation and lifecycle management for project operations. Moving I/O to the field shifts the process control system closer to production units. Control centers are jammed with customized system cabinets along with massive amounts of wiring with little documentation. Distributing the control system closer to the process equipment achieves greater project savings with fewer wires and engineering hours in a smaller space. Some facilities have implemented remote I/O strategies to reduce project costs, but other opportunities are inherent such as modular and parallel project execution. To achieve the next generation of benewww.controleng.com

<ƉůƵƐ /ŶĚƵĐƟǀĞ ƐĞŶƐŽƌƐ ĨƌŽŵ ŝĨŵ ĞĨĞĐƚŽƌ

EŽ ĐŽƌƌĞĐƟŽŶ ĨĂĐƚŽƌ͗ ŝĚĞŶƟĐĂů ƐĞŶƐŝŶŐ ƌĂŶŐĞ ŽĨ Ăůů ŵĞƚĂůƐ ,ŝŐŚ ƐǁŝƚĐŚŝŶŐ ĨƌĞƋƵĞŶĐǇ ĨŽƌ ŚŝŐŚ ƐƉĞĞĚ ĂƉƉůŝĐĂƟŽŶƐ ǆĐĞůůĞŶƚ ƉƌŽƚĞĐƟŽŶ ƌĂƟŶŐ͗ /Wϲϱͬϲϲͬϲϳͬϲϵ< ZĞƐŝƐƚĂŶƚ ƐƚĂŝŶůĞƐƐ ƐƚĞĞů ŚŽƵƐŝŶŐ

ĨŽƌ ĞǆĂŵƉůĞ͗

-20 %

/ŶĚƵĐƟǀĞ ƐĞŶƐŽƌ /&^ϯϬϱ /&<ϯϬϬϴͲ W<'ͬ<ϭͬsϰ ͬh^ͲϭϬϰ /ƚĞŵ ŶƵŵďĞƌ͗ ϰϬϯϮϱϴ

$38.40

MSRP: $48.00

ǁǁǁ͘ĂƵƚŽŵĂƟŽŶ24͘ĐŽŵͬŬƉůƵƐͲŝŶĚƵĐƟǀĞͲƐĞŶƐŽƌƐ

ůƐŽ ŶĞǁ ƚŽ ƵƚŽŵĂƟŽŶ24ΖƐ ƉŽƌƞŽůŝŽ ĂŶĚ ĂǀĂŝůĂďůĞ ƚŽ ƐŚŝƉ ƚŽĚĂǇ

ŽŶƟŶƵŽƵƐ ůĞǀĞů ƐĞŶƐŽƌƐ

ര^ƵďŵĞƌƐŝďůĞ ƉƌĞƐƐƵƌĞ ƐĞŶƐŽƌƐ

ŽŵƉĂĐƚ ůĞǀĞů ŵĞĂƐƵƌĞŵĞŶƚ

sŽůƵŵĞƚƌŝĐ ŇŽǁ ŵĞƚĞƌƐ ĞƚĞĐƚŝŽŶ ŽĨ ĨůŽǁ ĂŶĚ ŵĞĚŝƵŵ ƚĞŵƉĞƌĂƚƵƌĞ

&Žƌ ĂĐĐƵƌĂƚĞ ůĞǀĞů ŵĞĂƐƵƌĞŵĞŶƚ

M 100 %

FRE

PRI N G CI

EY BAC ON

90 DAYS

P P O RT

A R A NTE

100 %

N D-NA M

5 YEAR

PPLICATI EA

PRODUCTS

EPTIONA XC

H QUALIT IG

ǁǁǁ͘ĂƵƚŽŵĂƟŽŶ24͘ĐŽŵ ʹ ǇŽƵƌ ŽŶůŝŶĞ ƐƵƉƉůŝĞƌ ĨŽƌ ĂƵƚŽŵĂƟŽŶ ƚĞĐŚŶŽůŽŐǇ

SHIPP

ING

ER $ 50

input #12 at www.controleng.com/information

800-250-6772 (toll-free)

610-981-2900

ŵĂŝůΛĂƵƚŽŵĂƟŽŶ24.com

ǁǁǁ͘ĂƵƚŽŵĂƟŽŶ24.com

ANSWERS

AUTOMATION FUTURE

Project execution with a new generation control system: Honeywell Experion PKS Honeywell Integrated Virtual Environment (HIVE) uses Lean project execution principles (the Honeywell LEAP process was introduced in 2014), software and networking to decouple control applications from physical equipment, and controllers from physical input/output (I/O) devices. Modular designs allow multiple controllers to form one virtual controller. PKS stands for process knowledge system. Courtesy: Honeywell Process Solutions

â&#x20AC;˘

fits, consider a high-speed Ethernet field I/O network that connects controllers to universal I/O mounted in the production areas. Such communications should be cybersecure with a built-in firewall and enhanced with encryption technologies where needed while providing the technology to accommodate an inevitable increase in the amount of sensed data.

Four architecture advantages

Benefits of such an architecture include: 1. Universal I/O discovery capability allows a controller to access any networked I/O module and channel. A traditional approach of controller to I/O communication requires a direct one-to-one physical connection between controller and I/O cabinet. Networked I/O eliminates a significant amount of planning and manual work. The system designer engineers the control strategy and assigns it to a controller and it will find its relevant I/O. This decreases project engineering planning and engineering. 2. Packaged control capability provides a simple software option to deliver redundant control with high-speed performance. As a process controller subset, these control capabilities are ideal for packaged equipment and provide regulatory, sequence and logic controls. This eliminates the need for complicated subsystem integration. 3. A universal wireless hotspot provides wired or wireless communication to field instruments and allows each field I/O box to be a wireless hotspot, if needed. This enables field workers to execute digital procedures with live access to control system data during commissioning and operations. 4. Modular commissioning provides the ability to commission field I/O cabinets independent of the control system. With this capability, controllers can run on a laptop, plug into the remote cabinet at a module yard and perform a set of commissioning activities as if connected to the rest of the control system. With this flexibility, modular builds spanning multiple yards becomes simple.

September 2019

control engineering

These combined capabilities provide significant engineering, enabling projects to execute in less time with lower risk. For example, eliminating the risk and re-work inherent to late changes ensures automation does not become the critical path [bottleneck to completion]. Adding a new I/O as a result of change extends the control system network without requiring complicated changes to the control system. Traditional control engineering during a project requires meticulous planning since it is driven by a rigid hierarchical approach defined by a tightly bound physical relationships between controllers and I/O. Inefficiencies, re-work and risk materialize during seemingly inevitable late changes to I/O or controls that require a physical reconfiguration of the system. By allowing multiple physical controllers to appear as one virtual controller, the control architecture becomes a controller data center where process controls can be automatically load-balanced across the available controller computing resources. The advantages are powerful, especially when applied to the processing of late changes. It avoids the need to manually assign control strategies to specific controllers.

Cut process control IT costs

The virtualization technology described reduces IT costs by eliminating the amount of physical IT nodes by as much as 80%. However, even with that effort, a large IT infrastructure remains onsite for reliability and scope of loss reasons. Lifecycle costs decrease by using virtualization, which replicates virtual machine files from offsite to the onsite location. This fault-tolerant architecture enables operations from a central operations center or a regional data center. It has the same level of high reliability expected for critical process control. ce

Jason Urso is vice president and chief technology officer, Honeywell Process Solutions. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media, mhoske@cfemedia.com. www.controleng.com

ANSWERS

AUTOMATION FUTURE: TRAINING Mark T. Hoske, Control Engineering

Continuing education advances process productivity Process control productivity requires education for optimal technology specification, integration and use. Industrial suppliers are among those doing the educating.

ands-on training with actual process control hardware and software provides more realistic and memorable experiences, exposing seasoned veterans and next-generation digital workforce to real-world situations to improve productivity and decrease training requirements. To help process, batch, and hybrid industrial processes accelerate digital transformation and teach related workforces, Emerson has constructed three interactive plant environments (IPEs). The Minneapolis Interactive Plant Environment located in Shakopee, Minn., provides a safe training environment using more than 400 automation devices and products and more than 500 input/output (I/O) points, according to Steve Tooley, senior global customer and service training manager, global education, Emerson.

Training for pressure, flow, level, temperature, valves, wireless

Measurement points on site include pressure, flow, level, temperature, corrosion, flame and gas, liquid analysis, and gas chromatography. The facility allows instructors to set up realistic situations with hardware and software after classroom and bench training using 15 tanks and vessels, in three levels. Students can emulate production processes by moving water and mineral oil, avoiding interactions with hazardous chemicals or process interruptions at their sites. The three IPE sites are among 24 Emerson regional North America Training Centers offering on-site instructor-led courses, virtual classroom, eLearning and blended-learning options. Tooley said each facility helps recent graduates and industry veterans learn or review critical skills in process manufacturing and operations using actual process units and instrumentation. Tooley added that hands-on learning helps students learn quickly and effectively. After learning (or reviewing) practical controls and automation theories in a classroom, and at a benchtop setting, students can receive work orders

www.controleng.com

and go into the plant environment to perform what they’ve learned. Putting theory into practice with real-world scenarios, Tooley said, can expose students to common and rare situations to practice appropriate actions and responses. Courses can include device commissioning, calibration, and figuring out if a challenging measurement point is valid. They also review safety permits and required tools to complete different work orders and operate plants more efficiently. IPE helps by limiting distractions engineers and technicians might experience in their facilities, providing a wider vision of how a plant operates, explained Blaine Williams, global education manager, Emerson. Instructors, using years of field service experience, also mentor students to increase their skills. Beyond formal or customized training, some customers schedule time in the facility to integrate and try various combinations of devices, equipment, systems, or software prior to purchase. “Once students experience what we can do here, they often ask to stay longer and work on other things,” Williams said. The company’s first interactive plant KEYWORDS: Process control training, instrumentation environment facility opened in 2014 at training Emerson’s Service Center in Charlotte, Hands-on training augments N.C. The second facility, in Shakopee, is benchtop, classroom. co-located with Emerson’s “innovation Interact with instruments, headquarters for Rosemount products sensors and DCS. and services.” Augmented reality, wireless,

M More ANSWERS

Classroom, benchtop, hands-on training for devices, systems

Device and control system training can include tasks and scenarios such as: • Setup and use of process control networks and communications, such as 4 to 20 mA, Wi-Fi wireless (IEEE 802.11), and FieldComm Group’s WirelessHART, HART, and Foundation Fieldbus. control engineering

asset management and process troubleshooting.

CONSIDER THIS Is your team receiving training needed to optimize efficiencies?

ONLINE If reading from the digital edition, click on the headline for more links. www.controleng.com/magazine See CFE Edu online courses http://cfeedu.cfemedia.com

September 2019

•

ANSWERS

AUTOMATION FUTURE: TRAINING

The Emerson Minneapolis Interactive Plant Environment in Shakopee, Minn., provides a safe training environment using more than 400 automation devices and products and more than 500 input/output (I/O) points, along with Emerson’s DeltaV distributed control system and other enabling software. Courtesy: Emerson and Rick Peters, InsideOut Studios Inc. The Emerson Interactive Plant Environment is designed to enhance learning experiences using Emerson Rosemount products simulating real-life plant situations. Immersive training models plant environments to replicate most common (and unexpected) process scenarios. Courtesy: Emerson and Rick Peters, InsideOut Studios Inc.

