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All pneumatic motion requires clean and dry air with enough flow to provide the required pressure. The process of filtering, regulating and lubricating compressed air is known as air prep. The NITRA family of air preparation components include:

Solenoid valves are electrically controlled to direct air flow to sequence operations in pneumatic systems. Solenoid valves are used to control cylinders, rotary actuators, grippers and other pneumatic devices. Use a manifold to simplify plumbing for a bank of valves. Modular systems even allow networked control of valve group.

• Filters with 40 micron ﬁlter element (5 micron option) in sizes from 1/8” to 1” NPT port sizes • Regulators with adjustment from 20-130 PSI and 4-57 PSI • Combination ﬁlter/regulators available with same options in one unit • Lubricators in 1/8” to 1” port sizes • Total air prep units that combine all air preparation functions in one compact unit

Pneumatic Cylinders

• Available as stand-alone units or as part of a compact modular valve system • Stand-alone units can be used with optional manifolds to make system conﬁguration simpler • Available in 3-port/3-way, and 5-port/4-way styles • 4-way valves come in 2-position or 3-position styles with center closed or center open

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NFPA Tie-Rod Cylinders

The most popular style of pneumatic actuator uses compressed air acting on a piston inside a cylinder to move a load along a linear path. • Round body cylinders available in single-acting or double-acting styles, with up to an 18-inch stroke and 2-inch bore. Also available in stainless steel. Magnetic pistons are optional. • NFPA tie rod air cylinders come in double-acting style, with up to a 24-inch stroke and 4-inch bore. All include a magnetic piston. Adjustable air cushions are an option. • ISO 15552 air cylinders are double-acting cylinders with up to a 600mm stroke and 100mm bore. All include magnetic pistons and adjustable air cushions. • Metric and Inch compact air cylinders as well as dual rod guided air cylinders also available.

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Vol. 66 Number 10

ÂŽ

OCTOBER 2019

ANSWERS 18 | Packaging system integration advice from three case studies 24 | High-speed vision sorting technology records rapid improvement with industrial Ethernet 29 | Connecting I/O systems with the IIoT

COVER STORY: Example of a bag conveyor system that collects inspected products towards case packers. From there, the case conveyor infeeds products towards a robotic palletizing system. Courtesy: NCC Automated Systems

INSIGHTS 4 | Safety tips on SCCR for industrial control panels, industrial machinery 8 | Technology Update: PLC tag and address naming conventions 16 | Think Again: Tips to help IIoT projects

32 | Decode hybrid AI system potential 34 | Improving automation safety with self-taught industrial machines, robots 38 | Teaching industrial robots with AI 39 | Choose the right industrial wireless technologies for condition monitoring 41 | Applicability of wireless technology for manufacturing 42 | Defining the details of a wireless network installation 44 | New ways to increase productivity with smart systems

NEWS

14, 22 | Water/wastewater; Remembering Leonard Moore, Headlines Online 17 | International: Manufacturers need to prepare for cyber threat

Page 42: Wireless Courtesy: Phoenix Contact

INSIDE MACHINES

M1 | Benefits of robotics-as-a-service for manufacturers M5 | Survey respondents offer motor drive advice

CONTROL ENGINEERING (ISSN 0010-8049, Vol. 66, No. 10, 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. Periodicals postage paid at Downers Grove, IL 60515 and additional mailing offices. Circulation records are maintained at CFE Media, LLC, 3010 Highland Parkway, Suite #325 Downers Grove, IL 60515. Telephone: 630/571-4070. E-mail: CE@omeda.com. Postmaster: send address changes to CONTROL ENGINEERING, PO Box 348, Lincolnshire, IL 60009. Publications Mail Agreement No. 40685520. Return undeliverable Canadian addresses to: PO Box 348, Lincolnshire, IL 60009. Email: CE@omeda.com. Rates for non-qualified 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 $30.00 USA, $35.00 Canada/Mexico and $40.00 Other International. Please address all subscription mail to CONTROL ENGINEERING, PO Box 348, Lincolnshire, IL 60009. Printed in the USA. CFE Media, LLC does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the material contained herein, regardless of whether such errors result from negligence, accident or any other cause whatsoever.

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INSIGHTS

TECHNOLOGY UPDATE John Kovacik, UL; and Dan Neeser, Christy Rosati, Joe Pavia, Eaton’s Bussmann Division

Safety tips on SCCR for industrial control panels, industrial machinery How to determine short-circuit current rating (SCCR) and avoid misapplications. When the industrial control panel or industrial machinery does not have an adequate SCCR for the available short-circuit (fault) current, an electrical hazard exists.

short-circuit current rating (SCCR) for equipment is required by National Electrical Code (NEC) 409.110(4) industrial Control Panels and 670.3(A) Machine Nameplate Data. SCCR represents the maximum amount of current the assembly can withstand safely under short-circuit conditions. Additionally, the following general statement related to SCCR is included in NEC 110.10 Circuit Impedance and Other Characteristics: “The overcurrent protective devices, the total impedance, the equipment short-circuit current ratings, and other characteristics of the circuit to be protected shall be selected and coordinated to permit the circuit protective devices used to clear a fault to do so without extensive damage to the electrical equipment of the circuit.” Understanding how an industrial control panel’s SCCR is determined and what the markings on the product signify will help ensure the industrial control panel is adequate for the available fault current at the point of installation. Industrial control panels are defined by NEC section 409.2 as an assembly of two or more power circuit components, control circuit components or any combination of power and control circuit components.

Industrial control panels are listed in accordance with ANSI/UL 508A, the Standard for Industrial Control Panels, and covered by UL product category NITW (industrial control panels) as factory-wired assemblies of industrial control equipment, such as motor controllers, switches, relays, and auxiliary devices. The panels may include disconnecting means, power distribution blocks, motor controllers, and branch-circuit protective devices. UL Listed products installed and used in accordance with their listing are considered by the NEC to meet these requirements. SCCR marked on the equipment provides the information needed to help ensure a safe, code-compliant installation. For UL 508A panel manufacturers, two options are available to obtain the needed SCCR for a given panel: First, apply the method described in UL 508A, Supplement SB (determining SCCR based on the components in the power circuit). If the industrial control panel contains only control circuit components, marking the SCCR is not required (also noted in NEC section 409.110(4) Exception). The other option is to test a panel to achieve ratings higher than the value determined using Supplement SB. UL 508A Supplement SB is the preferred option for nearly all industrial control panels. The overall process of this is to: 1. Identify the lowest component SCCR and/or component combination SCCR rating with an overcurrent protective device (OCPD). 2. Increase the branch component SCCR and/or component combination SCCR rating with a feeder current-limiting OCPD.

SCCR represents the maximum amount of current the assembly can safely withstand under short circuit conditions. Courtesy: Eaton’s Bussmann Division.

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3. Identify the lowest interrupting rating of overcurrent protective devices in the industrial control panel. The lowest component SCCR (steps 1 and 2) and the lowest interrupting rating of the overcurrent prowww.controleng.com

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TECHNOLOGY UPDATE

tective device (step 3) results in the overall assembly SCCR. For step 1, power circuit components (components that supply power to external loads such as motors, lighting, heating, appliances, or convenience receptacles): either the product markings or the instruction sheets determine the SCCR. If there are no product markings, a default value can be used as indicated in UL 508A, Supplement SB, Table SB4.1. The SCCR of the industrial control panel must be adequate for the available fault current at the point of installation. In most applications, a default SCCR of 5 kA is not adequate. For these installations, UL 508A Supplement SB allows the manufacturer of the industrial control panel to achieve the required SCCR by using power circuit components tested by the component manufacturer for a high fault rating and incorporating them into the industrial control panel manufacturer’s UL report (procedure). It’s possible to raise the ratings of branch power circuit components – those on the load side of the branch-circuit overcurrent device (the overcurrent device closest to the load). Any component or overcurrent device on the lineside of the branch-circuit overcurrent device is in the feeder circuit. KEYWORDS: Short-circuit When a current-limiting device (fuse or current rating, SCCR, circuit breaker marked current-limiting or a industrial control panels transformer) is located in the feeder circuit, Determine short-circuit current rating (SCCR). it can be investigated to determine if it can Avoid SCCR misapplications. increase branch circuit component SCCR Adequate SCCR for the ratings. When transformers are used, both available short-circuit (fault) the branch-circuit overcurrent device intercurrent reduces electrical rupting rating and the component SCCR hazards. can be increased. CONSIDER THIS However, when current-limiting overcurAre your SCCR requirements rent devices are used, only the component meeting requirements and SCCR can be increased. It is not permitted avoiding hazards? to increase the branch-circuit overcurrent ONLINE device interrupting rating. If reading from the digital The final step is verifying the lowest edition, click on the headline interrupting rating of the overcurrent devicfor more resources, including es in the industrial control panel. If this is a section on “Common lower than any power circuit component misapplications in industrial control panels” and links to after the steps above, the assembly SCCR is UL and Eaton’s Bussmann lowered to this value. division with more on: Although the overall process may seem • Determining SCCR of simple and straightforward, understanding industrial control panels the rules of UL 508A Supplement SB and the per the 3rd Edition of UL 508A proper application of devices is a complex • Avoiding common and challenging concept. This is especially misapplications in true with regards to the use of current-limindustrial control panels iting devices.

M More INSIGHTS

• Explaining differences between arc flash and SCCR. www.controleng.com/ magazine

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SCCR versus arc flash

How does SCCR relate to arc flash? Equipment SCCR represents the maximum

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The industrial control panel is not rated for the available fault current, which could result in extensive damage, creating danger

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for anyone nearby.

amount of short-circuit (fault) current the assembly can safely withstand under short-circuit conditions. When the industrial control panel or industrial machinery does not have adequate SCCR for the available short-circuit (fault) current, an electrical hazard exists. The IEEE 1584 standard is the method in calculating arcing currents and incident energy level. When the upstream OCPD is the only device considered when calculating the industrial control panel incident energy and, i.e., the industrial control panel SCCR is not included in the calculation, a major hazard exists. OSHA section 1910.303(b), requires equipment (new and existing) to be rated to handle the available fault current without causing a hazard. For example, a fuse or circuit breaker is feeding an industrial control panel that has a 5kA SCCR. The available fault current on the line-side of the industrial control panel is calculated to be 15kA. If the industrial control panel SCCR is not considered in the calculation, the incident energy is based only on the magnitude of the arcing fault and the time to clear the fault by the fuse or circuit breaker. A label will be generated based on the incident energy calculated and placed on the inadequate SCCR industrial control panel. In other words, the industrial control panel is not rated for the available fault current, which could result in extensive damage, creating a dangerous situation for anybody working on or near the panel. In the above example, the arc flash warning label should state “DANGER,” meaning no one should be allowed to work on or near the industrial control panel when energized until the proper industrial control panel SCCR is achieved. The NEC and UL recognize the need to provide adequate protection against short-circuit events. This can only be achieved by understanding available fault current, communicating protection requirements to personnel and equipment suppliers, and properly applying components in the industrial control panel. Execution of a proper equipment SCCR plan will help provide adequate protection for employees and equipment. ce John Kovacik is principal design engineer, UL; Dan Neeser is senior field application engineer, Christy Rosati is field application engineer, and Joe Pavia is field application engineer, Eaton’s Bussmann Div. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media, mhoske@cfemedia.com. www.controleng.com

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INSIGHTS

TECHNOLOGY UPDATE Frank Lamb, Automation Primer

PLC tag and address naming conventions Tutorial: Learn about tag templates, common factory automation tag abbreviations, process control tag abbreviations, and five tag and address naming tips.

rior to this millennium, programmable logic controller (PLC) addresses were register based. Data was kept in registers with addresses like MW210, B3:6/2, N7:50, or DB5.dbx50.2. They’re not very descriptive, are they? These addresses could be assigned a “Symbol” or shortcut that would make them easier to program or find, but symbol names were often limited in length. Symbols also were not kept in the PLC; only on the programming computer and in the software. Descriptions also could be assigned to the addresses, but they also were only present in the software. They provided extra information about the address and its purpose, but were not searchable. With the advent of tag-based PLC systems, the address became much more descriptive, and the register-based addresses were hidden from view. Tag names have different rules depending on the brand or platform of the PLC. They can be 40 or more characters in KEYWORDS: PLC tags, length and use alphanumeric characters. address naming convention Some platforms allow spaces while some Tag name rules can vary by require an underscore instead.

M More INSIGHTS

brand of programmable logic controller (PLC) Factory automation, process control tag name abbreviations Five tag naming tips will help when deciding.

CONSIDER THIS What tag naming best practices will smooth your programming efforts?

ONLINE If reading from the digital edition, click on the headline for more resources. www.controleng.com/ magazine See CFE Edu online course on PLC programming basics http://cfeedu.cfemedia.com/ catalog

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October 2019

Tags are downloaded

Tags are actually downloaded into the PLC. They also can be organized alphabetically or numerically in the tag database, making the naming convention important. Since so many characters can be used, tag names can be quite descriptive and contain a lot of information. At the same time, long tag names with too many abbreviations can be hard to read. Common functions or terms such as AutoMode, AutoCycle, Fault or CycleStop are pretty common in industry and don’t require a lot of extra information. Systems or machines might be divided up into zones or stations and labeled Zone2, Cell15 or Station003, these tags could take a bit more documentation or description.

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UDTs (User Defined Data Types) also have made the tags more complex by allowing “dotfields.” An example might be “VFDrive2100.ActualSpeed” or “pOP150.ToSCADA.SEvents.Call.ForSupervisor”. Nesting UDTs allows for tags like the last example.

Tag templates

Larger companies and machine builders/system integrators usually create a template for programming that lays out how tags will be named. Many common tags already will be created in a template program, and others will be automatically generated from a spreadsheet. The conventions used will differ from company to company, but the intent is the same: to make the program more readable and easier to troubleshoot. There are two major divisions of tag naming philosophies. In the manufacturing industries such as automotive and other products, devices are often named by their function and location. They also often include a number referencing a page and line where the device is located in the electrical drawings. An example of this might be “PalletPushCyl_ ExtPX_4120”. This example indicates the Assembly (Pallet Pusher Cylinder), the Device and its position (Extended Proximity Switch), and the location in the electrical drawings (Page 41, Line 20).