Benign oil and water processes at the Emerson Interactive Plant Environment offers students a breadth of measurement points, enabling contextual training within a hazard-free environment. The goal is to build process proficiency and knowledge that far exceeds basic classroom knowledge. Courtesy: Emerson

•

• Work on pressure, temperature, level, and multivariable flow in classroom, bench, and in-plant settings • Using a handheld device, such as a smartphone or tablet, to stroke a valve or view control system parameters and operations • Force a 4 to 20mA output on devices • Advanced troubleshooting and maintenance • Error identification and reengineering of settings and measurement points • Bleeding a valve • Batch tank overfilling • Radar sensor disruption • Transmitter calibration and troubleshooting • Corrosion measurements • Safety instrumented systems (SIS) and firewalls • Setup and use of variable frequency drives

September 2019

control engineering

• Power monitoring, alarms, and notifications • Review of possible power and grounding issues • Review of FM global audit procedures • Device testing, removal and servicing • Use of applications such as augmented reality to see device tags and status, asset management software, mobile software, cloud-based connections, SIS and other software • Process safety scenarios • Training or marketing video production in a low-risk environment. “We go to plants and do simulations, but hardware and software configurations at IPE facilities make digital transformations more real inside realworld operations,” Williams said. “Since the IPE is a digitally transformed plant, we are able to demonstrate live diagnostic data and the benefits of our digital tools that allow students to better understand how to become more effective and increase their knowledge and skills,” Tooley added.

Even incremental changes can help

Even for field-service engineers that have been doing these things for 30 years or more, incremental changes in procedures can add up. “Using a ruggedized tablet to commission devices saves time and money by being able to view the control system ensuring the device is properly commissioned. Thus, eliminating the need to involve an operator to validate device status,” Williams said. ce

Mark T. Hoske is content manager, Control Engineering, CFE Media, mhoske@cfemedia.com, from facility tour notes and information from Emerson. www.controleng.com

PROUDLY

MADE

IN THE

Shalabh “Shalli” Kumar

Founding Chairman

USA

Mr. Kumar immigrated to the U.S. 50 years ago and has invented over 100 different very innovative technologies OEM Divisions OEM Divisions and products, such as PLS, Digisolver, AVG Automation India, Pvt. Ltd. AVG Automation, GmBH Catalog, Internet Embedded Applications Digibrake, Tonnage at angle, HMI, Slaes Division American WaterTouch Softener Specially de Guaranteed 7 StarWater Water <50PPM AnySpecially Time, All the EZAutomation EZAutomation American Softener deT PLC, Programmable Power Supplies, Made in America, Price Buster Guaranteed 7 Star Water <50PPM Any Time, All the EZAutomation EZAutomation LCD, Motherboards & Software “Home Automation products with latest Innovative Automation Products to make life easier for modern and busy Encoders and TDRs with“Home digital Automation products with latest to make life easier for modern and busy “Home Automation products with latest displays, iMarquees and many more. He to make life easier for modern and busy “Innovation by Design” “Home Automation products with latest to make life easier for modern and busy holds dozens of Patents. Over the years “Innovation by Design” he has been celebrated as the most outstanding New Citizen of Chicago, an American Jobs Creator, Entrepreneur of the Year, and has served on President Reagan’s Small Business Advisory Council and President Trump’s Transition Team. Besides inventing, he The Inventor devotes substantial time to philanthropy and community service.

OEM Divisions Industrial Automation Controls

“Most Innovative Automation Products, built like a tank, that will put a smile on your face.”

OEM DISPLAYS

www.avg.net

363 St. Paul Blvd. Carol Stream IL. 60188

Visualization Products • Operator Interfaces • Marquees • Industrial PCs • Text Panel Interfaces • Programmable Controllers

“Innovation by Design”

Resolvers and PLS Controls

• Operator Interfaces • HMIs with Built-in PLCs • Marquees • Text Panel Interfaces • Programmable Logic Controllers • Windows CE Platform Panels • Industrial Monitors

• Programmable Limit Switches • Resolvers and Decoders • PLC Input Cards • Press Monitoring Products • Electronic Motor Brakes • Counters, Rate Meters, and Speed Switches

• SmartLCDdisplaysTM & CE Operator Panels • PowerWareTM to create GUI in minutes • Short Time to Market • LCD Display & Touch screen Integration • Windows CE & Computer Motherboards • LCD Monitors & Computers

• Operator Interfaces • HMIs with Built-in PLCs • Marquees • Industrial PCs • Text Panel Interfaces • Programmable Controllers

• Programmable Limit Switches • Resolvers and Decoders • PLC Input Cards • Press Monitoring Products • Electronic Motor Brakes • Counters, Rate Meters, and Speed Switches

Free Tech/ App Support PROUDLY

MADE

IN THE

USA

We provide same day shipping, extended customer service hours, free technical support for extended hours, free shipping for most deliveries, and 30-day money back guarantee, as you would expect from a top online/catalog automation supplier, but here is

• • •

what makes us different ...

We design and manufacture 99% of our products in IL, IA, TN, MI, U.S.A. Innovation is in our blood, we never do just a “me too product” Ship Factory Direct, passing on to you the 50+% mark up by an importer like ADC/Maple

Introducing 17 exceptionally Innovative New Products 7 New EZTouchPLCs, HMI+PLC NEMA 26 Plug-in I/O Modules

EZ 9 HMI 10” Full Size

4/4X

4” to 15” Screens up to 112 modular I/O

EZ 7 HMI

EZRackPLC

NEMA 4/4X

$899

IIoT Ready EZRack PLC with Ethernet I/P Scanner

EZ Panel PCs

HMI

$599 SCADA

$799

NEMA 4/4X EZ9 10” Full size with additional OEM Discounts

EZ12 HMI

EZ Software Products

Eziest to design, unlimited tags & screens

Power Supply with

Starting

$2499

EZiMarquee

to replace InView & more

Fanless Panel PC with solid state SSD, Windows 10 & EZHMI or EZSCADA preloaded

Programmable Multi-function EZTimer

• PLC Protocols built-in • NO ladder logic change • Great Ethernet/IP connectivity • Connect & program wirelessly from anywhere in the plant

Programmable EZEncoder

Voltage Current

NEMA 4/4X

Up to 24V, 10 Amps

12, 24V DC & 120, 240V AC Models

• NO laptop • NO Special Cable • NO Software • NO Unplugging/ plugging connectors

1/3rd the Cost of BEI, Omicoder

Check out our new website with EZ navigation & configuration tool

EZAutomation Factory

PROUDLY

MADE

IN THE

USA

FACTORY DIRECT

customer plant SAVING YOU 50+%

CALL 1-877-774-3279 for Free Tech / Application Support or simply order online

PROUDLY

MADE

IN THE

Modular I/O

USA

The First & Only HMI w. Fully Modular PLC I/O. Seamless Software. 6”, 7”, 8”, 10”, 12”, 15” Displays & 64 of Cube I/O or 112 of Rack I/O

36 Exceptionally Innovative Unique Features, not found anywhere else. Lasts twice as long: NEMA 4X, 400 nits, 75KHrs@55°C & Drag-n-Drop Software

7” modular TouchPLC @$599 + I/O. PLC is FREE Work Horse EZTouchPLC EZ3 Most Compact 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35.

The only fully modular PLC & HMI with 32 Exceptionally Innovative and Unique Features and up to 112 I/O in one package. Highest, Fastest Processing power per cubic inch. 2 Serial, 2 USB, 1 Ethernet, Micro SD Highest Reliability and Noise Immunity in industry. Easiest Integrated HMI and PLC Drag-n-Drop PLC programming 7” EZTouchPLC software, common to all models, just for $149 Advanced functionalities, PID, Math, High Speed counters, PWM, + I/O 8 pt. Cube I/O even in Fastest Processing time Digital $29 Status LED for each I/O in every model. Analog Patented HMI on-line edit, No downtime Choice of 6”, 7”, 8, 10”, 12”, 15” displays for Modular I/O PLCs Choice of 7”, 8”, 10” and 12” for EZ7 Series Detachable models. All displays are TFT, rated at 400 NITs, 75K hours at 55 degree C. IP protection for qualified customers. At least 2 for 1 for Unitronics & Maple HMI + PLC, and C-more/Domore products Incredibly condensed, 27 different combo plug-in I/O modules. EZTouch.RackPLC I/O (17 modules) with patent pending design to avoid tab broken tabs. All models have EZ Wifi $49 option to connect to your laptop 7” EZTouchPLC without cable Low Cost, Best Value 32 I/O + I/O Detachable displays 2 upgrades for 6”, 7, 8”, 10, 12 models Fastest touch response time of any HMI Full project simulation on your PC “C” Level scripting and logic expressions Data logging, Recipes, EMails, USBs, free chart recorder 2 Serial, 4 USB, 2 Ethernet, Micro SD On-Screen Recipe Edit Remote Monitoring & Control smart phones & Ethernet 16 pt. Rack I/O 7” EZTouchRackPLC Most advanced alarm management Digital $59 Dual Driver capability to communicate to other PLC networks. + I/O PLC has its own communication to Profibus, DeviceNet. 12 pt. Analog Best looking objects and animation with 65K colors. EZ Sunlight readable models for 6” & 10” models. Most Rugged 0.090” thick anti-glare touch screen. Unicode for multiple languages. Full Project simulation on your PC. Every model Fully Loaded, No “R” Reduced Features models. Unique Visibility tag for best screen space utilization. IIoT ready EZTouch. RackPLC with MQTT for data-logging & Ethernet IP Scanner Modular Expandable to 2048 I/O USBs for local data-logging.

36.Last but not the least Highest immunity to shock & vibration and electrical noise.

$599

$149

EZTouchPLC Jr.

$499

EZTouchRackPLC

$899

$229

Integrated Drag-n-Drop Software

$149

Go to www.ezautomation.net for our New Product Configurator

PROUDLY

MADE

IN THE

USA

Incredibly Cost effective HMI+PLC Integrated in one unit with All-in-One Seamless software 4”, 6”, 7”, 10” Displays & 27 or 24 or 48 Fixed I/Os ®

Fixed I/O

30 Exceptionally Innovative Unique Features, same as EZTouch Modular PLC. Lasts twice as long: NEMA 4X, 400 nits, 75KHrs@55°C & Drag-n-Drop Software

3.5” 27 I/O EZTouchminiPLC @$299, PLC is FREE Introducing the Latest Engineering Marvel 3.5” TFT, 12 DI, 8 DO, 4 RLY, 2 AI, 1 AO + Quadrature Input for

EZTouch mini.PLC 12 Digital inputs sink or source including 2 quadrature inputs up to 250KHz & 1 for reset

3.5” TFT LED display, 400 nits, 75k hrs.