Factory tagname abbreviations

Devices in manufacturing often are designated by abbreviations as listed below: • Photoelectric Sensor: PE, PEC, PER • Proximity Switch/Hall sensor: PX, PRX • Limit Switch: LS • Master Control Relay: MCR • Pushbutton: PB, hPB (HMI) • Switch: SW • Solenoid Valve: SV • Control Relay: CR, K • Motor Starter: MS. The second school of thought is from process control industries, such as petroleum or chemical www.controleng.com

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INSIGHTS

TECHNOLOGY UPDATE • Limit Switch: LSL (Low), LSH (High) • Loop Control: FIC, PIC • Pushbutton/Switch: HS, HIS • Photoeye, Proximity Switch: ZS • Motor Starter: M • Pressure Transmitter: PT, PIT. The main consideration when creating tagnames is to remember the technician or maintenance person is the customer. The more the programmer can do to help someone find and understand the code, the better.

Five tag and address naming tips

Naming conventions for device or unit tag names matter to aid understanding and speed troubleshooting. Here are five important things to consider when deciding on tag names templates or rules:

Factory automation and process control tagnaming matters for consistency, understanding, and troubleshooting. Courtesy: Frank Lamb, Automation Consulting, Automation Primer

processing. Their technicians depend on their process and instrumentation diagrams (P&IDs). Coding guidelines for these are supported by ISA, but may differ from company to company. These drawings assign unit numbers to assemblies like tanks or skids and loop numbers to the different control components like instruments and sensors. Because device names are controlled, tag names in the process industries only include the P&ID number rather than the more descriptive method used in manufacturing. These designations are quite different than those used in manufacturing. For instance, a flow transmitter might be designated as 20-FT-1982-A, where the area is 20, FT is the type of sensor, 1982 is the loop number, and A means there is at least one other redundant device. Because tags can’t start with a number on many platforms, the order of characters may be changed, or a letter may be attached before the unit number. The tag for the device above might then be FT_20_1982A or d20_FT_1982A. This type of tag may not be as descriptive as those used in manufacturing, but a description might be attached reading “Flow Transmitter A for Loop 1982 in Unit 20”.

October 2019

3. Use underscores or capitalization wherever necessary to make the tag more readable. 4. If the software platform allows for local tags, assign all tags for a particular assembly or program before copying it to duplicate programs. This can save a lot of time. 5. Use a spreadsheet to create tags. This is easier than typing tags manually into a database. Tags can be incremented and duplicated more easily. PLC platforms allow for easy export/import of tags. This also ensures programmers use the same names as electrical and mechanical designers. ce

• Flow Transmitter: FT • Valve: HV, FV control engineering

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Devices might use designations like those listed below:

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2. Tags will appear in alphabetical and numeric order, so beginning tags with the same function or area letters/numbers is important for organization.

Frank Lamb is the founder of Automation Consulting LLC, the creator of Automation Primer and is a member of the Control Engineering Editorial Advisory Board, and Automation Consulting is a content partner. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com.

Process tag abbreviations

1. Make names as descriptive as possible as to the function of the tag. Use standardized terms and abbreviations technicians will understand. Add descriptions if necessary.

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OCTOBER 2019

Digital edition The tablet and digital editions provide links to additional article images and text online and links to other related, useful resources.

INNOVATIONS NEW PRODUCTS FOR ENGINEERS

56 | Vote now for Engineers’ Choice finalists The official ballot is open for voting for Control Engineering North American print and digital edition subscribers, for a limited time. Cast your vote using CFE Media’s New Products for Engineers platform at www.controleng.com/NPE.

BACK TO BASICS

62 | Control engineering: Basic terms explained

NEWSLETTER: Machine Control • 5 enduring developments in electronic motion control • 2019 Motor Drives Study • Manufacturing, automation leaders inspire, mentor • Hybridization as a disruptive, profitable energy strategy for manufacturers • Four ways industrial automation will evolve. Keep up with emerging trends: subscribe. www.controleng.com/newsletters.

Control Engineering eBook series: Motors and Drives Fall Edition Motors and drives make manufacturing plants run and keep them efficient. Maintaining motors and drives and keeping them cost-effective is crucial and requires knowledge of many different aspects. This helpful eBook will help readers learn about topics including what to consider when implementing a linear motion application and three steps to size motors. Learn more and register to download at www.controleng.com/ebooks.

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

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

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

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INSIGHTS

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

NEWS

Water, wastewater industry is going digital and getting smarter Technology updates in the water/ wastewater industry flowed through McCormick Place with the annual Water Environment Federation’s Technical Exhibition and Conference (WEFTEC) conference. The conference, Sept. 21-25, highlighted many of the latest developments in instrumentation, digitalization, pumps, and other technologies. Those in the water/wastewater industry are meeting challenges like any other industry: Making products that are smarter, faster, cheaper, lowering worker risk, and improving cybersecurity.

Information control

One common theme running throughout WEFTEC was the growing need to get information to customers. There is a lot of information users need from their pumps, pipes, filtration systems and more. How can the information be securely accessed? Digital technology, particularly in the form of process sensors, is becoming a major tool. “The digital industry is upon us in

the water and wastewater industry,” said Alan Vance industry manager – environmental, Endress+Hauser Group. Updated digital systems, properly used and configured, can help address cybersecurity concerns in ways legacy systems cannot.

Automation and safety

Automation also is increasing in the water/wastewater industry. According to Clay Mallett, a water industry specialist for ABB, that is a good thing. “I operated in the water and wastewater industry for 24 years, and the one thing I learned is the more I could take out of the operator’s control and automate it, the better we could meet our goals and improve treatment.” Increasing automation provides another incentive. Many of the sensors and devices used to track performance in water/wastewater are in locations most people would not want to go

Founder of Moore IndustriesInternational passes away at 85

eonard (Len) W. Moore, P.E., founder and owner of Moore Industries-International Inc. passed at the age of 85, according to information provided by the company that bears his name. Leonard W. Moore, Starting with one signal isolating/converting instru- the founder of ment, the SCT Signal Converter and Isolator, Moore and Moore Industrieshis employees designed, built and supported more than International, 225 products that isolate, protect, convert, alarm, mon- passed away at the age of 85. Courtesy: itor, control and interface with industrial or automation Moore Industriescontrol and monitoring systems. International Moore was born Nov. 26, 1933, in Hazelton, Iowa, where he attended elementary through high school. At the age of 16 he graduated high school and then attended Iowa State University where he obtained a BS in Electrical Engineering. After graduating college Moore entered the Army in 1953 as a weapons guidance specialist and spent time at Fort Sill, Okla. and Fort Bliss, Texas. He then served time in Japan training and teaching soldiers how to operate, calibrate and repair various guidance and artillery weapon systems. It was here where Moore realized he had a passion for instruments and control circuits. After his tour in Japan he left the Army and returned home to Iowa. Continued on p. 22

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Endress+Hauser’s booth at WEFTEC had several sensors and tools designed to gather quick and accurate readings that could be sent to a display for the user so they know when something is wrong. Courtesy: Chris Vavra, CFE Media

regularly. Automating the data collection process and alerting workers to problems remotely improves overall efficiency and makes worker happier. It’s also a good thing, in some cases, workers don’t have to interact with some of these pipes or pumps because they could be funneling dangerous chemicals. Smart technology on display at WEFTEC offers some hope for a brighter and cleaner tomorrow. Chris Vavra, production editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.

Headlines online Top 5 Control Engineering articles September 16-22 Articles include process control and instrumentation productivity, control system technology, Leaders Under 40 winners, modern manufacturing and electronic motion control developments. Machine vision trends, food inspection Machine vision inspections require lighting and sensors for food to be properly imaged. Prolonging power plant life through artificial intelligence A West Virginia University chemical engineer is tapping into AI to help boilers. Addressing digital migration challenges Digital transformation programs are creating several challenges. Optical lace developed to heighten robots’ sensors www.controleng.com

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INSIGHTS THINK AGAIN

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

Eight IIoT project tips If you’re stalled with Industrial Internet of Things (IIoT) implementations or haven’t begun, consider these eight expert tips.

ost industrial businesses art toolbox they know how to use, and know they need to advance you’ll win,” said Don Pearson, Inducproductivity with Industrial tive Automation’s chief strategy officer. Internet of Things (IIoT), While his company offers paid training, Industry 4.0, or Smart Factory initiatives. experts there also spent more than 10,000 Choosing, migrating, updating, and inte- hours producing free videos online, grating related technologies may seem an where students can receive free educainsurmountable obstacle. tion and certification. System integraIf so, your inertia about technolo- tors in the company’s program get free gy upgrades may enable competitors to support. Developers can use the Ignition gain an unfair advantage. Tips Exchange to share templates follow from system integraand projects. tors and automation vendors 3. Use an intelligent data at the 2019 Inductive Automahub to standardize industrial tion Ignition Community Condata structures and add conference in September. Among text to the raw data, said John IIoT enablers discussed was Harrington, co-founder and Ignition software, described as chief business officer, Highan industrial application platByte. Industrial data operaMark T. Hoske, form for human-machine inter- Content Manager tions (DataOps) incorporates face (HMI), supervisory control the operational activities needand data acquisition (SCADA), ed prior to data being used by manufacturing execution systems (MES) end applications. Software helps create and IIoT applications. intelligent industrial data, often unus1. Don’t let the cost of updating autoable because of missing or unknow data mation or operations-related software kill tags, structures and context. “Industrial a system integration or upgrade project. DataOps is focused on the challenges of Steve Hechtman, Inductive Automation working with industrial data or data from founder, president, and CEO was a system industrial automation and IoT devices,” integrator prior to founding the software Harrington said. company. He said he was laughed out of a 4. Reconsider project functionality prospective customer’s office after quotto move past traditional architecture defiing a system integration/upgrade project nitions, said Vikram Kumar, president, because of the high price of the software EZAutomation and AVG Automation. For required for the project. After working example, a major automaker had to call with developers to write his own software controllers “health monitoring stations” for automation projects, his system inteto move around traditional purchasing gration project “close rate was close to agreement bias, take advantage of IoT 100% after that point. Software should be capabilities and continue interacting with easy, fun, and affordable,” Hechtman said. traditional PLCs to improve productivity. 2. Ensure those integrating, installCybersecurity efforts and new industrial ing and using software have appropridata communication methods are helping ate training and support. “Give those process improvement initiatives with IIoT involved with a project a state-of-theapplications, Kumar said. 5. Get data where it needs to be when it’s needed to get the desired outcomes, said Benson Hougland, vice president, Opto 22. Using IIoT architectures Click the digital edition headline for photos, links. www.controleng.com/magazine can democratize data on the plant floor.

M More INSIGHTS

See IIoT related webcasts under Online Training at www.controleng.com.

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October 2019

control engineering

Continued on p. 22

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 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

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INSIGHTS

INTERNATIONAL: INDUSTRIAL NETWORKING Suzanne Gill, Control Engineering Europe

Prepare for cyber threats

Automation can increase productivity, efficiency, connectivity and cyber risks. ybersecurity issues are the same across all industry sectors. All industry sectors are increasing automation to help increase productivity and efficiency, and this requires greater connectivity, which also can expose systems to attack. The biggest differences among industry sectors is in the consequence of a successful attack. “We are seeing attacks taking place on a daily basis across all sectors of industry,” said Paul Hingley, product security and solution officer at Siemens Digital Industries. “Many are criminally motivated while some are sneaker hacks, from people trying to gain access for their own entertainment. The criminal attacks are usually looking to create a denial of service and so ransomware is becoming more prevalent across industry. This has resulted in hackers turning their attention to the softer targets provided by the operational technology (OT) layer.” Industrial OT investments can have anywhere from 10- to 20-year cycles, while information technology (IT) investment is more often in cycles ranging from one to four years. This means the IT infrastructure will be better protected. A great deal of legacy OT equipment still in operation was not designed for external connectivity and will never have been patched. That provides a softer target for cyber attacks.

Denial of service attack

One attack instigated a denial of service, resulting in the plant being offline for two weeks, costing the company billions of pounds in lost production. “To regain control of production, it was necessary to strip the software system and undertake ‘clean slate’ processes to bring the plant back into normal operational activity. This involved looking at the installed software to find anomalies and apply the correct patches. “We found that this particular attack was instigated onsite, via a USB. On another site we identified an attack as coming via a PC employed in the automation layer, which had been used to download patch updates, which at the same time had inadvertently installed a vulnerability,” Hingley continued. “Such events often occur due to the lack of protection originally installed on OT equipment — and this highlights the importance of undertaking security audits, so that engineers can understand what their installed base actually is and what connections they have. We find that many customers have remote access connections in the plant that they didn’t know had been applied by their solution providers.” In many factories, there will be no levels or depth www.controleng.com

of security due to long OT equipment lifecycles. There is a growing sense of purpose among engineers to better understand how legacy systems have been adapted to incorporate other elements of control. Often engineers will find a lot of undocumented work has been undertaken on installed systems and plant equipment. This is why an audit is a good place to start when considering cybersecurity improvements. New machine or equipment installations have required integration of a new PLC or controller into an existing system. Most end users have relied on the competence of the solution provider for installation using relevant compliance standards. The technical file that gets created usually relates to safety compliance. “Appreciation that one the biggest areas of compromise of a cyberattack is denial of service is not widespread,” Hingley said. “So, while a new system will have been correctly applied from the perspective of the technical file, the bigger problem is that if the safety system is affected by a security breach it may result in a complete denial of service of the safety system and so it would, legally, become a noncompliant machine.” It is for this reason the worlds of safety and security are moving closer together, and the HSE is becoming more involved with the requirements of security. “There is a whole new world of systems starting to appear because of the digital transformation that many factories are starting to undertake,” said Hingley. As a best practice, when it comes to security, he advised gaining an understanding of existing architectures and networks and to develop a database of these systems. The next step is to develop an audit around the connectivity and what is happening in the system. The next step is to aspire to follow the guidelines of IEC 62443, covering technical specifications and maturity levels and processes required within the OT domain (such as passwords, and how to control them). “These processes can be applied with technology, and when they work together, you will have created a defense-in-depth approach,” Hingley said. The IEC Standard 62443 creates a defense-indepth approach, looking at the technology that needs to be applied to the automation layer, it also looks at the maturity of the processes themselves that have to be applied into that level of control. ce

Suzanne Gill is editor, Control Engineering Europe. This article originally appeared on the Control Engineering Europe website. Edited by Chris Vavra, production editor, Control Engineering, CFE Media, cvavra@cfemedia.com. control engineering

M More INSIGHTS KEYWORDS: Cybersecurity, industrial OT Increased automation in manufacturing leads to greater cybersecurity vulnerabilities. Industrial operations technology (OT) has a longer lifecycle than information technology (IT). There is a growing sense among engineers to better understand how legacy systems have been adapted over the years. ONLINE Read more articles from Control Engineering Europe at www.controleng.com/ international.