LED indicators for all I/O

7” Display

5” x 4” x 2” deep

3.5” Display

$399

$299

Plug-in removable terminal blocks 8 Digital sourcing outputs, 50 V, 500 mA, short circuit proof

4, 1 form C Relay outputs, 5 Amp, 250 VAC

2 Analog In, 1 Analog Out Voltage, 0-10V, 12 bit

EZiest integrated programming $149 software

EZTouchPLC EZ3Nano EZTouchPLC EZ3Micro • 7” Fully loaded HMI • 16 DC Input • 8 Relay Outputs, 10 Amps 1 Form C with snubbers

7” 24 I/O

$499

• 7” Fully loaded HMI • 24 DC Input • 8 DC Outputs, 0.5 Amps short circuit proof • 8 Relay Outputs, 10 Amps 1 Form C with snubbers

7” 40 I/O

$599

7” 48 I/O

$699

including 4 Analog In, 4 Analog Out, 0-10V, 12 bit ®

Offering a New exceptionally Innovative service to give your product a distinct identity and part number

CALL 1-877-774-3279 for more details

For OEMs: Increase your Profits by $200K+ over 10 years

PROUDLY

MADE

IN THE

USA

Latest EZ9 Full size 10.4” is designed for OEMs offering great prices and discounts!!

EZ9 Full size 10.4” Saves more than $410 or 31% over comparable C-More EA9-T10CL Be aware of some low cost 10.1” wide screen models that have 20% less viewing area. EA9-10WCL C-More does not even fit the cut-out of standard EA9 & EZ9 10.4” models 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Patented HMI on-line edit, No downtime EZ mini Wifi to program/edit HMI without cable On-Screen Recipe Edit. “C level” scripting and logic expressions. Dual PLC Drivers with automatic tag conversion. EZiest Program Software, design time in hrs not days. IP protection for qualified customers. Full Project simulation on your PC. Best looking objects and animation with 65K colors. Remote Monitoring and Control, Smart phones & Ethernet. Most Rugged 0.090” thick anti-glare touch screen. Most advanced Alarm management and logging. Pass-through programming for all PLCs. and the list goes on... ®

EZ9, Low Cost OEM Model 2 Serial, 1 USB, Ethernet

20% more viewing area than wide screen models Scan QR Code from your camera to watch video

Full Size 10”

$899

Call Factory for additional OEM discounts

EZ7, The Detachable Marvel that solves the #1 Life span and Durability problem in an HMI

Save $$ to replace worn out touchscreen/display OR upgrade to bigger size for a low cost 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Detachable metal front having Display+Touchscreen NEMA 4/4X, Class I DIV II No cut-out, just 3/4” hole for HDMI cable Upgrade display from any to any size Dual PLC Drivers with automatic tag conversion. Only HMI that can still talk to AB’s DH+ Upload HMI program from USB without software/cable Best looking objects and animation with 65K colors. Remote Monitoring and Control, Smart phones & Ethernet. Most Rugged 0.090” thick anti-glare touch screen. Most advanced Alarm management and logging. Pass-through programming for all PLCs. and the list goes on...

Call 1-877-774-3279 use Promo Code CEIN19

or Email: SalesCE19I@EZAutomation.net or Simply Order Online using Promo Code CEIN19 for discounted starter kits for New Customers or New Applications

EZ7, with Detachable Front

2 Serial, 2 USB, Ethernet, micro SD

PROUDLY

MADE

IN THE

USA

ANSWERS

AUTOMATION FUTURE John Bernet, Fluke Corp.

Evolution of modern manufacturing: more data The Industrial Internet of Things (IIoT) and Industry 4.0 are widely known concepts, have not been widely adopted. On the way, physical device data connectivity can increase information flow to add efficiency, eliminate errors and increase uptime.

oday’s manufacturing industry looks vastly different than it did decades ago and rapid technological change has reshaped what’s possible. As smartphones have replaced clipboards, the day-to-day work of manufacturing has evolved to include Big Data and real-time automation. The workforce is changing, too, and companies have their sights on very different goals. So how did manufacturing get to where it is today? And what does tomorrow hold?

The data revolution, reliability

Traditionally, manufacturing companies struggled with incomplete and manual processes. A few highvalue assets garnered all the attention. Measurements never made it into the system of record, or the data collection required specific and expensive expertise. With the Industrial Internet of Things (IIoT), data collection and data analysis have been transformed. What would have required hours of expert analysis can be done by a computer in a fraction of the time. Automation gives us more data with less effort, gives us context for the data and turns the data into actionable insights. In a reactive environment, failures required teams to call in experts. That much-needed expertise drove up maintenance costs and extended downtime. With the introduction of smart tools, maintenance teams can handle the initial screening themselves, resolving many common equipment problems prior to failure and avoiding shutdown and external fees. Because of the advancements of Industry 4.0 and smart technology, operators and technicians are doing more in-house work. As tools have become smarter, they’ve also become multifunctional and less expensive. As electronics continue to evolve, the possibilities for industrial test and measurement will keep expanding. While the concept of reliability has been around for 30 or 40 years, smart technology has made it attainable for businesses of every size. Many manufacturing companies have been operating run-to-failure maintenance for decades. But more companies are

www.controleng.com

seeing a better path forward and embracing that being competitive means adopting new ideas. This means retraining personnel and using data insights to gain an edge. Reliability used to be considered a nice-to-have concept. Maintenance teams and management would say, “Reliability would be great if we had the resources or time.” The practice seemed limited to big companies where either downtime or assets were very expensive — top-tier machinery that would require a million-dollar fix needed sensors and telemetry to keep it healthy. Today, even small companies are adopting a reliability strategy to stay competitive. A plant that runs smoothly and efficiently is more profitable and can better recruit new talent.

Changing demographics

As team members with decades of specialized experience have retired, many manufacturing companies have had to deal with a loss of knowledge. It can be difficult to hire replacements at a similar level of expertise. The resulting skills gap poses a significant obstacle to the adoption of predictive maintenance practices. The good news is new hires are often more computer savvy. Digital natives are quick to learn automated data gathering, data manipulation, dashboard creation and real-time analysis. In the past, maintenance teams focused on troubleshooting and scheduled maintenance rounds. When an asset failed, the goal was to get it back up and running as soon as possible. Today, the goal is to get ahead of potential issues and predict impending faults. This means team members have to be more cross-functional and interdependent. There control engineering

COVER: Leveraging mobile-enabled maintenance technologies allows teams to stay more connected than ever. Maintenance and reliability professionals can view the data they need to finish the job right the first time. It also keeps them out of dangerous areas, such as arc-flash zones. Courtesy:

September 2019

•

ANSWERS

AUTOMATION FUTURE

While traditional maintenance teams completed manual routes, organizations that capitalize on modern technologies can stream asset data to the cloud. By eliminating manual measurements, personnel can attend to needed repairs and the ever-expanding backlog of work orders. Courtesy: Fluke Corp.

is more to this type of work than replacing bearings, seals, couplings and belts based on a calendar cadence. The digital transformation has made it possible to find the root cause early and keep machines running better and longer. Teams can reduce spending by monitoring conditional change and getting the full life out of each part. The transition from 100% reactive maintenance to planned maintenance or condition-based maintenance doesn’t happen overnight. Successful companies start by using small pilot programs and grow by proving success on a small scale to get buy-in based on results. The right tools integrated into a user-friendly system can track and trend data to detect problems before they cause downtime. By maximizing uptime and production, maintenance has become a strategic entity that impacts profitability and adds value to a manufacturing business. IIoT and Industry 4.0 are widely-known concepts though have not been widely adopted. Data connectivity in physical devices that can communicate with each other, and be remotely monitored, has business value. Work processes can become more efficient,

data entry errors are minimized or eliminated, and uptime increases while failures decrease. Data properly collected and leveraged provides critical insights and makes it possible to act at the most convenient times. Tools such as computerized maintenance management software eliminate the data silos by giving teams needed information at their fingertips. Paying attention to more than the bottom line creates business value. ce John Bernet is mechanical application and product specialist, Fluke Corp. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com.

M More ANSWERS

KEYWORDS: IIoT, data analytics, smart maintenance Information enables predictive maintenance. Pilot projects can show Industry 4.0 and IIoT benefits. CONSIDER THIS What could help your processes flow more smoothly?

ONLINE Click on the digital edition headline for more resources. www.controleng.com/magazine www.controleng.com/iiot-industrie-4-0

AZ Series )XAQHCÉ$NMSQNKÉ4XRSDLR

AZ 6HULHV )DPLO\ RI 3URGXFWV

Rack & Pinion Systems

1RZ :LWK

Compact Electric Cylinders

Electric Actuators

Rotary Actuators

Open loop performance. Closed loop control. input #13 at www.controleng.com/information

EtherNet/IP is a registered trademark of ODVA, Inc.

orientalmotor.com sales@orientalmotor.com 800-468-3982

ANSWERS

AUTOMATION FUTURE Stone Shi, Control Engineering China

Digital twins, engineering future automation Rapid growth of data collection make rapid expansion of digital twins more likely to add automation, supply chain efficiencies and optimization.

any enterprises today are talking about the concept of “digital twins.” Among them, the enterprises engaged in digital solutions such as product lifecycle management (PLM) tend to be the leaders and extend it into automation. Some people even say digital twins are an indispensable form of technology for Industrial Internet of Things (IIoT) applications. In addition to the value everyone delights in talking about, what is the extended value of digital twins?

Value from digital twins

Digital twins can enable the mass data flow brought by the IIoT in the future to remain efficient, orderly and secure in the process of integration, exchange and transfer. Admittedly, in the IIoT era, with the further popularization of low-energy consumption micro-sensor, 5G and other applications, people will be able to collect many kinds of physical data in real time. Economic efficiency and simulation of building the digital world also will be improved. But such progress does not mean that there is no need to consider cost, bandwidth and orderliness for Big Data transmission in the IIoT era. Previously, in many depictions of the IIoT future, people tend to assume data will be freely and directly exchanged between two or more objects. However, in a real and specific application scenario, it is more likely these data exchanges will take place between the “twins” of these objects in the digital world or among various information platforms, without the need for “direct dialogue.”

Application examples

Automobile enterprise service departments and even traffic management departments need to retrieve relevant data of a vehicle for their respective needs, it’s not hard to imagine they won’t need to call data directly from a vehicle sensor each time, but just need to read the specified data from the digital twin, which represents an accurate state of the real vehicle. This greatly reduces the repeated collection and transmission of data, thus reducing burdens to the system and protocol, as well as cost.

www.controleng.com

Substantial transformation

Extending this scenario to industrial situations with larger data volume, improvements will be substantial. Taking digital twins as the only interface for the exchange of data between real commodities, equipment, production lines and the outside world is also conducive to the effective setting and management of the access to data reading and application. Even today, digital twins is a concept mainly restricted to specialized fields. In the IIoT era, when Big Data is on the explosive increase, use of digital twins expand beyond management personnel and technical professionals. With a more user-friendly and customizable interface, it will transform the mode that goods, equipment and projects are delivered and served by enabling ordinary users to enjoy value from it.

Dual delivery: physical, digital

In the future, from ordinary consumers to professional industry users, extra value from data collection and analysis will be more important than just focusing on physical-world deliverables. Dual delivery in the physical and digital worlds will become a normal state, allowing users to develop limitless potential of the easy-to-operate and easyto-extend digital twins. Combined with the development of assistive technologies such as augmented reality (AR), such potential will be doubled and redoubled. For professional users, this means they can organize synergies and optimize business processes and production processes more quickly. For ordinary consumers, they can obtain diversified functions and experience from digital twins. Even if consumers don’t have to operate digital twins directly, this change also is expected to improve after-sales service and other aspects. Let us expect these scenarios to become reality as soon as possible. ce

Stone Shi is executive editor-in-chief, Control Engineering China. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com. control engineering

M More ANSWERS KEYWORDS: Future of

digital twin, digitalization, Big Data Accelerated use of digital twins seems like as more data is collected in the product lifecycle. Industrial benefits for digital twins will be driven by optimization potential. Delivery of physical and digital products will become common.