CONSIDER THIS What is the biggest challenge your company faces when it comes to cybersecurity?

October 2019

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ANSWERS

COVER: PACKAGING AUTOMATION Kevin Mauger, NCC Automated Systems Inc.; Robbie Kerfoot, Stone Technologies Inc., Robert Herman, Avanceon

Packaging system integration advice from three case studies A vegetable processor packaging project integrated weighers, baggers, robots, case formers and closers and conveyors. Packaging, records and raw materials were updated and automated across eight sites. Seven bakery lines converge in one packaging area that fills 20 cases per minute.

utomation and controls can help packaging implementations, and three system integrators offer insights into recent projects. • Kevin Mauger, president, NCC Automated Systems Inc., discussed an automated vegetable processing and packaging line with robotics, palletizing and conveyors that runs multiple products up to 320 bags per minute. Changeovers happen regularly. • Robbie Kerfoot, client engagement manager with Stone Technologies Inc., explained how packaging, records and raw materials, were updated and integratKEYWORDS: Packaging ed and automated across eight facilities. automation updates, case • Robert Herman, program manager studies — senior engineer, Avanceon, explained The line packages a variety how seven bakery lines converged in one of vegetable blends, meals and other items using robots, packaging area that fills 20 cases per minconveyors and palletizers; ute. Controllers needed replacing and prochangeovers happen regularly. gramming and network needed updating, Track and trace consistency over a three-day weekend. System integraacross eight production facilities tors check and tested code as they went. was needed.

M More ANSWERS

Packaging automation testing happened during and after development; simulation wasn’t an option.

CONSIDER THIS Can next-generation automation help your next machine or line redesign?

ONLINE If reading from the digital edition, click on the headline for more details, images, and links. www.controleng.com/magazine See related system integrator capabilities in Global System Integrator Report www.controleng.com/ Global-SI-Database

•

October 2019

QUESTION: Can you please describe the packaging-related project? Mauger: NCC provided a turnkey, fully integrated packaging system for a vegetable processor. The system included a full range of packaging equipment including multi-head combination weighers, VFFS baggers, robotic case loaders, case formers and closers, robotic palletizing cell and approximately 1,000 feet of conveyor. NCC project value was $7.5 million, not including customer purchased combination weighers and baggers. Kerfoot: This project consisted of hardware, software, and communications

control engineering

with various local and enterprise resource planning (ERP) solutions to ensure that finished goods from eight productions facilities located throughout North America were automatically labeled for distribution, all raw materials accounted for, and records updated for track and trace purposes. Locally, we directly interfaced with the existing packaging equipment to ensure the accuracy of automation was leveraged to decrease any human data entry errors. Herman: Over the past three years, Avanceon noticed a trend in packaging projects addressing system technology obsolescence. Packaging lines are traditionally an area of the factory that has to run 24/7/365 days a year, and, as a result, there’s often a feeling of “if it isn’t broke, don’t fix it.” In recent years, technology obsolescence has driven manufacturers to force packaging system upgrades. Common constraints and concerns are twofold. 1. There is never a good window of downtime. 2. The system needs to look and perform exactly like the system did before the outage to ensure that the operators accept the system. A recent bakery packaging upgrade addresses those concerns. Avanceon helped upgrade legacy control systems that control and orchestrate the packaging area for a bakery. The packaging system consisted of 7 lines running at over 20 cases per minute. Due to the high number of lines that converge into this packaging area there was no room for errors in a very limited downtime window. Q: What was the scope of the project and goals? Mauger: Originally stated definition of success: When this project is completed, NCC will have supplied and commissioned a food packaging line that provides customer with an efficient and effective www.controleng.com

Robert Herman is program manager - senior engineer, Avanceon. Courtesy: Avanceon

Cover: Bag conveyor system collects inspected products towards case packers. Courtesy: NCC Automated Systems

system producing all packages and cases at desired rates. The system will provide a safe operating environment for all employees involved on the line. Reason for project/business value: The plant was interested in installing a new packaging line for a frozen vegetable product line. The new packaging line will consisted of new processing equipment and new packaging equipment (including palletizing equipment). The line packages a variety of vegetable blends, meals and other items. Multiple products are produced and changeovers happen regularly. Previous state: Since this was a new packaging line, the current state did not exist. Similar lines next to where the new line was to be installed already were running the products, bags and cases. New state: A new product distribution system, four baggers and four scales were installed. In addition, a new packaging line was be installed simultaneously to handle the bags produced by the bagger. The cases produced from the packaging line were conveyed via new overhead case conveyor that will be palletized by a new palletizing system. The existing stretch wrapper was used to wrap completed pallets. Kerfoot: The client’s goal for the project was to standardize end-of-line (EOL) labeling/reporting across a variety of its sites. Herman: The scope of the project was to replace the PLC5/25 with 4 racks and over 60 modules connected via remote input/output (I/O) and antiquated data highway communication protocol to the rest of the plant. The old processor and system was to be replaced with a programmable automation controller and Ethernet-based I/O. The project included the software conversion, update to existing (and very tattered) electrical design documentation. The goal of the project was to replace all hardware (the existing processor was so full that it no longer could be edited), test new I/O and ensure existing functionality before a startup, without a ramp up curve. (Full production was required at the “go live” point, Tuesday, 6 a.m.) www.controleng.com

Based on the hardware and lack of humanmachine interface (HMI) screens, this type of project could not be completely simulated for total testing before go live. To reduce risk to the startup, the project team took special care in code conversion and with cross checking code and drawing reviews for quality throughout the project. Q: What types of automation, controls, or instrumentation were involved? Mauger: Automated machines included: Bagger transfer conveyors to auto case packing: Frozen product is discharged from the customer supplied freezer and onto the product distribution system. Each bagger can discharge up to 80 bags per minute (320 bags per minute, total). The bagger discharge conveyors include a bag flipper to properly orient the bag (seal side down). Case forming and case transfer to auto case loading: Two case formers form carton blanks and discharge them onto NCC empty case accumulation conveyors to supply four auto case loader stations. Auto case loading stations: Four auto case loaders will be supplied to pick and place bags into empty cases. Empty cases will travel into the case loader from the opposite side the bags enter the case loader. The case loader uses two vision-guided robots in a single-pick configuration, thus allowing for correction of 360 degrees of bag miss-orientation. Full case discharge to case closing: Full cases discharge from each case loader and travel onto full case accumulation conveyors. Case closer discharge to incline spiral conveyor: Sealed cases then discharge onto a case transfer conveyor prior to reaching the case lay down conveyor. Overhead case conveyor to decline spiral conveyor: The cases will discharge from the incline spiral conveyor onto overhead case conveyors. Palletizing: The palletizing system consists of case control engineering

Robbie Kerfoot is client engagement manager with Stone Technologies Inc. Courtesy: Stone Technologies

Kevin Mauger is president, NCC Automated Systems Inc. Courtesy: NCC Automated Systems

October 2019

•

ANSWERS

COVER: PACKAGING AUTOMATION conveyor to present the cases to the system, fork-style pallet dispenser, 3-strand empty pallet conveyor, two robots to build the pallet pattern correctly, 3-strand full pallet conveyors, powered roller conveyors to match with existing stretch wrapper roller conveyors, all safety fencing/guarding required and control panel. Kerfoot: For this project, we provided some new hardware (labeling equipment and servers), wrote the interface coding required to interface between the new hardware and the existing control systems, and in multiple cases modified the existing control system to be more efficient due to the new systems put in place. Herman: Most controls [legacy PLCs] converted were discrete inputs and outputs for photo eyes and conveyors as well as line speed references and added communications over message instruction routines to upstream and downstream processors. Q: What were particular project challenges? Mauger: There were four challenges that came up during the project: • How well the stand-up bags will run (new item) • Project delivery timelines • Very small case conveying and palletizing • Rework of existing control system. Kerfoot: One of the largest challenges was working with a corporate team to develop the solution, and then deploy that solution to a variety of local sites that each had its unique obstacles to overcome while still achieving the corporate team solution.

Herman: The main project challenge was the small startup window (a three-day holiday weekend) and the small margin for error after production began. Based on the execution process and quality control procedures, the project finished earlier than expected, which left a buffer day for additional testing time. Q: How were those issues resolved? Mauger: By recognizing known risks up front, we put mitigation and contingency plans in place. Kerfoot: The key to overcoming this particular challenge was ensuring all expectations of stakeholders, both corporate and local, were always communicated, discussed, and resolutions derived early when there were differences. Herman: The issue was resolved and mitigated with a strong quality plan for the execution, a rigid checkout schedule and detailed site-acceptance test (SAT) checkout list. Q: Can you share some positive project metrics? Mauger: We don’t have great access to the production performance after install, but we were on time, on schedule and on budget. Herman: Downtime window was the threeday Labor Day weekend. The electrical contractor team began wiring Saturday morning at 12:01 a.m. and finished Sunday at 5 a.m. On Sunday, the controls team completed a I/O check out and then moved into functional testing. Testing of the code went smoothly (due to quality control efforts), and the team finished up after a long day. As a result, Monday was left as a buffer for more testing and the chance for the team to take some rest. The system was commissioned within the startup ramp (0 to 60 mph in 2 seconds) with only 20 minutes of total downtime associated with the project. Q: What were the resulting lessons learned or advice you’d like to share? Herman: The biggest lesson learned (typical for obsolescence projects especially in packaging areas where timing is everything) is to closely watch the sequence timing. The new processor and communication protocols typically will run considerably faster than the older processing speeds. The small downtime that was experienced was a result of timing out of phase from prior logic cycle times. This logic was rewritten to address the faster processor. We spent additional time focusing on the areas where timing was important. As the line was run at full speed we tweaked the timers and scans accordingly. ce

Cover: Case conveyor infeeds products towards robotic palletizing system. Courtesy: NCC Automated Systems

•

October 2019

control engineering

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

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INSIGHTS CONTINUED

IIoT tips

Continued from p. 16 Using message queuing telemetry transport (MQTT), edge devices and database connectivity enable operations to look at problems differently, cost effectively and in a way that can scale. Rip and replace isn’t always possible, Hougland acknowledged. Risk can be mitigated using I/O to cloud platforms with edge computing that supports familiar controls programming languages and enhances security. Doing so helps in the effort to get rid of programmable logic controllers (PLCs) and office computers on the plant floor in favor of DIN-railed mounted industrial edge devices capable of data processing and real-time control, and even secure existing programmable controllers (PLCs) where necessary. Secure VPN tunneling directly from the edge devices can reduce communications risk and enhances cybersecurity, Hougland said, and IT can help.

‘

Risk can be mitigated using I/O to cloud platforms with edge computing that supports familiar controls programming languages and enhances security.

’

6. Use best practice automation standard templates to enable IIoT implementations, suggested Dennis Brandl, chief consultant, BR&L Consulting. It’s faster to get from A to B by following a pattern. Updating and creating new assets can be more flexible and adaptive by using tools available in established standards, he said.

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October 2019

ISA 88 Batch Control Systems extends well beyond batch software and should be considered for any flexible, modular, object-oriented control software designs. ISA 95 Enterprise/Control System Integration lowers the time and cost of integrating operations with the enterprise. It enables integration in weeks instead of months or years and improves the changes. ISA 99 Security for Industrial Automation and Control Systems provides a framework for lowering cybersecurity risk to acceptable levels. ISA 101 Human Interfaces for Process Automation Systems explains how to design high-performance HMIs. 7. Consider lifecycle costs when looking at hybrid operations technology (OT) and information technology (IT) technologies for the edge and an organization’s digital transformation, suggested Rick Cedrone, the head of Americas field marketing for Stratus. Using available, rugged edge computing resources creates setup and maintenance improvements and efficiencies. Virtualized architecture helps reduce costly IT involvement and makes it a strong platform for oil and gas and other challenging environments, Cedrone said. 8. Ensure communications are appropriate for the scale of the project. Device-to-device communications can bog down large IIoT systems. MQTT for industrial communications can provide an open-standard architecture and a cost-effective digital transformation and bridge the OT/IT gap, said Arlen Nipper, chief technology officer, Cirrus Link Solutions. Cirrus Link provides MQTT centric software for industrial automation and IIoT implementation, which expand use of sensors, data and analytics, on on-premise or off-site cloud applications. In 2018, using MQTT became less proprietary as Cirrus Link donated its MQTT Sparkplug B communications engine to Eclipse Software Foundation. It’s now an open, community-driven specification under the Tahu working group. ce Mark T. Hoske is content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com.

control engineering

Leonard W. Moore dies Continued, from p. 14

In 1968, he founded Moore Industries-International Inc. in North Hills, Calif. Starting out in a small office with one employee and a very small budget, Moore set out to design the most rugged industrial instrument solutions that he knew the industry needed. He used to say that at Moore Industries “we are an engineering company that solves customer’s problems by manufacturing bulletproof solutions.” Moore often said, “The best compliment we can get from our customers is that they forgot about our products or solutions because they performed so well that they just plain forgot they were ever installed.” This rugged design mentality, which he mandated, can be seen in most of the company’s products that are enveloped in solid aluminum cases instead of fragile plastic or polycarbonate housings. More than 50 years after its inception, Moore Industries’ world headquarters remains in North Hills, Calif. The company continues to manufacture all its products at this U.S. location, something Moore insisted upon. With two acquisitions, more than 19 industry associated patents, 200 employees and remote offices located in the United Kingdom, The Netherlands, Belgium, Australia and China, the company continues to engineer, design, manufacture and support existing and new products for worldwide process control and automation customers. In 2009, Moore was inducted as an ISA Honorary Member – among those whose support, and/or contribute to, the advancement of the arts and sciences of instrumentation, systems, and automation. ce www.controleng.com

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input #11 at www.controleng.com/information

ANSWERS

I/O MODULES

James Figy, Beckhoff Automation

High-speed vision, Ethernet yield rapid improvements Case study: VMek enhances networking hardware for color sorting with pluggable EtherCAT industrial Ethernet input/output (I/O) modules that reduce costs, equipment footprint and time to market.

ent Lovvorn, general manager of VMek Sorting Technology, has a singular vision that drives him: design and perfect his own high-speed vision systems. “I wanted to specialize in some segment of high-speed machine vision,” Lovvorn said. High-speed machine vision requires high-speed industrial communications to help realize a 50% reduction in equipment assembly time. Founded in 2014, VMek offers software and hardware products for vision sorting. The company’s sorting machines leverage technologies to meet the needs of customers in the agriculture industry, which include the biggest seed producers in the U.S. The Metrix uses two full-color GigE cameras and offers a throughput of 600 seeds per second, while the Element has four full-color GigE cameras with a throughput of 12,000 seeds per second. The ability to provide valuable data on every seed in real-time differentiates VMek systems from other color sorters that only separate parts. “VMek software performs composite analysis using the front and back images of each item. The software isolates each part and mates them together to complete a 360-degree full-part analysis,” Lovvorn said. This data allows manufacturers and producers to analyze why individual parts were rejected and compare lab results with plant floor realities. They also can use insights to plan for the future, Lovvorn said. “The seed companies can plan accordingly for the next grow cycle to either enhance or eliminate specific traits.”

Continuous improvement with I/O The Metrix Analytic Lab Color Sorter, one of VMek Sorting Technology’s top hardware solutions, uses two full-color GigE cameras to separate and gather data on seeds. Images courtesy: Kevin Blackburn

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October 2019

CONTROL ENGINEERING

VMek continues to refine its systems to provide more granular data and transmit them using OPC UA without increasing machine footprint. From the beginning, Lovvorn believed continuous improvewww.controleng.com

The compact Beckhoff Automation EtherCAT EJ boards reduce footprint on VMek hardware. Standard LED lights, which can be seen through a window on the Metrix and Element machines, provide EtherCAT diagnostic information for operators. VMek sorting machines include the Metrix Analytic Lab Color Sorter and Element Analytic Production Color Sorter.

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360-degree color vision helps find rejects and compare lab

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results with plant floor realities.

ment of these systems would only be possible by partnering with vendors: “When I started to lay the foundations for VMek, I searched for hardware and software partners that developed quality components the right way.” During a presentation on the EtherCAT industrial Ethernet protocol, Lovvorn learned about the network’s ability to use PCs as real-time machine controllers and investigated using EtherCAT for high-speed vision machines. This led to the decision to standardize on EtherCAT input/ouput (I/O) hardware. During a 2017 redesign of several systems, VMek set out to reduce costs and space requirements, but wanted to continue using EtherCAT hardware. This effort did not need to increase reliability, as the first machine that shipped in 2015 has operated without major faults or failures. VMek wanted to enhance its offerings and decrease time to market by reducing the amount of hardware modules and point-to-point wiring. www.controleng.com

The top seed companies in the U.S. divide acceptable seeds from those that do not meet color or size standards using software and hardware solutions from VMek.

Pluggable I/Os saves space, time

Through discussions, Lovvorn found a fitting solution: pluggable EtherCAT I/O terminals. These terminals mount directly to custom-designed PCB boards using predefined JST connectors, and the entire board connects to the larger PC-based system via prefabricated cables or coded plug connectors. Because the boards come prebuilt, this makes series production more efficient and cost effective compared to wired terminals. control engineering

October 2019

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ANSWERS

I/O MODULES

“The core benefits were logical and came down to the ease of use that enables us to build distribution boards with the exact functionality, size, connectors and labeling we need,” Lovvorn said. “Because the board for each machine is customized for our designs and processes, we can build machines prior to buying the components, which

delivers benefits in terms of equipment costs and just-in-time assembly.” By implementing EtherCAT I/O modules with printed circuit boards (PCB) for each sorting machine, VMek was able to cut time to market significantly. “We estimate that we reduced our equipment assembly time by 50%,” Lovvorn said. “We have also mini-

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Hardware adjustments helped cut costs by roughly

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$700 per I/O segment.

mized service time, if it’s ever needed.” Small adjustments at the hardware level helped VMek cut costs by roughly $700 per I/O segment, and the company reinvested these savings in R&D to continue to enhance its vision sorting machines and software. Lovvorn had two goals: to make the best vision sorting software and hardware possible and to collaborate with companies that work to lead in their fields. “In our industry, every company’s sorting technology has to be fast and efficient, but through our innovation and partnerships, we offer more,” Lovvorn said. “As leaders in agribusiness, our customers see our complex sorting algorithms and ability to gather data on every part as indispensable.” As VMek continues to enhance its vision sorting systems to better detect, eject and report for the top seed companies, he does not see this changing. ce James Figy, marketing communications specialist, Beckhoff Automation. Edited by Chris Vavra, production editor, Control Engineering, CFE Media, cvavra@cfemedia.com.

M More ANSWERS

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Din-Rail

KEYWORDS: EtherCAT, I/O module A sorting technology company looked to improve speed with EtherCAT input/output (I/O) modules. Implementing EtherCAT I/O modules with printed circuit boards (PCB) for each sorting machine, allowed the company to cut time to market.

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ANSWERS

I/O SYSTEMS AND MODULES Josh Eastburn, Opto 22

Connect I/O systems, the IIoT Traditional wired input/output (I/O) connections is crucial for most automation systems. The latest generation of I/O systems bridges the gap to bring these connections into the Industrial Internet of Things (IIoT).

ndustrial automation applications are benefitting from the growing availability of smart devices. These intelligent components, also known as Industrial Internet of Things (IIoT) devices, range in capabilities and sizes from small, individual sensors to larger, packaged control systems. One thing they have in common is the ability to communicate extensive information via digital communication links. Based on the conversation around IIoT, one might get the impression these smart devices will all be wireless. The reality is traditional wired inputs and outputs (I/O) will continue to be in demand as a fundamental automation need. Many devices, such as relays, solenoids, switches and transmitters, still make sense as basic components with simple functionality. This is especially the case for retrofit situations, but it also applies to new installations. Automation I/O systems take on new importance when they consolidate basic signals to make many existing hard-wired I/O points look like fewer IIoT devices. Consolidation is crucial for reining in the volume of data the IIoT produces and use classic wired signals in a modern networking architecture for IIoT applications. Organizations can use these I/O systems to attain their digital transformation and IIoT goals.

I/O system basics

Traditional wired I/O connections are an established technology going back many decades. I/O points are usually referred to as discrete (on/ off signals) or analog (signals varying over a range), whether they are an input to an automation controller or an output commanded by the controller. The terms discrete input (DI), discrete output (DO), analog input (AI) and analog output (AO) describe traditional I/O. In the early years, one I/O module contained one input or output channel, and several single-channel inputs or outputs could be installed on a chassis. Later, manufacturers increased the density of I/O modules. One module may contain up to 32 channels (Figure 1). www.controleng.com

Opto 22â&#x20AC;&#x2122;s latest I/O modules, such as this forthcoming groov RIO, have software configurable point types and expanded data connectivity options. Images courtesy: Opto 22

Each DI/DO/AI/AO channel on an I/O system module is rated for certain voltage and current characteristics. Modules can be distributed or standalone, expandable or rack-based. Field wiring connections traditionally were made using screw-clamp terminals; many users are transitioning to spring-clamp terminals for easier wiring and vibration resistance. Most I/O modules must be installed in a protected environment. Some are connectorized for use in classified and other demanding areas.

Flexibility, mix and match

With many options to choose from, users often mix and match I/O types to best fit the application. Some specific features make it easier for users to connect, configure and power I/O systems. Form factor: From a physical standpoint, I/O systems with compact form factors are easier to integrate into a system. Compact size can be achieved through higher I/O density, or by designing narrow-width modules. Some trade-offs need to be considered, however, since reduced size constrains permissible wire gauge and may make diagnostics more difficult. Features such as removable terminal block and wiring arm systems also allow for quicker assembly and replacement of modules (Figure 2). Signal options: Most I/O systems offer signal levels at 24 VDC or 120 VAC for discrete points, and 4-20 mA or 0-10 VDC for analog points. Relay contact

M More ANSWERS

KEYWORDS: I/O systems, I/O modules, Industrial Internet of Things (IIoT) Input/output (I/O) applications benefit from the rise of the Industrial Internet of Things (IIoT). Users have many options to choose from and can mix and match I/O types to best fit their applications. The latest generation of I/O systems offers greater connectivity through Ethernet networks. ONLINE Read this article online at www.controleng.com for more on I/O systems in the age of IIoT.

CONSIDER THIS What other benefits can users gain from the IIoT connecting to I/O devices?

control engineering

October 2019

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ANSWERS

I/O SYSTEMS AND MODULES

Figure 2: Space in the field is always at a premium, so designers and installers appreciate I/O systems with compact form factors like this Opto 22 groov EPIC shown installed in a control panel.

Figure 3: The latest generation of remote I/O systems use Ethernet to replace expensive home-run wiring with one network connection.

•

DOs also are common. Thermocouple (TC), resistance temperature detector (RTD) and integrated circuit temperature detector (ICTD) are specialized versions of AIs. They’re often used to provide high input density and to avoid the need for separate temperature transmitters. Some manufacturers offer more specialized I/O, including rate (Hz), resistance (ohms), or millivolts (mVs). Mixed and multifunction I/O: Typically, all the channels in one module are alike in basic format — all DI, all AO, etc. Some newer systems offer modules containing discrete inputs and discrete outputs, or a mix of all four basic types. In the past, the variety of typical signal levels has required designers to plan for I/O allocations to match field instruments, made difficult because field device design details may not be defined until later in a project. To address this issue, many I/O system suppliers offer multifunction I/O modules that accept related types of signals on the same terminal points, using softwarebased configuration to configure specific characteristics for each. These modules may be more expensive, but they simplify the initial design and provide flexibility for future changes. Power distribution: Related to the discussion of I/O signal levels is how those signals are powered. Usually, loop power is either sourced from the I/O location or sinking from the field. Designers need to evaluate the I/O module isolation characteristics to ensure there are no constraints on how to wire I/O points sourced from various locations. Many I/O systems use open Ethernet protocols instead of traditional and proprietary industrial fieldbuses. This means some of these I/O systems can leverage commercial power over Ethernet (PoE) technology to operate remote I/O and power loops. Available power is limited, but PoE allows I/O systems to be installed without dedicated power supplies in some applications. Software-based configuration: A final key I/O system feature is software-based configuration of I/O modules and points. This attribute lets users adjust, view and document I/O ranges and features. A well-designed user interface also provides useful diagnostics. If the system includes a webbased interface, then this information can even be accessed on a user’s PC or mobile device.

October 2019

control engineering

Going the distance

Determining the communications link from the I/O module up to a monitoring or control system is just as important. A communications adapter is sometimes needed to enable the I/O modules to communicate with a supervisory system. Regardless, I/O supervisory communications is another area where technology improvements are making things easier for designers. Two concepts are important. The first is knowing the difference between local and remote I/O; the second is understanding the scope of communication possible for each I/O channel. Local I/O is directly connected with a controller, or quite close, often using a proprietary bus or serial connection. In contrast, remote I/O can be located anywhere in relation to the rest of the system and is connected using one of many networking or fieldbus technologies. The earliest iterations of I/O systems consisted of I/O adapters and modules that could only be interfaced with the controller (or PC) that mastered them, whether they were local or remote. Standard Ethernet networking was introduced for industrial I/O in the late 1990s; today it is common. While it has some distance limitations compared to traditional industrial I/O fieldbuses, Ethernet using industrial communications protocols, such as Modbus/TCP, EtherNet/IP, or Profinet, can provide capable and reliable I/O communications. Modern network methods offer other benefits for I/O as well. Ethernet is a well-understood, high-speed standard. It’s also the basis for corporate computer systems, facilitating interoperability. I/O adapters on Ethernet also can act as peers, publishing data to any number of devices.

I/O gets upgraded

Modern I/O systems can be networked using standard Ethernet, not limited to master-slave communications. New architectural possibilities can link traditional wired and smart wireless, and I/O and IIoT. In a medium- to large-scale project, field wiring is a large cost, especially when wireless options aren’t feasible. The latest remote I/O systems reduce the cost of integrating far-flung devices, using one Ethernet cable between controller and remote node (Figure 3). These systems also pair I/O control with embedded IT technologies to transform remote slaves into distributed data nodes. Independent of the master, remote I/O modules can communicate with a messaging queuing telemetry transport (MQTT) broker to enable peer-to-peer connectivity in the field. Such pairing means field data can be sent to cloud services or databases, integrating the network into the IIoT. ce

Josh Eastburn is director of technical marketing, Opto 22. Edited by Chris Vavra, production editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com. www.controleng.com

input #15 at www.controleng.com/information

ANSWERS

ARTIFICIAL INTELLIGENCE Ashish Khushu, chief technology officer, L&T Technology Services Ltd.

Decode hybrid AI potential New artificial intelligence (AI) software will contribute to the creation of more competitive sensor systems. Hybrid AI helps robotics, other automation.

Industrial AI tools include knowledge-based systems, fuzzy logic, automatic learning, neural networks, ambient intelligence, and genetic algorithms. Courtesy: L&T Technology Services Ltd.

rtificial intelligence (AI) platforms will trigger disruptive innovations across enterprises, from manufacturing to consumers. It is imperative to look into the widespread and complex issues AI can successfully tackle. In addition to capabilities in todayâ&#x20AC;&#x2122;s software, AI is an amalgamation of several concepts, which can align and produce greater results. In the industrial sector, AI tools have evolved to include knowledge-based systems, fuzzy logic, automatic learning, neural networks, ambient intelligence, and genetic algorithms. The power and affordability of computing systems have made sensensor AI applications more widespread. Hybrid tools may gain a greater role. Additional technological developments in AI will impact sensor systems include data mining, multi-agent systems, and distributed self-organizing systems.