CONSIDER THIS How can accelerated adoption of digital twins deliver competitive advantages?

ONLINE www.cechina.cn www.controleng.com/ international

September 2019

•

ANSWERS

AUTOMATION FUTURE Lisa Richter, Control System Integrators Association

Improvement by association: engineers collaborate on best practices At the core of Control System Integrators Association (CSIA) are people willing to share experiences and best practices to help each other succeed with business skills and technologies for control system integration. EDITOR’S NOTE: Some of the best attributes of humanity can be seen in a roomful of engineers openly helping and learning from each other, rather than regarding others with distrust and suspicion. This case study in collaboration shows how associations can create a brighter future by integrating knowledge and cooperation.

M More

ANSWERS

KEYWORDS: System

integrators, best practices, association case study Associations can help members share knowledge to build a better future. CSIA marked 25 years of sharing system integration best practices in 2019. System integrators can help with digital transformation.

CONSIDER THIS What would you have rather learned from someone else, rather than having experienced it yourself?

ONLINE Online version of this article has more information. CSIA provides more about its founding, including sources for info cited at www.controlsys.org/ about/history. Control Engineering provides more information on system integration topics at www.controleng.com/ system-integration.

•

September 2019

n 2019, the Control System Integrators Association (CSIA) celebrated a quarter of a century and came full circle when it returned to North Carolina 25 years later, April 29 through May 3, for its Executive Conference. The event, which drew more than 530 attendees globally, offered education and networking in formal and informal settings to help system integrators (SIs) stay current, grow their businesses and prepare for the future. It also offered the opportunity to celebrate the 25th anniversary of its founding with an opportunity to reflect on its humble beginnings.

Steve Jobs of the CSIA

Originally known as systems houses or simply integrators, control system integrators emerged as an independent profession in the 1960s, when computers first arrived on the factory floors and inside industrial control houses. The people who developed the expertise to program and connect the technology that heralded a new industrial revolution came from various academic and professional lineages; no one forum existed for members of this emerging profession.

control engineering

Charlie Bergman, a retired engineer, recognized the emergence of the control system integrator as an independent profession and began publishing a four-page newsletter in 1989. It supported this emerging profession by publishing information on how to run a successful business. Subscribers could benchmark their progress by sharing sales trends and other key statistics.

Foundational values

Less than 5 years later, 25 of Bergman’s readers met at the Shell Island Resort, a small hotel in Wrightsville Beach, N.C. Many were skeptical about consorting with competitors and potentially giving away their secret sauce. But instead of finding a you-can’t-touch-this mentality, these pioneers discovered a culture of sharing and support. “Most of us were guarded, at best,” said CSIA co-founder Jamie Jordan, now president of Stravicom Global Inc., a professional services firm in Charleston, S.C. “But Charlie encouraged us by telling us that those who share with others will be strengthened and will also strengthen the industry.” Co-founder Robert Zeigenfuse, president of Avanceon, in Exton, Pa., agreed. “Charlie established, with his now infamous pitch, ‘Share one idea and get 10 in return and save $50,000 of consulting,’” he said. “He [Bergman] established the norm of unselfishly sharing of business practices. This alone sets our organization and industry apart from all others I have seen.”

Sharing ideas, lessons

Profits from the first meeting seeded the second conference in 1994, where attendees voted to form the association as an affiliate of the National Elecwww.controleng.com

The Hot Stove panel at the 2019 CSIA Executive Conference included (left to right) Mark Voigtmann, partner, Faegre Baker Daniels; Nigel James, president, Burrow Global Services; Adrian Fahey, CEO, Sage Automation; and Ray Bachelor, chair, Bachelor Controls. Those involved share experiences no one should repeat, like sitting on a hot stove. Courtesy: Control System Integrators Association

trical Manufacturers Association (NEMA), which would eventually become the standalone CSIA. Since then, the association has grown from a small group of early adopters to its current size of more than 500 member companies in 35 countries. The association also has expanded on its core competency of exchanging ideas, solutions and lessons learned to create additional member benefits such as a Best Practices and Benchmarking Manual, certification and continuing education, and insurance and legal programs specific to system integrators. From Bergman’s vision came the defining concept of the future of CSIA: Sharing knowledge, best practices and key performance indicators (KPIs) to advance the success of all SIs. Co-founder Pat Miller, chair, Engineered Energy Solutions Inc., Somerville, N.J., who was instrumental in organizing the earliest efforts, recalled: “Charlie told us to share ideas with one another, and it would come back tenfold.” But the conference was not all spent in the past. In fact, it provided the perfect opportunity to also focus on going forward. “To keep the association relevant, we have been working with the next generation of leaders,” said Jose Rivera, CSIA CEO. “As we have been doing at recent conferences, a lunch was organized to allow this group to get to know each other better. Professional speaker Lisa Ryan shared her advice regarding onboarding younger generations. In addition, a panel of SI company owners provided career guidance to future leaders.” The association continues to look ahead with the theme of the 2020 Executive Conference: “Claiming the Role of the SI in the Digital Transformation.” In addition, CSIA has formed a task force to tackle this emerging trend and help its members prepare for the future. “This task force is to figure out if industrial automation SIs have a role to play in the digital transformation beyond their traditional role of technology implementation,” Rivera said. “If so, what is this role, and what do SIs need to do to prepare for this emerging opportunity?” ce www.controleng.com

Lisa Richter, industry director for the Control System Integrators Association in Oakbrook Terrace, Ill. CSIA, which is a CFE Media and Technology content partner and global, nonprofit professional association with a mission to advance the practice of control system integration to benefit members and its clients. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media, mhoske@cfemedia.com.

According to Charlie Bergman... CONTEMPORARIES of Charlie Bergman describe him as a “visionary,” “pioneer,” “thought leader.” In the same breath, they describe him as intelligent, persistent, opinionated, even “cantankerous.” It’s difficult to say which of these described traits he would have considered most flattering. But all would agree, he had a way with words. Here are some of the more notable quotables: • “If you’re not keeping score, you’re only practicing.” • “Competition is good and will take you to higher profits.” • “Pricing professional services is not for amateurs.” • “Once users’ needs are met, wants explode.” • “People do business with those they like.”

How CSIA helps FROM THE OUTSET, the common thread throughout CSIA’s activities has been to raise the bar of knowledge and performance for those involved. To that end, CSIA is committed to: • Improving the business skills of its members • Helping integration firms of all sizes, engineering specialties, product experience and industry knowledge share their collective business wisdom to help control their individual destinies • Providing a forum to discuss common business issues • Enhancing the professionalism of independent control and information system integrators • Communicating the resulting benefits to the broad business community.

control engineering

September 2019

•

ANSWERS

MOBILE HMI

Jonathan Griffith, AutomationDirect

HMI remote-access options Among mobile human-machine interface connections, seek more cybersecurity.

obile human-machine interface (HMI) access is a necessity for many industrial automation applications, and two typical methods exist to implement this connectivity with routers and virtual private networks (VPNs): A standard router without VPN and a cloud-hosted VPN router. The first is a standard router, and although it is not secure, it is still used in many existing mobile HMI applications, and even in some newer ones. A primary attraction is its low cost, but this approach is discouraged because it poses significant cybersecurity risks when port forwarding is enabled in the firewall as this exposes the network to external threats. A cloud-hosted VPN router simplifies information technology (IT) complexity by creating an encrypted connection from a local VPN router to a cloud-hosted VPN router via the internet. Remote users can securely access the local components and systems via the cloud-hosted VPN router. This lowers cybersecurity risk and eases configuration and maintenance. A third type of router connectivity with a traditional VPN router implementation is not considered here because it involves opening inbound connections and creates complications and risks similar to a standard router implementation.

M More ANSWERS

KEYWORDS: Mobile HMI,

secure VPN monitoring Options for mobile HMI access include a standard router, cloudbased VPN router, or creating inbound connections. Security needs to be considered. Simpler options have advantages.

CONSIDER THIS Could more mobile HMI access help you do your job better?

ONLINE If reading from the digital edition, click on the headline for more including table comparison of remote access HMI connections. www.controleng.com/magazine www.controleng.com/ info-management/hmi-oi

•

September 2019

Standard router

In many industrial applications a standard router and firewall is used to protect the corporate and industrial plant network, requiring users to manually configure and manage all routing and firewall settings. This type of router does not usually have a VPN to encrypt data, but it creates port forwarding “holes” in the firewall for remote users to access specific applications and components in the plant network. Most HMI users want remote and local access. Laptops normally connect to the HMI web server for monitoring data and making changes to setpoints and other parameters, or they connect to the HMI with programming software to troubleshoot or make program changes. To connect remotely using a standard router, port forwarding is usually configured to allow access to the HMI, or to a local PC running remote access software.

control engineering

The local PC provides the remote user with the ability to run the HMI programming software. HMI mobile apps also require port forwarding so the remote user can access the local HMI for control or viewing data. These apps usually provide the same functionality as browser-based remote access, but via an app rather than a browser. The main concern with this approach is the security risk associated with port forwarding in mobile and PC-based applications. It’s easy for a hacker to determine which ports are open on a firewall, and gain access to the corporate or plant network via the router. While port forwarding can be extremely efficient and useful when done within a corporate or plant network, it is extremely dangerous to use this functionality at an internet-corporate interface. Organizations should avoid this router approach for new installations and should convert existing standard router installations to a more secure connection such as a cloud-hosted VPN router instead.

Cloud-hosted VPN router

Cloud-hosted VPNs provide a secure connection with simple setup and network configuration. Typical cloud-hosted VPN options include a local VPN router, a cloud-hosted VPN server, a VPN client and connected automation components (Figure 1). A secure connection is established after the local router (at the plant/controls network) and VPN client (software installed at the user’s laptop or mobile device) each make a connection to the cloud-hosted VPN server. The local router makes this connection immediately upon startup, but a VPN client only connects upon a verified request from a remote user. Once both connections have been made, all data passing through this VPN tunnel is secure. Most cloud-hosted VPNs provide a free monthly bandwidth allocation for basic operation and then throttle data access once this allocation is reached, and also offer a premium plan for additional bandwidth. For example, one product offers 5GB of free VPN data exchange per month, sufficient for most troubleshooting, monitoring and programming needs. Security risk is reduced when the local router initiates communication to the server via an outbound connection through standard open ports, such as HTTPS. This usually avoids changes to the corporate IT firewall and satisfies IT security concerns. To add confidence, users can look for cloud-hosted VPNs that have an industry-certified information security managewww.controleng.com

ment system such as ISO/IEC 27001:2013. This indicates the supplier has implemented comprehensive security programs and controls. Another advantage of a cloud-hosted VPN is simple router configuration. Since the secure local router will be connected to a predefined cloud server, the router comes preconfigured with complicated VPN networking settings in place, allowing non-IT staff to install it. All that’s required is knowing the IP addresses of the automation components connected to the local area network and if the internet service provider (ISP) or corporate-wide area network router (not the cloud-hosted VPN router) provides IP addresses dynamically or statically. Other advanced options may include cloud data logging and alarm notification, which provides a subset of HMI functionality and also is easier to use than custom programming. These services allow users to log system data and receive customized critical alarms on their mobile devices or laptops, providing a convenient, web-based historical record of system performance available when needed.