Hybrid AI systems

M More ANSWERS

KEYWORDS: Artificial intelligence, AI for sensor systems Hybrid AI creates value more quickly. Automation, robotics, weld programming are among AI applications. Computing power has helped AI advance. CONSIDER THIS What AI applications do you need to reconsider?

ONLINE If reading from the digital edition, click on the headline for another diagram, more info. www.controleng.com/magazine See eBooks at www.controleng.com/ebooks

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October 2019

The tools and methods driving hybrid AI have minimal computation complexity and can be implemented on small assembly lines, single robots, or systems with low-capability microcontrollers. These approaches use ambient intelligence and mix different AI tools to use the best of each technology, encompassing a more advanced framework when compared to traditional AI mechanisms. Hybrid AI systems using elements of different AI techniques can produce more strengths and fewer weaknesses. An example is the neuro-fuzzy system, which combines the uncertain handling of fuzzy systems with the learning strength of artificial neural networks. Hybrid AI can help with automation, manufacturing and robotics, including weld programming. An existing system consists of two software systems working in series to

control engineering

construct viable robot programs to boost efficiency. The first system, the computer-aided design (CAD) model interpreter, accepts a CAD model and determines the welds required. This data is fed to the program generator, which reorientates the weld requirements in line with the actual real-world orientation of the panel. The program generator sends any programs sequentially to the robot (normally one program per weld line). Additional software systems could be incorporated into the existing system at the point where the robot programs are sent to the robot system. At that point, the communication method is standard transmission control protocol/internet protocol (TCP/IP), and any programs sent can be viewed as text files.

Mixing sensor, logic systems

Researchers are mixing sensor systems and some powerful new technologies; results include less use of energy, space, and time, along with more output for less cost. Machines read-in data from real objects and lay-down successive layers to build up an object model from a series of cross sections. AI reduces costs and time in most applications. AI can increase effective communication, reduce mistakes, minimize errors, and extend sensor life. Over the past decade, industries have explored various opportunities to make the shift towards developing and applying hybrid intelligent management systems across various operations capable of using multiple AI techniques. It may take another decade for engineers to recognize the benefits due to a lack of familiarity and the technical barriers associated with using these tools, but this field of study is expanding. Hybrid AI systems can deliver long-term sustainable business benefits throughout the industrial value chain. Company leadership needs to leverage available best-in-class solutions to transform legacy systems into modern-day models. ce

Ashish Khushu is chief technology officer, L&T Technology Services Ltd. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com. www.controleng.com

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input #16 at www.controleng.com/information

ANSWERS

ARTIFICIAL INTELLIGENCE Tina Hull, Omron Automation Americas

Self-taught industrial machines, robots lower risk Future automation safety will involve machines that learn. Artificial intelligence (AI) and machine learning (ML) advances can prompt robots and other industrial machinery to learn from a massive pool of safety-related data.

he primary focus of industrial safety measures used to involve isolating the machines from personnel as much as possible. Technological advancements in automation equipment have made it possible for machines — particularly collaborative robots — to work with human operators in close quarters. These technologies have features like rounded edges and force-feedback sensors to reduce the likelihood of an injury upon contact with an operator. In addition, automation systems are transitioning from fixed to autonomous mobility. One manufacturing solution poised to transform manufacturing involves connecting a collaborative robotic arm to a self-navigating mobile base. For control design engineers to employ risk reduction measures for innovations like this, they need to understand the requirements of the technology, its potential hazards, and the ways operators will be working with it. As systems get more complex, it becomes more challenging for manufacturers to analyze all the data

Autonomous mobile robots can self-navigate a facility using onboard mapping software. Images courtesy: Omron Automation Americas

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October 2019

control engineering

applicable to a risk reduction plan. The amount of information can be overwhelming, and the mechanisms available to govern the decision-making process are limited. Artificial intelligence (AI) can help overcome these limits with multiple options the automation designer may not have considered. This quality combined with its sheer number-crunching power makes AI an essential part of automation systems.

Determining safety requirements

The standard IEC 62061, which deals with safetyrelated electrical, electronic and programmable electronic control systems, defines functional safety as: “Part of the safety of the machine and the machine control system which depends on the correct functioning of the SRECS (safety-related electrical control system), other technology safety-related systems and external risk reduction failures.” This definition makes more sense when reframed as a goal, which is to design a system that, in the event of a failure, will fail in a predictable manner. The manufacturing industry has become proficient with hardware solutions. Safety standards provide manufacturers, integrators, and end users with a best-practice methodology to achieve tolerable risk levels for these solutions. We also can draw upon these standards to help determine the safety requirements for developing technologies. At present, there are no safety standards specifically for an industrial robot integrated with a mobile platform. We can gather relevant information from existing safety standards, such as ANSI B11.0 or ISO 12100 for risk assessments, ANSI RIA R15.06 or ISO 10218-2 for industrial robotic systems, ANSI/ RIA R15.606 or ISO 15066 for collaborative robots, ANSI/IT SDF B56.5 or EN 1525 (to be replaced by ISO 3691-4) for industrial trucks, and ISO 13849-1 for failure prediction and validation. Sources of hazards and recommended risk reduction measures should be available in vendor manuals. After determining the applicable standards, the engineer needs to evaluate and design for things www.controleng.com

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ANSWERS

ARTIFICIAL INTELLIGENCE

The factory of the future uses artificial intelligence and mobile manipulators to boost quality, flexibility, efficiency and traceability.

that influence the space, such as workflow, obstacles, accessibility, misuse and training. Technology also plays a role, as feedback error can cause measurement noise that affects position tracking, and compliance in the joints can have inherently nondeterministic behaviors. The engineers also should consider ways in which the system absorbs energy, the methods used to limit forces, and the use of safety functions.

Integrating artificial intelligence

The main challenge of ensuring the safety of nearfuture technologies is not a lack of applicable information, but rather an overabundance of it. When there are too many variables, the major limitations of developing binary rules to represent past experiences become more apparent. As technology advances while the development of KEYWORDS: Machine standards lags, designers are often left with safety, artificial making future predictions. This causes them intelligence, machine learning to overestimate or underestimate the necesArtificial intelligence (AI) sary safety functions. can help manufacturers Manufacturers can deal with this inforanalyze the data involved mation more effectively if they expand their with safety issues. toolset supporting the data-crunching and AI can help make robots decision-making processes. In particular, and other equipment more they can find a welcome solution in the form ergonomic and adapt to specific workers. of AI and machine learning (ML) algorithms. An AI system could recommend new systemONLINE specific guidelines based on case studies and Read this article online at research data as these become available. www.controleng.com for discussion of AI, safety ML brings hidden correlations to light by hardware, software with links analyzing large amounts of data to discover to more from Tina Hull and underlying patterns and trends that aren’t machine safety under topics readily visible using traditional statistical and discrete manufacturing. tools. Humans can find abstract models from CONSIDER THIS these correlations and perform experiments How else can artificial to determine how well the models work. intelligence and machine Designers and engineers can rely on a learning help improve your plant-floor operations? smart system to guide design, making sure

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to incorporate the best approaches and stay as close as possible to the desired solution. AI is important for eliminating biases that could hamper decision-making. Since memory is a large part of how the brain makes decisions, experts’ perceptions of past experiences can create biases that affect how they deal with new situations. An expert also could either fail to recognize that crucial information is missing or make the mistake of starting with an endpoint solution at the beginning of the decision-making process. ML algorithms reduce biases because they find patterns in the current and actual data that help solve a particular problem as part of the process, using either a supervised training set or an unsupervised starting point.

Data-driven challenges

The driving force behind the introduction of AI into industrial equipment is the sheer plethora of safety-related information in today’s manufacturing facilities. There’s so much data out there even experienced workers are having trouble learning and retaining it all — not to mention the junior employees who are just stepping into their first manufacturing job. By getting the machines to learn for themselves, companies can take advantage of a powerful risk-reduction tool that will offer both shortterm and long-term data on safety requirements in a changing environment. Everything being applied in safety solutions today is based on things engineers, operators and manufacturers have learned from the past. In that sense, AI isn’t all that different. Neither humans nor algorithms start off knowing anything about industrial safety — we must all make connections using bits and pieces from past experiences that we can apply to new situations. We learn what works and what doesn’t work, and we use this knowledge to make future decisions. AI works the same way. ce

Tina Hull is TUV Functional Safety Expert and product engineer, Omron Automation Americas. Edited by Chris Vavra, production editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com. www.controleng.com

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ANSWERS

ARTIFICIAL INTELLIGENCE, ROBOTICS Robotic Industries Association (RIA)

Teaching industrial robots with AI Artificial intelligence (AI) is an efficient method of teaching an industrial robot new skills and can streamline manufacturing processes.

igh-level planning is relatively easy for humans, but for the industrial robot, it can be a struggle. Just as manufacturers are always trying to streamline the manufacturing process, engineers are always looking for new ways to efficiently and easily train industrial robots. Artificial intelligence (AI) is an efficient method of teaching an industrial robot new skills.

Benefits of using AI to train industrial robots

Making robots easier to train helps make automation more accessible to a wider range of industries. In businesses where industrial robots are new, it’s harder to find engineers and skilled human operators to train the robots. AI helps to simplify the training process. With AI infrastructures, a human can focus on what needs to be done, not how the robot needs to do it.

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It’s harder to find engineers and skilled human operators to train the robots. AI helps to simplify the training process.

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AI can train several robots at once, so less time is spent on training. This is especially helpful to industries experiencing labor shortages. It can be difficult for a human operator to show a robot how to move things the same way the operator would move them; AI technology lets the operator teach the robot more intuitively. With AI, it’s easier for an operator to track the robot’s learning than it previously was with conventional training methods. For example, in bin-picking a robot is trained to pick objects out of a bin. This helps humans avoid tedious, time-consuming tasks like sorting

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bulk orders of parts. Through the use of simple annotations and sensor technology, AI reduces the training process needed to teach industrial robots to pick the correct objects out of a bin. The conventional process would require training the robotic automation system many rules so it knows what parts to pick up — this involves running many iterations and experiencing a lot of trial and error. The time spent is especially cumbersome. Then, humans would have to teach the robotic automation system when it made errors, in order to refine the robot’s training. AI-based tools let a human operator simply look at a photo of parts jumbled in a bin, and tap on a few examples of items to be picked up. In this AI process, the robot matches images of example parts with its vision sensors. Instead of developing complex rules, it’s as easy as showing a child how to sort toys. ce This article originally appeared on the Robotics Online Blog. The Robotic Industries Association (RIA) is a part of the Association for Advancing Automation (A3), a CFE Media content partner. Edited by Chris Vavra, production editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.

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KEYWORDS: Robotics, artificial intelligence High-level planning is a challenge for industrial robots compared to humans. Artificial intelligence (AI) can help simplify the learning process for robots. AI-based tools allow a robot to match images of example parts with its vision sensors.

ONLINE Read more articles from the RIA online at www.controleng.com/robotics.

CONSIDER THIS How could smarter software with AI help with teaching robot what to do and when? www.controleng.com

ANSWERS

WIRELESS

John Bernet, CMRP, Fluke Corp.

Wireless condition monitoring

Wireless sensors can help discover maintenance issues before they happen by supplying real-time information. See four methods and four steps.

ondition monitoring is the best way to proactively determine when machines need maintenance. Collecting realtime data on an asset’s condition provides an accurate, up-to-date picture of asset health. This lets companies use resources more efficiently instead of relying on a calendar for planning maintenance actions. For assets that often fail at random, such as rotating machinery, calendar-based maintenance is ineffective. Regardless of the type of asset, condition monitoring is the best bet for reducing unplanned downtime and production gaps and helping boost a company’s bottom line. Condition-monitoring systems often start with wireless sensors. Machines monitored by wireless sensors can let a user know the machine needs to be inspected or maintained. When equipment is continuously monitored with wireless sensors, users are alerted to changes or deviations from the norm. Once installed, they monitor assets 24/7 and trigger alarms when conditions reach certain thresholds. Wireless sensors also increase safety and efficiency. They are easy to install, even on assets in dangerous or hard-to-reach places. Once the sensors are installed, maintenance team members can avoid repeated trips to take regular measurements from these assets. The next steps are to diagnose the potential fault and its severity so users can plan the best corrective action. Numerous technologies can detect machine faults and their severity. By matching the asset and the company’s needs and budget with available technologies, users can boost reliability and maximize maintenance dollars and resources.

Condition-monitoring methods

Predictive technology methods that detect potential faults the earliest aren’t always the best choice for each situation. Early detection technologies typically required expensive diagnostic tools, and maintenance team training to use the tools and interpret data. Striking the right balance between the amount of warning a user has about the fault and the amount of time and money needed to spend to diagnose the fault is key. The most advantageous time to act isn’t always the earliest possible time. What condition-monitoring methods might fit the company’s needs? Here are some technical considerations for four common methods.

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Oil analysis is capable of detecting faults early. Monitoring lubricant, wear, and contamination offers a multifaceted look at asset condition and can alert users to potential issues before any actual damage occurs. Oil analysis can be useful for low-speed machinery (<5 rpm), where vibration analysis may be difficult. Oil analysis can save money by eliminating time and materials spent on premature oil changes. Obtaining oil samples and interpreting oil analysis data can be complex, and using a lab brings additional costs. Not all assets have oil that can be analyzed.

2. Ultrasound analysis can discover things oil anal-

ysis can’t, such as bearing wear or fatigue so early that it is often too soon to replace the bearings, and they should just be greased. Decibel readings reflect friction, and increased decibel readings can indicate a potential fault resulting from too much friction. Ultrasound can detect leaks — such as compressed air or steam — by identifying sounds at frequencies that wouldn’t be heard in a plant’s ambient noise. Ultrasound can be useful for low-speed machines.

Wireless sensors are easy to install, even on assets in dangerous or hard-to-reach places. Once installed, maintenance team members can avoid repeated trips to such assets to take regular measurements. Courtesy: Fluke Corp.

Vibration monitoring analysis has been established for decades, so vibration patterns and anomalies are well documented. They are easy to follow; extensive training or experience is generally not required. Vibration analysis also can identify the most common mechanical faults: imbalance, looseness, misalignment and bearing issues. It identifies faults 12 to 18 months in advance, which allows plenty of time to react while there is still life in the asset, but without the waste of replacing or repairing them too early. control engineering

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ANSWERS

WIRELESS

Because faults can be detected before they an asset’s performance is impaired, there is time to diagnose the fault’s severity and plan the necessary maintenance action without impacting production.

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KEYWORDS: condition monitoring, wireless sensors, maintenance Wireless sensors can provide real-time information for condition monitoring applications. Condition monitoring tools include oil analysis, ultrasound, vibration and thermography. Steps to implement condition monitoring include performing a criticality analysis and identifying potential failures. ONLINE Read this article online at www.controleng.com for an additional story from the author.

CONSIDER THIS What machines in your plant would benefit most from wireless sensors?

4. Thermography can uncover electrical hot spots, faulty connections, overheated bearings, pipe blockages, issues with tank levels and other issues. Use vibration combined with thermography for rotating machines to avoid asset damage. Wireless sensors can communicate real-time information related to all of these methods. By monitoring measurable conditions, such as capacity, temperature, pressure, or sound, and sending a signal when the relevant quality changes or reaches a certain threshold, wireless sensors make it possible to users to know about potential faults right away.

Condition-monitoring steps

Several steps can help establish a successful condition-monitoring routine. When making changes to a maintenance program, a best practice is to start with

a small pilot program and grow it over time, rather than attempting to change everything at once. This allows the maintenance team and the organization’s leadership to buy in as they see the positive impacts of the changes. Condition monitoring provides warnings about faults and makes it possible to schedule repairs without unplanned downtime and lost production. Here are four recommended steps: 1. Conduct a criticality analysis. It makes sense to keep the closest eye on the assets that have the most significant impact on the bottom line. If they aren’t being continuously monitored already, these assets are good candidates for wireless sensors. 2. Identify probable asset failures. 3. Decide on the technology best suited to identifying these failure modes, keeping in mind the team’s training and experience and the budget. 4. Trend and analyze the data from the wireless sensors to plan and execute maintenance actions at the most advantageous times, reducing unplanned downtime and extending the life of the assets. ce John Bernet, CMRP, mechanical application and product specialist, Fluke Corp. Edited by Chris Vavra, production editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.

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ANSWERS

WIRELESS

Bryan Christiansen, Limble CMMS

Wireless applicability Wireless manufacturing applications include machine-to-human and machineto-machine (M2M) communications. How can wireless add productivity?

ireless technology has become one of the fastest growing and adopted platforms businesses use today and is beneficial to all categories of organizations, including manufacturers. Wireless is finding applications in every stage manufacturing workflow, from development to production, warehousing, and distribution. With the collaboration of the Internet of Things (IoT) coupled with LPWAN (a WAN subcategory), wireless system use will continue to expand. Industrial wireless networking is attractive because it can provide cost-effective deployment, usefulness in hazardous environments, and overall operational convenience. Areas where manufacturers commonly use wireless are machine-to-human communication, machine-to-machine (M2M) communication and maintenance management.

1. Machine-to-human communications

Worker safety and the drive to achieve zero incidents remains a challenge in manufacturing companies. Wearable devices, first popular as a trendy fashion accessory, are helping to improve safety. Wearable wireless devices are fitted with smart sensors that connect through wireless to the internet. Hazardous work in the industry is now being managed through the practice of connecting personal protective equipment (PPE) to a network that remotely monitors workers’ interaction with their working environment. Plant managers can track workers’ exposure to toxic gases, low oxygen, radiation, and use similar technology to avoid collisions between humans and moving equipment, such as robots. Other products include smart helmets that monitor fatigue and how long a wearer’s eyelids are closed, radiation-blocking underwear, and smart safety shoes. Wearable tech is becoming a staple, rather than a luxury, on the factory floor because of its safety and productivity benefits for workers.

2. M2M communications

In manufacturing, wireless communication allows plant owners to reinvent several aspects of manufacturing through automation integration to convert factories into intelligent and unified systems. Several industry organizations use wireless signals to monitor every stage of production and control, with

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little error, every sequence to deliver quality products. Application examples include control of conveyors, wrapping machines and coating machines at painting stations. Wirelessly controlled robots can help with automatic assembly, machine tool control, packaging, labeling, inspection testing and other areas.

3. Wireless maintenance management

With the advent of wireless sensors, it is now feasible to monitor different parameters (temperature, vibration, pressure, noise, and others) in real-time in more applications without cables. Wireless sensors also mean equipment can be moved from one location to the other, if necessary, with fewer problems. Even mobile equipment like cranes and forklifts can be monitored on this platform. For critical assets that require non-stop monitoring from remote stations (power lines, oil fields, gas lines, etc.), these M2M applications are supported with video streaming surveillance products, which allow maintenance personnel to take immediate action. Other applications continue to evolve for maintenance management. Workers can wear smart glasses with augmented reality (AR) support, which allows them to receive maintenance instructions from experts while in the field. For better inventory management, radio frequency identification (RFID) can identify individual assets for tracking. Wireless maintenance management benefits from a robust wireless infrastructure. Frequent downtime, excessive production stoppage, and escalating maintenance costs are indicative of reactive maintenance, which is repairing or servicing equipment after it fails. Plant managers should consider switching to more proactive maintenance strategies like preventive, predictive, or reliability-centered maintenance (RCM). Manufacturers need to consider energy management. The U.S. industrial sector accounts for almost one-third of national energy consumption. Wireless sensors can measure and generate actionable insights to manage energy use. ce

Bryan Christiansen is the founder and CEO at Limble CMMS. Limble is a mobile CMMS software company that helps managers organize, automate, and streamline maintenance operations. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media, mhoske@cfemedia.com. control engineering

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KEYWORDS: Wireless technology, maintenance Wireless use is expanding for manufacturing with greater use of automation. Wireless ommunications can be between humans and machines or between machines. Maintenance can benefit from wireless technology. ONLINE Read this article at www.controleng.com to see “Potential wireless dangers” to consider and links to other wireless stories.

CONSIDER THIS What wireless applications can add to your productivity?

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ANSWERS

WIRELESS

Justin Shade, Phoenix Contact USA

Defining details of a wireless network installation When starting to design a wireless network, it is important to define the who, what, when, where, and why of the installation.

ireless networks can provide great value and cost savings in industrial installations. The ability to provide information from point A to point B with the same reliability and accuracy as a wired network while saving money, is a huge benefit — so long as the implementation is thought through and designed correctly. Designing a wireless network has many variables and unknowns: those involved cannot “see” everything in the air. With wired networks, those involved know where data is going, what else is “on the wire,” and can predict network performance. The same can be said for wireless systems if the correct steps are taken during the design and validation process. When starting to design a wireless network, it is important to define the who, what, when, where, and why of the installation.

Who are the network stakeholders; who will maintain the network? When first discussing the implementation of a

wireless network, it is important to know who will be financing the project, as well as who will be using and maintaining the network. These could be two different groups of people who have different views on how the network will be implemented. Is an engineering group funding the project or an executive group? Each of these groups has different goals. The engineering group is looking for the best solution to solve a problem.They will not necessarily focus on the cost of the system, as long as it solves the problem. An executive management leader may be more focused on the ROI and cost of the system. To make the design process more manageable, it is important to know which of these groups is involved (and it could be both) and how to satisfy their concerns with a reasonable solution. From the day-to-day side of the installation, operations technology (OT) engineers focus on the data coming from the network that relates to the application. They want to get the data in a visual, readable way so they can efficiently interpret it, for example, a human-machine interface (HMI) screen or webpages for the Ethernet devices. Information technology (IT) engineers also are interested in the data but more in the raw format. They want to be able to manage, maintain, and configure the wireless system but with the tools they use daily. Using a commandline interface for these types of functions is more native to an IT engineer than a web manager.

What is the expectation of the network? What is the use case?

Figure 1: Engineers on the operational technology (OT) side of an application want to get the data in a visual, readable way so they can efficiently interpret it. Images courtesy: Phoenix Contact

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The “what” question is probably the most overlooked and underappreciated question in the wireless design process. What is the user’s expectation of the network? It isn’t enough to ask, “What do you want it to do?” What the user wants the network to do and what is possible are two completely different things. For example, if a customer expresses need for remote access to a programmable logic controller (PLC), it sounds like a simple application. Other “what” details could make a difference: What if this PLC is 5 miles away, without wireless infrastructure, and data must be available 24/7? Digging deeper and www.controleng.com

understanding the customer’s needs and expectations is important. Getting all requirements upfront makes it easier to provide a suitable solution. With these details, the design engineer can accurately discuss options with the customer. Discuss what can and cannot be achieved and give a realistic estimate of how much it costs to do what they want the way they want it done, or provide an alternative approach, which might cost less, but have some limitations. The design engineer can evaluate, test, and validate the design based on those expectations.

When are the deadlines for each installation milestone?

Knowing the project timeline is important because it can help define what wireless solutions are possible. Some projects have long cycles, which include specification, bid, design, test, installation and validation. These projects can take months or years to complete. Other projects could be just days from idea to installation. Knowing the user’s timeline will help the company plan time accordingly and help communicate what is and what is not possible to the customer in that time frame. If the customer needs a quick turnaround but also requires installation of some infrastructure — such as antenna towers, permits, or renting vehicles — let the user know if the requested time frame is possible or not.

Where is the system being installed?

Knowing where the system is going to be installed is important. The design engineer needs to know what infrastructure is available for the new wireless system. Is conduit available? Are equipment rentals needed to install new equipment? Are antenna towers already erected, or will new ones be needed? Second, are there any existing wireless systems or planned wireless systems in the same area? In today’s world, wireless is everywhere, but it cannot be seen. Knowing the location of the new installation allows the designer to evaluate and research wireless systems already in the area. Involve the owners of those systems in the conversation, so the new design can coexist with existing installations.

Why are they installing a wireless network?

Why is the customer installing a wireless system? Why not run a cable? Why install a wireless system in general? Are they installing the wireless system to solve a problem? Is that problem costing the user money? Do they have extra budget they need to spend before the end of the year? Are they trying to comply with a new process specification required or they get fined? These questions help give the designer an idea of the importance of the installation and how to design based on that knowledge. For example, if the user is installing a wireless sys-

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Figure 2: The “where” of an application has a very large impact on the design. For example, a wireless network on a factory floor will differ from one in a remote refinery.

tem because they have extra budget at the end of the year, they will have a fixed budget. The proposed system design needs to be considered based on a fixed budget. On the other hand, if it is a mission-critical upgrade because the company is losing communication to assets and every minute they are down they lose thousands of dollars, the design may be different and demand a premium. The why is most important understand. Have good and open communication with the user throughout every step of the design process. If the “why” changes, the design might change as well.

Thorough planning prevents heartache

Understanding the who, what, when, where, and why aspects of a system design is crucial to a successful wireless installation. Gather all the details from the user in the beginning and keep an open line of communication. If changes occur during the project, discuss them with the customer, and explain how those changes will affect the overall system from a cost, function and reliability standpoint. Do not be afraid to ask for more explanation from the user. More often than not, if it’s being asked in the first place, that means the user hasn’t thought about it, either. Asking those questions now could save a lot of heartache later. ce

Justin Shade, senior product marketing specialist — wireless, Phoenix Contact USA. Edited by Chris Vavra, production editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.

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KEYWORDS: wireless networks, wired networks, operations technology Wireless network installation requires a great deal of planning from the design engineer and the customer. The design engineer needs to gather as much information as possible before beginning a project. Open communication and a willingness to ask as many questions as possible will spare both sides trouble later.

ONLINE Read this article online at www.controleng.com for more stories about wireless networks.

CONSIDER THIS What was the biggest consideration or challenge when your company installed a wireless network?

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ANSWERS

ADVANCED PNEUMATICS Sandro Quintero, Festo

New ways to increase productivity with smart systems Intelligent pneumatics offer flexibility for Industry 4.0; cyber-physical systems (CPSs) can help valves achieve greater connectivity and intelligence.

ntelligent pneumatics combine standardization with flexibility, which is propelling pneumatics into the age of Industry 4.0. The technology behind intelligent pneumatics unites the benefits of traditional pneumatics with those of controlled and complex electrical motion. Despite the simplicity, it integrates more functionalities than conventional technology. The trend in automation towards networked, decentralized, and intelligent systems with optimum function integration is happening because technical and economic requirements are increasing. The demand for additional features, such as interpreting environmental information, is also on the rise in the age of Industry 4.0. The communication opportunities, including the ability to have components communicate with each other, are opening up new areas of activity. This permits more specific preventive maintenance and clears the way for autonomous production with self-regulating systems.

Status quo, mechatronics

Conventional mechatronic systems bring together mechanical systems, electronics, control technology and information technology and enable them to interact in actual automation applications. They are the only way to ensure pneumatics can be integrated in electromechanical applications and are essential for precise positioning of pneumatic drives. Modular mechatronic systems facilitate extensive func-

The Festo intelligent valve has industrial Ethernet, a controller for flexible function via app, valves with sensors for closed-loop control, analog and digital inputs, and integrated supply-pressure and temperature sensors. Images courtesy: Festo

â&#x20AC;˘

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control engineering

tion integration, such as greater system adaptability and standardization. This results in system improvements and optimizations all along the value chain because fewer components have to be selected, procured, assembled and wired. Digital communication provides additional benefits, because for example the influence of electromagnetic compatibility (EMC) on analog values, which helps rule out system faults.

Mechatronics lack flexibility

Despite the benefits of modular mechatronic systems, flexibility can improve. Retrofitting system adaptations during the design and engineering process or parameter changes required for format changes during operation are only possible with expensive and time-intensive modifications. A modular design offers some flexibility, but only within the limits of the particular module. The general rule is any parameters that could change must already be taken into consideration at the design stage. According to the rule of 10, costs for subsequent adaptations increase by a factor of 10. It makes no difference whether the changes are needed to adjust the sizing to a change in loads, or to add new functions requested by the end customer.