Mobile app-based remote access

Industrial HMI and programmable logic controller (PLC) components are increasingly supported with mobile apps. This provides users with remote access anytime from anywhere, with monitoring and control capabilities. To securely access industrial equipment, the mobile device must also employ VPN technology to encrypt the data from the mobile device to the plant network. Without mobile VPN, the firewall ports at the plant will need to be opened, creating a similar scenario to the standard router and leaving the plant network vulnerable to a cyberattack. Using a hosted VPN provides a secure VPN connection for laptops and mobile devices; the latter is via a fully supported mobile application with VPN. Once securely connected to the plant network through the mobile VPN app, the third-party HMI or PLC app can then be opened and connected to the local HMI and PLC components as if the mobile user was on-site, because the user is there virtually. Some routers provide a hosted VPN with connections for laptops and mobile devices. Apple iOS and Google Android mobile device apps provide users with a secure plant network connection. Some cloud-hosted VPN vendors also provide app-based access to data logging software running in the cloud, along with widgets for configuring customized dashboards to be viewed remotely (Figure 2). This built-in cloud logging could be particularly effective for an original equipment manufacturing (OEM) machine builder with thousands of machines installed worldwide at hundreds of locations, each with multiple users. The OEM would provide a VPN router for each machine, pre-configured to log data and including customized dashboards for remote viewing on the mobile app. No effort would be required by the OEM’s customers to

www.controleng.com

Figure 1: AutomationDirect’s StrideLinx cloud-hosted VPN offers secure connectivity for mobile HMI applications hosted on laptops, smartphones and tablets. Images courtesy: AutomationDirect Figure 2: AutomationDirect’s C-more HMI mobile app works securely when used with the secure StrideLinx VPN router. It’s also available for Google Android.

configure, install or maintain remote access software — other than installing an app on a smartphone or tablet. For more comprehensive access beyond dashboards, remote users could access local HMIs and PLCs via apps using the mobile VPN from the hosted VPN supplier. Some mobile HMI software works securely when used with a supplier-specific VPN router. Local equipment also could be securely accessed remotely by a PC for programming, monitoring or troubleshooting. ce Jonathan Griffith is product manager for industrial communications and power supplies at AutomationDirect. Edited by Mark T. Hoske, content manager, Control Engineering, mhoske@cfemedia.com. control engineering

September 2019

•

ANSWERS

MOBILE HMI

Daymon Thompson, Beckhoff Automation

New mobile HMI designs respond to user, device needs HMI software should mix elements of web design and controls engineering to create effective operator interfaces for industrial displays and mobile devices of all sizes.

s mobile devices are more commonly used to manage industrial operations, web-based options for human-machine interfaces (HMIs) continue to grow. Flexible operator interfaces based on HTML5 and JavaScript enable access from ruggedized industrial tablets and consumer technologies, including wearables, smartphones and tablets from any manufacturer. Recent HMI software advances provide the ability to create responsive, web-based operator interfaces with multi-touch for intuitive operation. Although this software relies on information technology (IT) design standards, it also must be reliable from an industrial standpoint. In addition, these HMIs operate and monitor multivendor architectures that require special connectivity measures. For many years, engineers integrated HMI solely for control panels inside factoKEYWORDS: humanries. When using mobile devices became a machine interface, mobile possibility, the interfaces, at first, were crude HMI interpretations of screens with some alarms Mobile human-machine interface (HMI) technology and notifications from the plant floor. Multican take advantage of touch functionality on an industrial display HTML5 and CSS to create was a pipe dream. more interactive interfaces Mobile-first design strategies are imporfor users. tant for ensuring the HMI is ready for smartResponsive HMI phones, tablets and the like. Above all, it is components can speed up the design process for users. important to consider HMI as a responsive Mobile HMI allows users to operations tool rather than a series of pages; complete tasks off-site with a software should leverage the mobile devices secure connection. power and ease of use..

M More ANSWERS

ONLINE

Read this article at www.controleng.com for links to additional stories from the author on topics such as machine design and data acquisition strategies.

CONSIDER THIS What mobile HMI features would help your plant the most?

•

September 2019

Responsive HMI designs

The term responsive means content on HMI screens should adapt different layouts based on the screen’s specifications. This is particularly true for mobile devices. It is difficult displaying a lot of text and graphics on smaller screens. Fingers are much less precise navigation tools than a computer mouse or keyboard. Designing HMIs as dynamic syscontrol engineering

tems with reusable components and themes, rather than static pages built from scratch every time, allows engineers to create responsive interfaces that adapt to each user’s screen size and device type. These concerns should be considered during the design phase, rather than after the design for the “standard” HMI screen has already been finished. It’s also possible to harmonize the mobile touch interface with the industrial displays by selecting control panels and panel PCs that integrate multi-touch functionality. When evaluating HMI software, engineers should ensure platforms support all of these capabilities for industrial and mobile screens. Responsive content begins with dividing the screen’s layout into blocks that can automatically reorient depending on screen width. For example, four content blocks may display all at once on a computer monitor or mid-size industrial control panel. On a smartphone, however, they should stack on top of each other, allowing the user to see one at a time while scrolling down. Similarly, a menu bar across the top of a wider screen should automatically convert into a dropdown menu icon on a tablet, which is referred to as a hamburger button in mobile interface design. This does not reduce the amount of content or functionality available. Instead, it makes the content more digestible based on the hardware used. These principles are familiar to web designers, but for controls engineers, they may not be as apparent.

Familiar programming environments

While larger companies may have user experience (UX) teams dedicated to mobile interface creation, many factories and machine builder original equipment manufacturers (OEMs) rely on a group of controls engineers for these upgrades. Rather than requiring engineers to learn a new programming environment, some HMI software supports programming via familiar platforms such as the automation software. This means controls engineers have a shorter www.controleng.com

Multi-client

HMI software should support programming in a graphical editor familiar to controls engineers, such as Microsoft Visual Studio, and offer standard tools to implement CSS themes and build additional programs with APIs. All images courtesy: Beckhoff Automation

learning curve when programming HMIs, in part, because they can manage all machine code and projects in the same place. Graphical editors should allow engineers to build responsive, HTML5 and JavaScript-based HMIs with the same toolset and programming environment used for the machine control programming. They should also provide a toolbox stocked with premade interface components to cover common elements such as buttons, dials, sliders and menu layouts. Having reusable HMI control components accelerates the design process. This includes various buttons and alarms that perform the same function throughout the system. Engineers also should select software that supports themes for Cascading Style Sheets (CSS) to build new pages without having to create new style parameters for each object. With some software packages, CSS is generated based on theme designs and works in the background to enable faster implementation. For example, colors and styles for alarms, content blocks or body text automatically apply to new pages. If a specific style requires adjustments or updates, these happen in a central location and take effect across the platform. HMI software also should be extensible. If preset controls cannot be customized enough for specific tasks, then the software should provide an integrated application programming interface (API). Some HMI software allows users to create objects once and store them as reusable extensions to the HMI software for future use. This capability enables engineers to create whatever program they require in C# that can talk to a piece of hardware, another API, an obsolete database, or a custom protocol as long as there is a server connection.

HMI servers, real-world connectivity

Mobile HMI allows operators to complete plantfloor tasks onsite or offsite via a web browser and

www.controleng.com

a secure connection. However, to enable this capability for multi-client, multi-server and multi-runtime concepts, an HMI server must support powerful architectures. Some software supports servers on local devices or in the cloud. As a result, client devices can use communication protocols, such as OPC UA, automation device specification (ADS) or ADS over message queuing telemetry transport (MQTT), ensuring reliable and secure data transmission between devices and the server. With data binding, engineers can link specific controls in the HMI to field devices. To avoid issues from communicating through multiple servers and technologies, some software packages make connections from virtual buttons on the HMI to actual functions in the programmable logic controller (PLC) via OPC UA, as an adopted protocol for its vendor independence and built-in security mechanisms. These connections are represented in a treebrowsing menu, which allows users either to browse the memory of the control device or to browse the namespace of an OPC-enabled device. While many HMI platforms require users to complete the timeconsuming process of mapping these connections upfront, others perform this function in the background for faster configuration and programming. From server architectures to responsive designs, effective mobile HMIs ensure engineers can interface with real systems in an intuitive manner. This capability is extremely important if systems require remote troubleshooting or data access. Mobile HMI has the power to modernize many applications and provide access to live production data anywhere. Because HMI performs such crucial functions, engineers must design and implement it with reliable software that values controls engineering and user experience design best practices. ce

HMI servers should support multi-client, multi-server and multiruntime concepts, providing options for local or cloud-based servers and secure communication protocols, such as OPC Unified Architecture, Automation Device Specification or ADS over MQTT (message queuing telemetry transport).

Daymon Thompson is automation product manager â&#x20AC;&#x201D; North America, Beckhoff Automation. Edited by Chris Vavra, production editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com. control engineering

September 2019

â&#x20AC;˘

ANSWERS

MOBILE HMI

Mariana Dionisio and Danny Strinden, Emerson

Mobile HMI strategy helps digital transformation Leveraging a mobile human-machine interface (HMI) strategy can help an organization’s digital transformation by improving operations and a company’s overall digital intelligence.

he prospect of a digital transformation journey for an organization can be daunting, but a shortcut might be near. A mobile-friendly environment with an intuitive human-machine interface (HMI) can help advance an organization’s digital transformation by expanding digital intelligence throughout the workforce and improving operations. By using familiar mobile devices such as phones and tablets (Figure 1) to securely access important process information including displays, alarms, real-time values and historical trends, organizations can create new efficiencies and competencies. This brings positive cultural and behavioral changes. Organizations also can leverage a mobile HMI strategy to foster additional competencies related to digital transformation, such as decision support and continuous situational awareness. KEYWORDS: human-machine

M More ANSWERS

interface, HMI, process control system, PCS Mobile human-machine interface (HMI) technology can help companies improve their digital transformation. Giving operations secure information on their mobile devices can improve their response to abnormal situations. Mobile HMI technology also can improve collaboration by letting users share real-time information with one another.

ONLINE Read this article online at www.controleng.com for more information about mobile HMIs on the plant floor.

CONSIDER THIS What immediate benefits could a mobile HMI strategy provide to your company?

•

September 2019

Simple information access

Simple, read-only mobile access to process information and displays from an HMI control system can quickly progress organizations on a digital transformation journey by helping to extend a secure architecture in a way that will continue to be useful. Since mobile connectivity is now nearly ubiquitous, extending mobility and enabling users to access plant process data is a natural progression. This access can be achieved by adding a digital layer to existing systems. This allows organizations to leverage current mobile devices and wireless or cellular networks to securely access and share critical process information. Mobile software natively integrated with process control systems (PCSs) offer additional benefits including a

control engineering

cybersecurity architecture that supports network and information security. Adding native, readonly mobile access to a PCS within an organization’s existing secure mobile environment delivers the process information personnel need, wherever and whenever they need it. An enterprise also will continue leveraging its established architecture as it continues implementing further digital transformation initiatives.