Flexibility, networking

Although numerous definitions exist for cyber physical systems (CPSs), there isnâ&#x20AC;&#x2122;t a commonly accepted definition. However, what is certain is CPSs will play a pivotal role in Industry 4.0 applications. CPSs, in terms of basic structure, are mechatronic systems. They also have integrated smart sensors and greater software intelligence. One possible application is predetermining external influences using data recorded internally without the need for additional sensors, and then sharing this information internally and externally with other systems via suitable communication interfaces. Such systems can be adapted without the need for new or additional hardware because the functional adaptations are executed using software and apps, or the system auto-tunes itself, or via control system instruction. www.controleng.com

Implementing requirements for Industry 4.0 such as system-wide data usage depends on the system, and the product and can be limited as a result. The reason is simple: the data recorded in the device by sensors is not shared with other stations because there is no data interface. For example, the temperature data measured in proportional valves is only processed in the valve itself. No other diagnostic functions are carried out, even though this would provide the means to determine, for example, if there is a defective fan in a control cabinet. The factory of the future the industry needs products with integrated sensors and an Industry 4.0 interface. It is essential this interface meets international standards for data management and communication. The software interface standard OPC Foundation’s Unified Architecture (OPC UA), published as part of the IEC 62541 series of standards, is a good example.

Flexible technologies, Industry 4.0

Actuators used in the pneumatic parts in the form of a bridge circuit are one of the new technologies driving Industry 4.0 forward. The four 2/2-way piezo pilot and diaphragm poppet valves with integrated smart sensors offer huge flexibility. In contrast to conventional mechatronic systems, these smart sensors are embedded directly in an intelligent valve terminal. This means pressure measurement sensors no longer act as a separate module that needs to be selected via the configurator. The range of tasks is also expanded as the pressure measurement sensors can be used for tasks such as diagnostic functions. • Four 2/2-way valves (diaphragm poppet valves) are connected in series to form a full bridge • Each diaphragm poppet valve (gray) is proportionally piloted and controlled by two piezo valves (blue) • The digitally controlled piston can take on the functions of a wide range of mechanical control pistons found in common directional control.

Motion apps replace hardware

Thanks to downloadable motion apps, the intelligent valve terminal offers the traditional valve functions of 2/2-way, 3/2-way, 4/2-way or 4/3-way valves as well as proportional technology and servopneumatic functions in one device. All these functions can be implemented in a CPS using motion apps. This is special because it all can be done with one valve of the same design. This valve combines the benefits of pneumatic and electric automation technology. The intelligent pneumatic valve integrates complex movements, variable positioning, condition monitoring and other functionalities into one component while consuming less energy. The flexibility, implementation speed and the

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Thanks to fast activation of new functions via software apps, machine developers can create a basic machine type and then, depending on which apps are selected, equip it with different functions and features as per the application requirements.

overall economic benefits compared with “hardwired” conventional systems are much greater. Since changing parameters in systems such doesn’t necessarily mean the hardware needs to be adapted, the rule of 10 no longer applies. Adaptation costs are kept within tight margins, even if changes are made during phases well after the design phase.

New dimensions in automation

Digitization will have a major impact on production. For the first time, CPSs are enabling solutions that combine mechanical systems, electronics and software and also get systems ready for Industry 4.0 applications, including pneumatics. Compared with modular mechatronic systems, they offer an impressive combination of maximum standardization and a high level of flexibility. Since the intelligent pneumatic valve uncouples pneumatic functions from the mechanical hardware and makes them available via apps, a wide range of pneumatic motion tasks can be performed with one valve type. This offers many measurable benefits along the value chain. CPS solutions enable complex movements like gentle retraction into the end position as well as various speed profiles or positioning tasks that were only possible with servo-pneumatics or electrical automation. They also make it easy to realize a wide range of functions, condition monitoring, preventive maintenance and it reduces energy consumption. Any higher purchase costs for CPS for simplified processes compensate OEMs and end customers, increases productivity and process reliability. ce

Sandro Quintero is the product manager — valve terminals & electronics at Festo. Edited by Chris Vavra, production editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com. control engineering

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KEYWORDS: pneumatic

valves, Industry 4.0 Intelligent pneumatics combines standardization with flexibility, which is propelling pneumatics into the age of Industry 4.0. Cyber-physical systems (CPSs) will help connect pneumatic valves to other applications for greater connectivity. Intelligent valve terminal technology allows a wide range of pneumatic motion tasks to be performed with just one valve type.

ONLINE Read this article online at www.controleng.com for more information about pneumatic valves in the age of Industry 4.0 and what it means for manufacturers.

CONSIDER THIS What benefits could your facility get from smarter pneumatic valves?

October 2019

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Turn Remote Sites Into Smart Remote Sites Cellular Networking Solutions to Connect, Monitor and Control Remote Assets Red Lion Controls

Every business strives to protect revenue, as well as ensure uptime and availability for customers. The oil and gas, alternative energy, power, utilities, water and wastewater spaces face unique challenges when working toward these goals. They must achieve seamless connectivity, regardless of expansive territories, asset age and types of communication technology. Using cellular networking to build smart remote sites overcomes many infrastructure, financial and safety barriers. Today’s energy and utility companies operate in competitive, closely scrutinized business environments. These organizations must adhere to stringent regulatory requirements to prevent downtime for customers. When equipment fails, the resulting downtime leads to immediate financial and safety consequences. As competitive forces grow and business demands intensify, companies can capitalize on the benefits of the Industrial Internet of Things (IIoT) to improve their processes and data assets. Companies require more consistency, better visibility of networks, reduction of waste and loss, and increased compliance with regulatory requirements. Smart technology has the ability to connect all devices and control systems. It also delivers the visibility to collect and analyze data from both new and legacy devices. High-availability smart sites can: • Minimize or eliminate unscheduled downtime • Reduce time to repair • Provide continuous operation, regardless of communication • Increase visibility of equipment and sites • Prevent unsafe conditions • Comply with increasing regulatory conformity

insidesales@redlion.net www.redlion.net

Register to download the paper at: https://marketing.redlion.net/acton/media/34560/smart-remote-connected-sites-white-paper input #20 at www.controleng.com/information

Why M12 Connectors Are The Right Fit For The IIoT Joe Amato | Director Of Sales And Business Development - Binder USA Though M12 connectors were available decades before the IIoT was even a concept, they have become the preferred connector for industrial Ethernet. For data transmission, they are used on the device side â&#x20AC;&#x201C; pulling data from devices and transmitting it to the application where data is aggregated to provide useful information to the user. They make the connections between the PLC, sensors, and the I/O blocks, as well as to wireless access points. M12 connectors are also used to transmit high levels of power supplies for extended time periods in applications such as AC motors and drives, motor control switches, and low-voltage applications like fieldbus Ethernet components and network devices.

With backwards compatibility, replacing older and less robust technology like RJ45 connectors is relatively simple and cost effective. Manufacturers of M12 connectors continue to innovate, adding new features to meet the quickly changing needs of the robotics, automation, food and beverage, alternative energy, and cellular communication industries. Positionable, lockable, field-wireable connectors, capable of transmitting impressive amounts of data and power, ensure that the M12 will continue to be an essential component of Industry 4.0 and beyond.

M12 technology continues to evolve. Machine designers and OEMs are incorporating M12 connectors into new machines, as well as updating existing infrastructure.

joe.amato@binder-usa.com www.binder-usa.com

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9/25/2019 9:20:41 AM

ANSWERS

INSIDE MACHINES: ROBOTICS Tanya M. Anandan, RIA

Robotics-as-a-service benefits Robotics-as-a-service helps with tighter global competition, allowing short-term robot without a long-term investment. One application reduced costs by 30%.

obotics-as-a-service (RaaS) is an emerging trend in manufacturing. Rising labor shortages, competitive global markets, and automation are changing traditional business models. Whether it’s a shortterm need, companies wanting to try before they buy, forgoing a capital expenditure (CAPEX), or lowering the cost of entry to robotic automation, RaaS can be useful for companies. RaaS provides robots on demand, when and where needed. More users are seeking flexible automation implementations. More suppliers are offering rental and leasing options to satisfy the demand. Some are mature companies answering the call; others are manufacturing industry startups. This is a major turnaround from even several years ago when the manufacturing industry was wary of the idea of cage-free robots rubbing elbows with human coworkers. Now every major robot manufacturer has a collaborative robot on its roster, and a slew of startups add more options. RaaS, like human-robot collaboration, is helping make more robots more available to more applications.

On-demand robots Out-of-the-box offerings like the TaskMate by

Ready Robotics, which are easy to use and easy to deploy, are among RaaS options. “The TaskMate is a ready-to-use, on-demand robot worker that is specifically designed to come out of its shipping crate ready to be deployed to the production line,” said Ready Robotics CEO Ben Gibbs, noting manufacturers without the time to undertake custom robot integration are looking for out-of-the box automation. Rental options make the foray easier. “Time is their most precious resource,” Gibbs said. “They may have to do a little fixturing or put together a parts presentation hopper. Besides that, it’s something they can deploy pretty quickly. We’re driving towards providing a solution that’s as easy to use as your personal computer.” The system consists of a collaborative robot arm mounted on a stand with casters, so it can be wheeled into position on the production floor. The ease of portability suits high-mix, low-volume production where it can be relocated to different manufacturing cells. Two varieties each have robot arms, equipped with a force sensor and a universal interface that allows different robot grippers to be hot-swapped onto the end of the arm. Contributing to the system is the proprietary operating system, the Forge operating system (OS) software. A simple flowchart interface (pictured) controls the robot arm, end-of-arm tooling (EOAT) and other peripherals. No coding is required. Running the Forge/OS software, the controller provides the same easy programming interface but is designed as a standalone system for other robots.

Cloud robotics and RaaS

Figure 1: An out-of-the-box collaborative robot solution on wheels is easy to redeploy as production needs change. A rental option further enhances return on investment (ROI). Courtesy: Ready Robotics/ Robotic Industries Association

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CONTROL ENGINEERING

A common element in the RaaS rental model is cloud robotics. Ready offers customers the ability to remotely monitor its robotic system or others connected to its controller. “We can set them up with alerts, so when the production cycle is completed or the robot enters an unexpected error state, they can receive an email notifying the floor manager or line operator to check the system,” Gibbs said. Users also can save and back up programs to the cloud, and deploy them from one robot to another. If an operator inadvertently lost a program, they could drop the backup version from the cloud onto the system and be up and running again in minutes. www.controleng.com

“We provide a menu to our customers of how they might want to consume our products and services,” Gibbs said, including traditional CapEx (capital expenditure) purchase or “they can rent the system with no contract for however long or short of a duration they want.” For an additional charge, the company can manage the entire asset. “We set it up, we program it, and we remotely monitor it to make sure it’s maximizing its uptime. We can come in and tweak the program if it’s running into unexpected errors.” The systems have cell modems for remote software updates.” We handle all of the maintenance, or it’s handled by our channel partners.”

Figure 2: Intuitive software interface with a flowchart design and compatibility with multiple robot brands makes programming easier and faster. Courtesy: Ready Robotics/Robotic Industries Association

No-term rental; easy first robotic use

Gibbs said flexibility is the biggest advantage to their rental option. Even with the 3-month trial rental, customers are not required to keep it for the full term. “We have a no-term rental. That’s even more appealing because it can come entirely out of your operating expenditure (OPEX) budget. Instead of going through a lengthy CAPEX approval process, we’ve had some customers just run their corporate credit card, because the rental is below their approval level for an OpEx purchase. They can easily set up the system and use it for a few months. That alone provides them with a much stronger justification for moving forward with CAPEX if they want, or just continue to expand their rental. At the end of the first month, if they decide that it’s not working out,” Gibbs said, they can just send it back. If the customer chooses to continue renting, Gibbs said it’s more cost-effective to sign a contract. This reduces the risk for everyone, so there’s often a financial incentive. “The primary way we differentiate ourselves is that we offer that no-term rental with a fixed monthly fee, which allows these factories to capture the traditional value of automation. We don’t have a meter running that says you ran it 22 hours this day, so you owe us for 22 hours of work. We encourage them to run it as long as they want. The expectation is the longer you run it, the cheaper it should be.”

High-mix, low-volume flexibility

Attwood Marine in Lowell, Mich., is one of the world’s largest producers of boat parts, accessories and supplies. They make thousands of different parts, but cater to a small marine market. The challenges of high-mix, low-volume production in a competitive market had them looking for flexible automation. Attwood deployed the TaskMate to a half-dozen cells on the production floor performing computer numerical control (CNC) machine tending, pickand-place tasks like palletizing, loading/unloading conveyors, case packing, and repetitive testing, such as actuating a switch or pulling a cord 250,000 times.

www.controleng.com

Figure 3: Autonomous mobile robot navigates production floors to transport pallets and heavy loads via the most efficient route, while safely maneuvering around people and other obstacles. Courtesy: Mobile Industrial Robots A/S, Robotic Industries Association

By deploying one robot system to multiple production cells, Attwood was able to spread its return on investment (ROI) across multiple product lines and realize up to a 30% reduction in overall manufacturing costs. Small- to mid-sized businesses and large multinationals can use the robot for machine tending CNC lathes. KEYWORDS: robotics, robotics“Multinationals may have robot proas-a-service, RaaS grammers on staff, but usually not RaaS allows companies to use enough of them,” Gibbs said. “Automarobots on a short-term basis. tion engineers are in high demand and Some RaaS is pay-as-you-go very difficult to come by. Any technology model; others offer subscriptions. that makes it faster and easier for people Technology advances and ease of use are helping RaaS gain traction. to set up robots is a tremendous value.” Some large multinationals “like to be ONLINE asset-light and do a rental, but everyone Read this at www.controleng.com loves the ease of programming.” for more on mobile robots, leasing,

M More ANSWERS

and renting a work cell.

Pay-as-you-go model

Business models under the RaaS umbrella vary and are evolving. Startups

CONSIDER THIS What applications in your plant would benefit from RaaS?

control engineeering

October 2019

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BRING YOUR MACHINE TO LIFE WITH AN AUTOMATION CONTROLLER

ANSWERS

INSIDE MACHINES: ROBOTICS

Aerotech’s standard controllers are ﬂexible enough to handle almost any application. From the simple motion of this mechanical wasp’s head, to coordinating multiple axes in your machine, Aerotech automation controllers are the answer. Users can program in G code, .NET (C#, VB.NET), C, MATLAB®, or LabVIEW®. Aerotech will also customize the controller for your needs. Contact us today to get started. Figure 4: On-demand material handling robots come in all sizes, payloads and reaches for rental by the week. Courtesy: RobotWorx/Robotic Industries Association

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Ethernet Connectivity

like Hirebotics and Kindred leverage cloud robotics to monitor robot uptime, collect data, and enhance performance using AI. They charge by the hour, or even by the second. Users pay for only what they use. Each service model has its advantages. Some RaaS companies offer subscription-based models. Some took a page from the sharing economy, emulating companies like Airbnb and Lyft. For some, pay as you go is preferred to the overhead and infrastructure with a long-term commitment.