Extend access, widen understanding

Since mobile access is implemented as a digital layer on top of the PCS, mobile HMI software needs to aggregate information from multiple sources, allowing personnel access to data across the enterprise. Mobile HMI design tools need to distill a torrent of data from throughout the enterprise into a stream of actionable information relevant to each person’s role. These tools should be tailored to prevent personnel from failing to make the right decisions due to data overload. As an organization’s digital transformation evolves, the amount of available process and enterprise data will increase over time; so will the need to turn large amounts of data into information. Mobile HMIs also may include tools that help limit which information personnel have permission to access. In this case, mobile software natively integrated with the PCS may take advantage of existing data access permissions, and additional limitations or security extensions can be designed for the mobile HMI software.

Digital transformation competencies

A digitally transformed organization will be able to gather, filter, and analyze more data. The organization can turn it into actionable information specific to each role. By leveraging existing systems and architecture, and by adding secure, read-only mobile access, organizations can create new effiwww.controleng.com

ciencies and build competencies resulting in positive cultural and behavioral changes as well as operational improvements. Situational awareness — Mobile access to critical process information provides enhanced situational awareness whether personnel are located next to the equipment, in the office or offsite. Increased awareness along with meaningful, intuitive visualization of data can assist in analysis and can drive accurate and more rapid decisions. Notifications can be received natively on mobile devices so people in any location can maintain visibility into process conditions and monitor abnormal situations. Rather than viewing numbers and interpreting them to build knowledge, mobile HMIs can display operator graphics, trends and other charts such as those shown in Figure 2. These types of visualization provide more information than the raw data by giving personnel a more qualitative, intuitive and holistic picture of a company’s operations. Decision support — Personnel can use decisionsupport tools and analytics with mobile devices for faster and higher-quality decisions. A mobile HMI can aggregate and present the data on screens that are easy to understand, enabling personnel to make informed decisions based on operational data from across the enterprise. Key performance indicators (KPIs) are measurements of enterprise performance that provide valuable decision support and are commonly calculated from data aggregated from multiple sources. A mobile platform capable of securely displaying KPIs can be especially valuable for delivering this knowledge to personnel outside of the control room. Mobile users have, for example, found success in monitoring and addressing environmental KPIs that have exceeded targets. By having immediate mobile access to this information, operators can quickly deliver information to management. This lets operators handle decision-making processes involving multiple data sources to better manage the process and their environmental limits. In addition, mobile devices provide analytics to personnel so they can frame plans and respond to an abnormal situation no matter where they are. Personnel also have the flexibility to access additional data and go deeper into analyses as needed.

Team, enterprise collaboration

Using a mobile HMI strategy to provide continuous situational awareness and improved decision support can enhance collaboration and act as a catalyst for digital transformation. Through a natively integrated mobile HMI, personnel will use the same operator displays, alarms, trends, and other charts to collaborate and troubleshoot issues. These HMI elements provide a common language among operators, engineers, managers and technicians.

www.controleng.com

Figure 1: Intuitive mobile HMIs allow an organization to take advantage of positive cultural and behavioral changes related to digital transformation, in part by leveraging the same screens and information as operators use in the control room. Images courtesy: Emerson

For example, an international organization revealed one of its biggest operational challenges was clear communication among field operators and control room operators. By taking advantage of a natively integrated mobile HMI, the field operators and control room operators were able to collaborate by using a shared language. This improved efficiency and reduced the potential for safety incidents. This common HMI language in a mobile environment will help foster a collaborative cultural change within an organization. Using a mobile HMI, the enterprise will marshal resources around the same information and act as a team to collaborate on problems and make decisions based on collective knowledge. Today, organizations can build their knowledge base and encourage faster and more informed decisions based on secure mobile access to up-to-the-minute conditions. This process intelligence is empowered by mobile and intuitive HMIs. Organizations can take advantage of existing networks to extend knowledge to roles in any location, with instant information access that may have once been limited to control systems. Implementing mobile access to process information with intuitive HMIs provides an organization with an easy win that helps set the stage technically and culturally for future digital transformation efforts. ce

Figure 2: This radar-plot display increases situational awareness and allows the user to quickly see if a KPI value is deviating. In this example, the cooling water demand is starting increase.

Mariana Dionisio and Danny Strinden are DeltaV product managers, Emerson. Edited by Chris Vavra, production editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com. control engineering

September 2019

•

ANSWERS

MOBILE HMI AND SCADA Travis Cox, Inductive Automation

Using web browsers for HMI, SCADA applications New capabilities in mobile-responsive design make human-machine interfaces (HMIs) and supervisory control and data acquisition (SCADA) applications more valuable on the plant floor.

mazing technology is at our fingertips today with HTML5 and CSS3 and native apps for phones and tablets. The adoption of mobile devices have taken over desktops as the preferred computing medium. Think of all the incredible applications leveraged daily; what if these were possible with a humanmachine interface/supervisory control and data acquisition (HMI/SCADA) application? Well, they are. Web browsers and web technology are mature enough for the industrial sector, and these improvements call for a new approach to HMI/SCADA. With the powerful tools, web technologies and next-generation visualization system in modern HMI/SCADA applications, users can build industrial applications that automatically respond to a unique situation. Modern tools also can mobilize the power of the plant floor by empowering the user to create beautiful, mobile-responsive industrial applications that run natively on KEYWORDS: HMI, SCADA, any mobile device and web browser. mobile devices Using a modern web browser proModern web browsers and vides access to an HMI/SCADA applidevelopments make HMI/SCADA cation anywhere without plugins. Users applications user-friendly for plant can get access to Google applications on floor applications. any device that supports a modern web Mobile-responsive design browser. The same can be true for HMI/ allows users to take information with them on the plant floor. SCADA applications. This is possible Security is a major concern for because of HTML5 and CSS3 and native HMI/SCADA applications being apps for phones and tablets. used on the plant floor. HTML5 is the fifth release for the ONLINE Hypertext Markup Language and is used Read this article online at to define and structure content on web www.controleng.com for pages. All web pages have implemented additional stories from the HTML in one way or another. CSS stands author on topics such as edge for Cascading Style Sheets, and CSS3 is computing and upgrading hardware and software systems. its latest release. CSS revolutionized how to define the layout of webpages, most CONSIDER THIS of which were built on HTML. CSS3 has What is the biggest obstacle to some advanced styling capabilities and can expanding mobile device use on your plant floor? be made responsive using media queries.

M More ANSWERS

•

September 2019

control engineering

This means such web pages have an optimized look for different screen sizes and resolutions.

New industrial mobile possibilities

These mature technologies provide many possibilities for HMI/SCADA applications including: • URL-friendly • Custom navigation • Powerful web components • Gestures and multi-touch • Mobile-responsive design • Styling • Federated identity: single sign-on (SSO) and two-factor authentication (2FA) • Native apps for Apple iOS and Google Android. Industrial web application designers need to control how users navigate and use applications. No two HMI/SCADA applications are the same so nothing can be pre-canned. Some applications have one screen. Others can navigate from one screen to another and drill into different sections or open popups for more detail. While navigating, a SCADA application should be URL-friendly and update the URL. Web applications work through URLs. They’re the addresses used to access various resources. Most of the time, they’re used to access a website on the internet. Users can copy the URL and send it to another user to get access to the same screen or resource without having to navigate to it. URLs also make it easy to understand where the user is in an application. Powerful user interface (UI) components are available for the web, and it’s easy to build components. People interact with these components a lot, and it’s easy to bring them into the HMI/ SCADA realm. Components such as powerful charts, menus, carousels, embedded maps and others support touch and gestures, such as swiping and multi-touch for zooming. They’re also mobilewww.controleng.com

responsive and designed to work well on desktops and smartphones. Mobile-responsive design is the most important feature with HTML5 and CSS3. It allows users to build one application that automatically changes to match the size of the screen, whether it’s a desktop, laptop, tablet, or phone. All modern websites are built with mobile-responsive design and present the same data but in different form factors based on the device. Users will get one view on a desktop with more detail — and a phone-optimized view on a smartphone. For example, if a user is looking at tabular data, they’ll get a traditional table with multiple columns on a desktop — but on a mobile device, there will be cards for each row. The table no longer shrinks down in the mobile device, losing column visibility. Every part of the HMI/SCADA could be built this way, which requires a new approach when thinking about the application. Building separate applications for mobile is a thing of the past. CSS provides styling for web pages. Users can develop style classes (objects) that are reusable and defined in one place. Styling can be for background colors, foreground colors, fonts, borders, and design elements. This allows users to switch the style on the fly or update parts of the style without having to go to each screen. Defining styles is an important part of HMI/SCADA development and ensures consistent styles across multiple applications. CSS3 also provides animation. An animated style class transitions through two or more style configurations over some period of time. For example, using an animated style class can be a powerful way to show data changes (such as an alarm state or machine state) on a component over time.

COVER inset: Modern web browsers are leveraged for new mobile capabilities and other capabilities in Ignition 8 from Inductive Automation. Images courtesy: Inductive Automation

Mobile-responsive design saves development time and seamlessly adjusts to screen size, as shown in Inductive Automation Ignition Perspective.

Securing SCADA systems Security is one of the most important parts of any HMI/SCADA application, especially as more users gain access. Most organizations already use several cloud applications, such as email, document sharing, and customer tracking. These applications use SSO with existing corporate credentials and allow access to all applications in one place. This is possible using trusted federated identity technologies, such as security assertion markup language (SAML) and OpenID Connect. It’s possible to use those technologies with SCADA. Instead of having shared accounts, each person can log in to securely gain access to data they need. These systems can verify identify through two-factor authentication (2FA), which requires credentials and an additional step like a PIN sent to their phone. Many organizations don’t allow SCADA applications on smartphones due to security concerns. Using this technology, however, allows users to get data from different applications effectively and securely. Smartphones also are incredible pieces of hardware technology. Smartphones have an amazing number of sensors built in such as GPS, camera, www.controleng.com

accelerometer, Bluetooth, and others. Applications can be made available to web browsers and smartphones at the same time. However, with smartphones, these applications can gain access to these sensors, which can unlock great opportunities. Imagine using the GPS to automatically switch to the appropriate screen as the user walks around the plant or by tagging their location when entering in data. Imagine being able to place barcodes in strategic areas users can scan to provide machine manuals, operating procedures, or other information. Imagine being able to take pictures or stream video of a process to a corporate support team for remote troubleshooting. Now is the time to leverage modern technologies in HMI/SCADA applications. And it’s never been easier. The possibilities are endless, and these technologies are available. ce Travis Cox is co-director of sales engineering at Inductive Automation. Edited by Chris Vavra, production editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com. CONTROL ENGINEERING

September 2019

•

ANSWERS

MOBILE HMI

Mark Howard, EU Automation

Mobile HMIs need to catch up

Mobile human-machine interfaces (HMIs) offer value, but may be overlooked because of cybersecurity and risk management issues.

hile most people might not consider it one, the ATM is a great example of a human-machine interface (HMI). By using a keypad, or a touchscreen, the user operates the machine and instructs it to dispense cash according to the amount requested. This is a secure process using a PIN, built-in cameras and communication with the global bank network. ATMs are going mobile, as is banking in general. Banking customers want “anytime anywhere” capabilities, and plant managers using HMIs want the same luxury. Mobile HMIs are readily available, but their adoption has been slow in some industrial sectors. Cybersecurity, risk management and coverage are some of the reasons cited to explain this hesitation. A fixed HMI in a plant bridges the gap between human and machine. Using supervisory control and data acquisition (SCADA) software, the HMI displays information on the pressure, temperature and process data to provide an overview of the present situation on the plant floor. HMIs have modernized in the last decade and now can control and monitor multiple machines at once to provide a complete overview of a production facility. Mobile HMIs — accessed on smartphones, tablets and other handheld KEYWORDS: Human-machine devices — allow operators to monitor perinterface, HMI, cybersecurity formance, production and problems from Mobile human-machine anywhere. Potential benefits can be outinterface (HMI) devices have evolved a lot in the last decade. weighed by perceived risks.

M More ANSWERS

While mobile HMIs have improved, concerns remain about cybersecurity and risk, slowing adoption. Remote monitoring and control enable insights.

ONLINE Read this article online at www.controleng.com for more information about HMIs and cybersecurity and their effect on the plant floor.

CONSIDER THIS What benefits derive from adopting mobile HMIs?

•

September 2019

Mobile HMI challenges

Cybersecurity is a concern for any connected device. This is especially true for a device that can be taken anywhere, connected to any Wi-Fi hub, or even lost on public transport. Challenges have been addressed in other industries, such as banking, representing a lost opportunity for users in industrial applications. Mobile HMIs could boost profits due to quicker reaction times and insights into factory performance. Cybersecurity always will be a con-

control engineering

HMIs can now control and monitor multiple machines, to provide an overview of a production facility. Courtesy: EU Automation

cern for business owners. Many of today’s SCADA software providers have stringent protection in place with data encryption, firewalls and consistent patch management. Out-of-the-box mobile devices don’t have the same software protection as dedicated hardwire systems, wireless cybersecurity can be added with the same protection as fixed systems. Risk management is another perceived challenge. Facility managers may envision machines being controlled by mobile devices any and everywhere. Meanwhile, the confused operator on the factory floor doesn’t have a clue why the machine isn’t performing like it should. However, mobile HMIs have incorporated enough safeguards to allow for affective unattended remote operation. For example, in-situ cameras can detect if someone is present and alert the remote user, preventing injury from remote operation. Safeguards also can ensure the remote worker is in close enough proximity to be aware of local hazards such as storms or floods. Because of this need to localize people, the use of user profiles is increasingly important. These profiles will incorporate location awareness to prevent someone from accidentally operating a plant from home on their mobile device, or worse — a child finding a fun “game” to play. HMIs have the cybersecurity and safeguards in place to catch up. Remote monitoring and control from a mobile HMI will enable better insight of facilities, quicker reactions to problems, and more dynamic control of the plant. They can help ensure bottleneck are prevented and output is maximized. ce Mark Howard is U.S. manager, EU Automation. Edited by Chris Vavra, production editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com. www.controleng.com

ANSWERS

ELECTRICAL CONTROL SAFETY Dave Durocher, Eaton

NFPA 70E standard changes to reduce electrical incidents Changes to the NFPA 70E standard will provide a better way to define risk assessment for energized work and reduce potential electrical incidents for workers.

orking on energized equipment is one of the more dangerous scenarios technicians face in the field. As a result, there’s been a concerted industry effort to improve the understanding of electrical shock and arc flash hazards. I believe one of the most important standards in this safety push is the restructured language within the 2018 edition of the National Fire Protection Agency (NFPA) 70E “Standard for Electrical Safety in the Workplace.” In the past, the standard addressed electrical hazards and risks holistically when considering energized electrical work. But today’s latest guidelines now identify hazards and risks independently and include recommendations for a thorough risk analysis that considers the hazard, the planned work task, and the potential human error. Together, the changes result in a clearer understanding of energized work and help reduce electrical incidents.

Understand the improvements

Just a few years ago, the standard was comprised of five “hazard-risk” categories that outlined the required personal protection equipment (PPE) a worker had to wear to reduce electrical arc flash exposure. But today’s version addresses hazard and risk separately, to help site managers and technicians better understand the dangers of energized work via a series of linear steps. All parties must understand “hazard” and “risk” for this process to work: • A hazard is the calculated heat energy at any given point of an electrical system and is used to determine the correct level of PPE. A hazard is either present or not present.

NOTE: This article originally appeared in December 2018 Plant Engineering, another CFE Media and Technology publication. www.controleng.com

• Risk is the combination of likelihood and severity of a potential injury while performing the work task. To further illustrate risk, consider an electrician at a manufacturing plant operating a circuitbreaker disconnect on a 480V low-voltage motor control center (MCC) with the enclosure door closed. The likelihood of a shock injury is near zero, with no exposure to energized conductors, and the likelihood of an arc flash event is extremely low. Now consider a task where the electrician is using a multi-meter to test phase voltages with the MCC enclosure door open. The hazard is the same, but the risk of electrical injury from shock hazard and arc flash is higher because the electrician is exposed to energized conductors.

Changes in the 2018 NFPA 70E Standard result in a clearer understanding of energized work and help reduce electrical incidents. Image courtesy: Eaton

Do a thorough risk analysis

NFPA 70E requires an exhaustive risk assessment before energized work begins—a great safety advancement. A risk assessment reviews electrical hazards, the planned work task, and the protective measures required to maintain an acceptable level control engineering

September 2019

•

ANSWERS

ELECTRICAL CONTROL SAFETY of risk. In practice, this means scheduling a workplan meeting to discuss and document issues for the task at hand, the tools required, maintenance history of the equipment, test records of the equipment requiring energized work, and the calculated amount of heat-energy exposure. The following summarizes the seven steps technicians should follow before performing energized work: 1. Characterize the hazard or the electrical process involved. 2. Identify the energized work to be performed. 3. Define failures that could result from exposure to electrical hazards and the potential for harm. 4. Assess the severity of the potential injury. 5. Determine the likelihood of the occurrence for every hazard. This includes consideration of the resulting impact of possible human error based on the planned work task, such as a tool dropped near energized conductors at a worker’s feet. 6. Define the level of risk for the associated hazard. 7. Wear appropriate PPE as determined during the hazard analysis. If the risk is too great, do not perform the energized task.

M More ANSWERS

KEYWORDS: Control panel safety, NFPA 70E NFPA 70E changes in 2018 include education about energized electrical work. Separate understanding of hazards and risks Consider the hazard, the planned work task, and the potential human error to help reduce electrical incidents. ONLINE With this article online, link to related articles.

CONSIDER THIS Are hazards adequately identified when the next energized control enclosure is opened is opened in your work area?

•

September 2019

The human factor

One new and important aspect of NFPA 70E’s prescribed risk analysis is the recognition of human error, as seen in step five, above. Per the standard, “Risk assessment procedures shall address the potential for human error and its negative consequences on people, processes, the work environment and equipment.” With that, standard users should not only look to have a detailed process for performing energized work, but also maintain some method of quantifying human error. In my opinion, accounting for error is an important addition to this evolving standard. To this end, some organizations require the issuance of energized work permits that account for the human element. This puts the onus on site leadership to double-check every detail before giving energized work the go-ahead, ensuring control engineering

an extra level of business accountability. If work involves unacceptable levels of hazard and/or risk, a decision to perform the work during a future planned outage can be made.

Lead on safety

NFPA 70E is an industry-consensus guide, not binding law, so it’s up to an individual business to choose to implement a site-specific electrical safety program. It’s important to note that industries do exist where turning off the power can lead to more severe problems. There are instances in the oil and gas industry, for example, where turning off the power can lead to a greater hazard than working on energized equipment. That said, I believe it’s in everyone’s best interest to wait for a planned future outage whenever possible instead of working on energized electrical equipment. Of course, leadership teams have the right to make their own choices. While one group may choose to issue energized work permits, another may skip that step, which is completely within its purview. However, organizations that forego work permits can pay a price. If someone is injured or killed during energized work, regulatory organizations such as OSHA or the Mine Safety and Health Administration (MSHA) may require an explanation as to how the work was allowed and ask for detailed safety program documentation, including a work permit. Beyond the standard, new technologies support recent trends of performing energized work outside a defined NFPA 70E flash-protection boundary. Site managers can look to network-connected devices, such as motor management relays, partial discharge on-line monitors, and motorized racking technologies, to gather the information they need to troubleshoot electrical systems without requiring workers to suit up and work on energized equipment.

To increase safety, follow NFPA 70E

While it’s always better to wait for a planned outage to work on electrical equipment, that’s not always an option. Should you need to perform energized work, be sure to identify the hazards and risks and complete a thorough risk analysis that considers all potential risks, including human error. With a clearer understanding of the consensus standards and maintenance/troubleshooting requirements of a defined energized task, you can do more to advance a safety culture at your site, helping to reduce the chances of shock and arc flash events in the future.

Dave Durocher is global mining, metal, and minerals industry manager for Eaton. ce www.controleng.com

ĂƵƚŽŵĂƟŽŶ24.com dŚĞ ŽŶůŝŶĞ ƐŚŽƉ ǇŽƵ ĐĂŶ ƌĞůǇ ŽŶ

N COUPOSED! ENCLO

ĂƵƚŽŵĂƟŽŶ24.com

800-250-6772 (toll-free) or 610-981-2900

M 100 %

FRE

$ PRI N G CI

EY BAC ON

90 DAYS

P P O RT

ŵĂŝůΛĂƵƚŽŵĂƟŽŶ24.com

A R A NTE

100 %

N D-NA M

2 YEAR

PPLICATI EA

PRODUCTS

EPTIONA XC

H QUALIT IG

zŽƵƌ ŽŶůŝŶĞ ƐƵƉƉůŝĞƌ ĨŽƌ ĂƵƚŽŵĂƟŽŶ ƚĞĐŚŶŽůŽŐǇ

SHIPP

ING

ER $ 50

ǁǁǁ͘ĂƵƚŽŵĂƟŽŶ24.com

ĂƵƚŽŵĂƟŽŶ24.com

ZĞůŝĂďůĞ ƉƌŽĚƵĐƚƐ ĂŶĚ ƐŽůƵƟŽŶƐ

ĨƌŽŵ

Ψϭϵ͘ϬϬ

Ψϰ͘ϯϬ

WƵƐŚďƵƩŽŶƐ ĂŶĚ ƐǁŝƚĐŚĞƐ ĨƌŽŵ ^ŝĞŵĞŶƐ /ŶŶŽǀĂƚŝǀĞ ĚĞƐŝŐŶƐ ĨŽƌ ƐŝŵƉůĞ ŝŵƉůĞŵĞŶƚĂƚŝŽŶ

WŽƐŝƟŽŶ ƐĞŶƐŽƌƐ ĨƌŽŵ ŝĨŵ ĞĨĞĐƚŽƌ ĂŶĚ ŵŝĐƌŽƐŽŶŝĐ

ůĂŝŵ ǇŽƵƌ ϭϬ й Žī ƚŽĚĂǇ͊

ZŽďƵƐƚ ƐŽůƵƚŝŽŶƐ ĨŽƌ ƉŽƐŝƚŝŽŶ ŵŽŶŝƚŽƌŝŶŐ ĂŶĚ ŽďũĞĐƚ ĚĞƚĞĐƚŝŽŶ

DISCOUNT*

WITH COUPON CODE:

AM24-FALL

ĨƌŽŵ

$92.77 ΎEŽƚ ĐŽŵďŝŶĂďůĞ ǁŝƚŚ ĂŶǇ ŽƚŚĞƌ ŽīĞƌƐ͘ sĂůŝĚ ƚŚƌŽƵŐŚ ϭϮͬϯϭͬϮϬϭϵ͘

tŝƌŝŶŐ ďůŽĐŬƐ ĨƌŽŵ tĞŝĚŵƺůůĞƌ

ĨƌŽŵ

Ψϭϴϱ͘ϬϬ

ZŽďƵƐƚ Dϴ ĂŶĚ DϭϮ ƐŽůƵƚŝŽŶƐ

^/E D/ ^ s& Ɛ ĨƌŽŵ ^ŝĞŵĞŶƐ sĞƌƐĂƚŝůĞ ƐŽůƵƚŝŽŶƐ ĨŽƌ ďĂƐŝĐ ĂƉƉůŝĐĂƚŝŽŶƐ

800-250-6772 (toll-free) or 610-981-2900

ŵĂŝůΛĂƵƚŽŵĂƟŽŶ24.com

ǁǁǁ͘ĂƵƚŽŵĂƟŽŶ24.com

ĨŽƌ ĐŽƵŶƚůĞƐƐ ĂƉƉůŝĐĂƟŽŶƐ͊

ĨƌŽŵ

Ψϳϱ͘ϬϬ

DĂĐŚŝŶĞ ůŝŐŚƟŶŐ

ĨƌŽŵ

ĨƌŽŵ > ϮtKZ<

Ψϲϳ͘ϮϬ

ŶĞƌŐǇͲĞĨĨŝĐŝĞŶƚ ůŝŐŚƚŝŶŐ ƐŽůƵƚŝŽŶƐ

^ƚĂĐŬ ůŝŐŚƚƐ ĨƌŽŵ WĂƚůŝƚĞ

KƵƌ ƐƚƌĞŶŐƚŚƐ ʹ ǇŽƵƌ ĂĚǀĂŶƚĂŐĞ͊ dŚĞ ĐŽŵƉůĞƚĞ ƉĂĐŬĂŐĞ Ăƚ ĂƵƚŽŵĂƟŽŶ24.com

>ŽǁͲŵĂŝŶƚĞŶĂŶĐĞ ƐŝŐŶĂů ůŝŐŚƚŝŶŐ ĨŽƌ Ă ǀĂƌŝĞƚǇ ŽĨ ĞŶǀŝƌŽŶŵĞŶƚƐ

ĂƐǇͲƚŽͲƵƐĞ ǁĞďƐŝƚĞ ǁŝƚŚ ƌĞĂůͲƚŝŵĞ ĂǀĂŝůĂďŝůŝƚǇ ŝŶĚŝĐĂƚŽƌ &ŝƌƐƚͲĐůĂƐƐ ƉƌŽĚƵĐƚƐ ĨƌŽŵ ďƌĂŶĚͲŶĂŵĞ ŵĂŶƵĨĂĐƚƵƌĞƌƐ ĞƐƚ ƉƌŝĐĞƐ Ăƚ ĂŶ ĂǀĞƌĂŐĞ ŽĨ Ϯϰ й ŽĨĨ D^ZW ůů ƉƌŽĚƵĐƚƐ ŝŶ ƐƚŽĐŬ ŝŶ ŽƵƌ h^ ǁĂƌĞŚŽƵƐĞ &Z ƚĞĐŚŶŝĐĂů ƐƵƉƉŽƌƚ ďĞĨŽƌĞ͕ ĚƵƌŝŶŐ ĂŶĚ ĂĨƚĞƌ ǇŽƵƌ ŽƌĚĞƌ

ĨƌŽŵ

ΨϭϮϵ͘ϮϬ

>K'K͊ >ŽŐŝĐ ŵŽĚƵůĞƐ ĨƌŽŵ

ΨϭϬϭ͘ϳϴ

ĨƌŽŵ ^ŝĞŵĞŶƐ ZĞĂĚǇͲƚŽͲƵƐĞ ƐŽůƵƚŝŽŶƐ ďĞƚǁĞĞŶ ĐŽŶƚĂĐƚŽƌ ĂŶĚ W>

ƚŚĞƌŶĞƚ ƐǁŝƚĐŚĞƐ ĨƌŽŵ tĞŝĚŵƺůůĞƌ ǆƚĞŶƐŝǀĞ ĐŽŶƚƌŽů ĨŽƌ ĚĂƚĂ ĚŝƐƚƌŝďƵƚŝŽŶ

ǁǁǁ͘ĂƵƚŽŵĂƟŽŶ24.com

» Questions? We are happy to support you!«

tĞƌŶĞƌ >ĂŵďĞƌŐĞƌ dĞĐŚŶŝĐĂů ^ƵƉƉŽƌƚ ŶŐŝŶĞĞƌ

PPLICATI EA

FRE

tĞ ƐƚĂŶĚ ďĞŚŝŶĚ ŽƵƌ ƉƌŽĚƵĐƚƐ ĂŶĚ ŽƵƌ ƐƵƉƉŽƌƚ͕ ƚŽŽ͊

ZĞůŝĂďůĞ ƐƵƉƉŽƌƚ ďĞĨŽƌĞ͕ ĚƵƌŝŶŐ ĂŶĚ ĂŌĞƌ ǇŽƵƌ ŽƌĚĞƌ

P P O RT

ƵƐƚŽŵĞƌ ƐĞƌǀŝĐĞ ƚĞĂŵ ĂǀĂŝůĂďůĞ ĨƌŽŵ DŽŶʹ&ƌŝ ϴĂŵʹϲƉŵ ^d &ƌĞĞ ƐƵƉƉŽƌƚ ĨƌŽŵ ŽƵƌ dĞĐŚŶŝĐĂů ^ƵƉƉŽƌƚ ŶŐŝŶĞĞƌƐ

H QUALIT IG

>ŝǀĞ ĐŚĂƚ ĂǀĂŝůĂďůĞ ŽŶ ŽƵƌ ǁĞďƐŚŽƉ

ZĞůŝĂďůĞ ƉƌŽĚƵĐƚƐ ĨƌŽŵ ǁŽƌůĚͲĐůĂƐƐ ŵĂŶƵĨĂĐƚƵƌĞƌƐ

PRODUCTS N D-NA M

ŽŶƟŶƵŽƵƐůǇ ŐƌŽǁŝŶŐ ƌĂŶŐĞ ŽĨ ŝƚĞŵƐ WƌŽĚƵĐƚƐ ŚĂŶĚ ƐĞůĞĐƚĞĚ ĨƌŽŵ ďƌĂŶĚͲŶĂŵĞ ŵĂŶƵĨĂĐƚƵƌĞƌƐ

EPTIONA XC

ǀĞƌǇƚŚŝŶŐ ǇŽƵ ŶĞĞĚ ĨƌŽŵ ƐĞŶƐŽƌ ƚŽ ĐŽŶƚƌŽů ĐĂďŝŶĞƚ

ZĞůŝĂďůĞ ƉƌŝĐŝŶŐ ĂǀĂŝůĂďůĞ ƌŝŐŚƚ ŽŶ ŽƵƌ ǁĞďƐŝƚĞ

PRI N G CI

ǀĞƌĂŐĞ ŽĨ ƵƉ ƚŽ Ϯϰരй Žī D^ZW EŽ ŵŝŶŝŵƵŵ ŽƌĚĞƌ ƋƵĂŶƟƚǇ ůů ƉƌŝĐŝŶŐ ĂǀĂŝůĂďůĞ ŽŶůŝŶĞ͗ ŶŽ ĂĐĐŽƵŶƚ ƌĞƋƵŝƌĞĚ

SHIPP

ZĞůŝĂďůĞ ĚĞůŝǀĞƌǇ

ING

ďǇ ƚŚĞ ĨĂƐƚĞƐƚ ŵĞĂŶƐ ƉŽƐƐŝďůĞ

ER $ 50

&ƌĞĞ ŐƌŽƵŶĚ ƐŚŝƉƉŝŶŐ ŽŶ Ăůů ŽƌĚĞƌƐ ŽǀĞƌ ΨϱϬ ůů ƉƌŽĚƵĐƚƐ ƐƚŽĐŬĞĚ ŝŶ ŽƵƌ h^ ǁĂƌĞŚŽƵƐĞ

90 DAYS

ARANT

2 YEAR

100 %

EY BAC ON

ůů ƐƚŽĐŬĞĚ ŽƌĚĞƌƐ ƐŚŝƉ ƐĂŵĞ ǁŽƌŬŝŶŐ ĚĂǇ

ZĞůŝĂďůĞ ŐƵĂƌĂŶƚĞĞ ŽŶ Ăůů ƉƌŽĚƵĐƚƐ ŝŶ ŽƵƌ ƉŽƌƞŽůŝŽ ϮͲǇĞĂƌ ǁĂƌƌĂŶƚǇ ŽŶ Ăůů ƉƌŽĚƵĐƚƐ ϵϬͲĚĂǇ ŵŽŶĞǇ ďĂĐŬ ŐƵĂƌĂŶƚĞĞ EŽƚ ϭϬϬ й ƐĂƟƐĮĞĚ͍ ZĞĐĞŝǀĞ ϭϬϬരй ƌĞĨƵŶĚ͊

tĞ ĂƌĞ ŚĂƉƉǇ ƚŽ ĂĚǀŝƐĞ ǇŽƵ ƉĞƌƐŽŶĂůůǇ͊ 800-250-6772 (toll-free) or 610-981-2900

ŵĂŝůΛĂƵƚŽŵĂƟŽŶ24.com

LIVECHAT ǁǁǁ͘ĂƵƚŽŵĂƟŽŶ24.com

Visit www.controleng.com/stratusedge

7KH (GJH Is Where The $FWLRQ ,V

today to download the trend report!

The introduction of edge computing is the most VLJQLÍ¤FDQW SODQW IORRU DGYDQFHPHQW LQ LQGXVWULDO FRPSXWLQJ VLQFH WKH LQWURGXFWLRQ RI VXSHUYLVRU\ FRQWURO DQG GDWD DFTXLVLWLRQ 6&$'$ \HDUV DJR 7KLV QH[W ZDYH RI GLJLWDO WUDQVIRUPDWLRQ RIIHUV WUHPHQGRXV SRWHQWLDO WR WKRVH ZKR UHVSRQG HDUO\ DQG FDSLWDOL]H RQ WKH LPSURYHPHQWV WKDW FDQ EH EURXJKW WR WKHLU RSHUDWLRQV

Edge computing is the future. 'RZQORDG WKH WUHQG UHSRUW WR VHH UHVXOWV RI WKH UHFHQW &)( 0HGLD DQG 7HFKQRORJ\ VXUYH\ RI LWV UHDGHUVKLS UHJDUGLQJ RSSRUWXQLWLHV FKDOOHQJHV DQG DWWLWXGHV ZKHQ LW FRPHV WR OLYLQJ DW WKH HGJH