Mobile robots for hire

Intelligent Drives Automation Controller

Custom Software

Vision

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Autonomous mobile robots (AMRs) are available via RaaS model also. RIA members Aethon and Savioke lease mobile robots for various applications in healthcare, hospitality and manufacturing. Startup inVia Robotics offers an RaaS subscription for its warehouse “Picker” robots. AMRs, part of the logistics robot market, have advanced to serve an always-on supply chain. In the last two years, prototypes and beta deployments have turned into full product lines with significant investor funding. Major users like Amazon, DHL, Walmart and Kroger are adding to their mobile fleets. Europe-based Mobile Industrial Robots (MiR) began in North America two years ago. After seeing comparable North American growth, MiR has launched a lease program. Responding to customer demands for larger payloads, MiR introduced its 500-kg mobile platform in June 2018. The MiR500 (pictured) features a pallet transport system that lifts pallets off a rack and autonomously delivers them. ce

Tanya M. Anandan is contributing editor for the Robotic Industries Association (RIA) and Robotics Online. RIA is a not-for-profit trade association dedicated to improving the regional, national, and global competitiveness of the North American manufacturing and service sectors through robotics and related automation. This article originally appeared on the RIA website. The RIA is a part of the Association for Advancing Automation (A3), a CFE Media content partner. Edited by Chris Vavra, production editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.

Visit aerotech.com or Call 412-963-7470

AH0319A-CSG

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October 2019

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ANSWERS

INSIDE MACHINES: DRIVES Mark T. Hoske, Control Engineering

Survey offers drive advice

Motor drive advice was offered in a write-in question in the Control Engineering motor drive research, summarized in the September issue.

M More

ANSWERS

KEYWORDS: Motor

drives, servo drives, variable-speed drives, medium-voltage drives Motor drive survey respondents advise. Lowest price might not be lowest lifecycle cost. Filtering and harmonics are important.

CONSIDER THIS Is it time to upgrade motor drives or install additional drives to save energy and reduce motor wear?

ONLINE If reading from the digital edition, click on the headline for more info, resources.

he 2019 Control Engineering Motor Drives study asked respondents, “Based on your experiences and knowledge, what’s the best advice you can offer?” Some responses follow, lightly edited for style. See more online.

Drive application advice

Check for temperature rise on motor, how harmonic contents spread into the grid, and the overall efficiency at partial load. It doesn’t matter which brand of drives you choose for your application. Most important are quality of the product, availability, and standardization. Standardization can reduce the stock of spares required and helps support personnel understand the drives used. Know the specific details of your applications requirements before specifying the drive. For example, know peak velocity usage, not just average velocity. Similarly, know the maximum torque that the application demands. Consider all of this with the motor’s performance in light of the specific drive to be used. Failing to do the pencil-work prior to specifying the drive is almost a guarantee of disappointing performance later. Know the application before selecting a drive.

Correct drive sizing

As efficiency standards change for induction motors, watch for inrush currents and breakdown torque and breakdown current changes. Inrush currents are rising and can cause challenges with electronic overloads. Know your application, particularly high friction and/or high inertia starting. To get the full use of your available motor torque, the drive must be correctly sized. For very large motors performing heavy-duty cycle work, be certain that the transformer and conductors do not cause large voltage drops when the application is at its greatest demand. For large hammer mills using wound rotor motors and liquid rheostats, we target <5% voltage drop at the motor at 200% full load amps (FLA). It’s very common for engineers unfamiliar with the application to undersize the transformers and conductors.

Products, parts, support

Buy from someone with good technical knowledge and a lot of hands-on experience. Hire and kept good technical support people on staff. Check compatibility before ordering, if you’re not using similar products. Double-check specs and requirements for motor and drive selection.

Drive pricing, quality

Buy the best you can afford. Keep your equipment in good shape. All machines will break down at some point (mostly at the worst possible time). Cheap stuff usually doesn’t work well, breaks down easily, and/or has bad technical support. Do not get hung up on bells and whistles. Most settings will remain factory default and work fine.

Design, maintenance, retrofit

Don’t think you can delay or skip preventive maintenance Read drive manuals before installation. Keep an open mind, standardize as much as possible, make sure you keep up with your manuals. ce

Position, speed and torque control are most important with servo drives. Courtesy: Control Engineering 2019 Motor Drives Study

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October 2019

control engineering

Survey managed and data compiled by Amanda Pelliccione, CFE Media and Technology research director. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Techology, mhoske@cfemedia.com. www.controleng.com

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INNOVATIONS

ENGINEERS’ CHOICE AWARDS Amanda Pelliccione, Research Director

Vote now for Engineers’ Choice Finalists The official ballot is open for voting for Control Engineering North American print and digital edition subscribers, for a limited time. Cast your vote using CFE Media’s New Products for Engineers platform at www.controleng.com/NPE.

ote now! For a limited time, the official Engineers’ Choice ballot is open for voting for Control Engineering North American print and digital edition subscribers. At www.controleng.com/NPE, vote for the best Engineers’ Choice finalists of 117 entries across 29 categories. Based on your experience, please vote in as many categories for which you feel qualified based on technological advancement, service to the industry, and market impact. Details and photos are available for each product. Winners and honorable mentions will be featured in more detail in the February 2020 issue of Control Engineering.

Hardware – HMI, Operator Interface, Thin-Client • RXi industrial flat panel display, Emerson Automation, www.emerson.com • EZTouch EZ7 HMI/PLC operator interface, EZAutomation, www.ezautomation.net • GT25 rugged HMI, Mitsubishi Electric Automation, https://us.mitsubishielectric.com/fa/en • Graphite 12.1-in. outdoor HMI, Red Lion Controls, www.redlion.net • Simatic HMI IWP700 Industrial Web Panel, Siemens, www.usa.siemens.com • Simatic IFP Basic industrial flat panel display, Siemens, www.usa.siemens.com • TP700 Comfort INOX projected capacitive touch panel, Siemens, www.usa.siemens.com • Touch Panel 600 operator interface, Wago Corp., http://wago.us

• MIC-770 compact, fanless industrial PC, Advantech, www.advantech.com • C6032 ultra-compact industrial PC, Beckhoff Automation, www.beckhoffautomation.com • CX7000 embedded PC, Beckhoff Automation, www.beckhoffautomation.com • Simatic IPC1047 industrial PC, Siemens, www.usa.siemens.com • Simatic IPC627E compact industrial PC, Siemens, www.usa.siemens.com

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October 2019

Amanda Pelliccione is CFE Media’s research director and manager of awards programs, apelliccione@cfemedia.com.

• Simatic IPC847E industrial rack PC, Siemens, www.usa.siemens.com

• In-Sight 9000 vision system, Cognex, www.cognex.com

• Sinumerik MCU-1720 motion control unit, Siemens, www.usa.siemens.com

• Geva 400 multiple camera vision system, Teledyne DALSA, www.teledynedalsa.com

Industrial Internet of Things Connectivity – Edge Controller • groov EPIC edge programmable industrial controller, Opto 22, www.opto22.com • Sinumerik Edge machine tool application, Siemens, www.usa.siemens.com Industrial Internet of Things Connectivity – Gateway • Wise-710 Industrial Internet of Things gateway, Advantech, www.advantech.com • Simatic PN/J1939 Link gateway, Siemens, www.usa.siemens.com Machine & Embedded Control – PLCs

Hardware – Industrial PCs, CNCs

Informed voting, an important responsibility: Voting on this ballot is only open to qualified* subscribers of Control Engineering products. One ballot per qualified subscriber will be accepted; multiple ballots from the same qualified subscriber will be invalid. Ballots received from non-qualified subscribers will be invalid. (*Employees of product manufacturers with a finalist in the current program and their properties, agencies, vendors, and representatives — even if Control Engineering subscribers — are ineligible to vote.)

Motion Control • IntelliPress electric bench top press, Bimba, www.bimba.com • CytroBox hydraulic power unit, Bosch Rexroth, www.boschrexroth.com/en/us • XM-42 embedded controller, Bosch Rexroth, www.boschrexroth.com/en/us • Kinetix VPH hygienic servo motor, Rockwell Automation, www.rockwellautomation.com • NP planetary servo gearbox, Siemens, www.usa.siemens.com • Simogear KS adapter, Siemens, www.usa.siemens.com Motion Control – Drives

• EZTouch mini.PLC compact touch screen controller, EZAutomation, www.ezautomation.net

• Unidrive DFS free-standing drive, Control Techniques, www.controltechniques.us

• PLCnext programmable logic controller, Phoenix Contact, www.phoenixcontact.com/us

• Altivar Process ATV6000 medium-voltage drive, Schneider Electric, www.schneider-electric.us

• Unistream PLC, Unitronics, https://unitronicsplc.com

• Sinamics G120X drive, Siemens, www.usa.siemens.com

• Micro PLC, VIPA ControlsAmerica, http://vipausa.com

• GA800 variable-speed drive, Yaskawa America, https://yaskawa.com

Machine Vision, Code Readers • DataMan 370 fixed-mount barcode reader, Cognex, www.cognex.com

control engineering

Motion Control – Drives, Servo • FlexPro FE060-25-EM pcb mount servo drive, Advanced Motion Controls, www.a-m-c.com

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Cast your vote at www.controleng.com/NPE.

• i950 servo inverter, Lenze, www.lenze.com • Kinetix 5100 servo drive, Rockwell Automation, www.rockwellautomation.com • Sinamics S210 servo package, Siemens, www.usa.siemens.com Motion Control – Linear Transport • XTS linear transport system, Beckhoff Automation, www.beckhoffautomation.com • MagneMover Lite transport system, Rockwell Automation, www.rockwellautomation.com Motion Control – Pneumatics • BPGS pneumatic gripper system, Bimba, www.bimba.com • PA NFPA actuator, Bimba, www.bimba.com • Sipart PS100 electropneumatic valve positioner, Siemens, www.usa.siemens.com Motion Control – Robots, Robotics • VT6L all-in-one 6-axis robot, Epson America, https://epson.com • RG2-FT intelligent gripper, OnRobot, www.onrobot.com • Robotiq Sanding Kit, Universal Robots, www.universal-robots.com Network Integration – Data Acquisition • ELM314x Economy EtherCAT measurement module, Beckhoff Automation, www.beckhoffautomation.com • DA30D protocol converter, data acquisition system, Red Lion Controls, www.redlion.net Network Integration – Ethernet Hardware, Switches • PROmesh P20 Ethernet/Profinet switch, Indu-Sol GmbH, www.indu-sol.com • P2M industrial Ethernet node, Parker Hannifin Motion Systems Group, www.parker.com Network Integration – I/O Systems • ioThinx 4510 IIoT modular remote I/O, Moxa, https://moxa.com • Flex 5000 discrete safety I/O module, Rockwell Automation, www.rockwellautomation.com • S7-1500 CM 8xIO-Link V1.1 communication module, Siemens, www.usa.siemens.com • Simatic DP ET 200eco PN distributed fail-safe peripheral module, Siemens, www.usa.siemens.com • Simatic ET 200SP analog output module, Siemens, www.usa.siemens.com • IO-Link master module, Weidmuller, www.weidmuller.com Network Integration – Signal Conditioning • DT dual-channel transmitter, Acromag, www.acromag.com • ECT-DIN 2-wire output-loop powered isolator, converter, Moore Industries, www.miinet.com Network Integration – Wireless • Digi WR54 router, Digi International, www.digi.com • Simatic RF615 compact UHF-RFID reader, Siemens, www.usa.siemens.com

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• Tosibox Lock 150 industrial router, Tosibox Oy, www.tosibox.com Power – Energy, Power Protection

Process Control – Process Sensors, Transmitters • Rosemount 5300 level transmitter, Emerson, www.emerson.com

• High Density rack power distribution unit, Eaton, www.eaton.com

• Prowirl 200 multivariable vortex flowmeter, Endress+Hauser, http://us.endress.com

• Pow-R-Line XD switchboard, Eaton, www.eaton.com

• Hot Tap digital flowmeter, Exair, www.exair.com

• Pow-R-Trak busway, Eaton, www.eaton.com • FR-XC multi-functional regenerative converter, Mitsubishi Electric Automation, https://us.mitsubishielectric.com/fa/en

• MVQ101 smart valve sensor, ifm efector, www.ifm.com/us • Sitrans P320/420 pressure transmitter, Siemens, www.usa.siemens.com Process Control Systems

• PTV terminal block, Phoenix Contact, www.phoenixcontact.com/us

• ControlEdge PLC R151, Honeywell Process Solutions, www.honeywellprocess.com/en-US

• TeSys Island load management system, Schneider Electric, www.schneider-electric.us

• Simatic PCS neo V3 distributed control system, Siemens, www.usa.siemens.com

• MD high-density sub-metering platform, Siemens Smart Infrastructure, https://usa.siemens.com/buildingtechnologies • Varitector PU II UL surge protection device, Weidmuller, www.weidmuller.com Power Supply, UPS

Safety – Machine Safety • Hazardous Location NEMA 4 Cabinet Cooler, Exair, www.exair.com • Data Access Port, Panduit, www.panduit.com • PSRswitch RFID-coded, non-contact safety switch, Phoenix Contact, www.phoenixcontact.com/us

• 5P lithium-ion uninterruptible power system, Eaton, www.eaton.com

• outdoorScan3 outdoor safety laser scanner, Sick, www.sick.com

• SSG-RP-1H extreme temperature UPS, Falcon Electric, www.falconups.com

• Simatic RF1000 access control badge reader, Siemens, www.usa.siemens.com

• PROtop high-end range power supply, Weidmuller, www.weidmuller.com • Broome10 power supply, Woehner, https://woehner.de

Safety – Process Safety, Intrinsic Safety • RSA-224 remote switch actuator, CBS ArcSafe, www.cbsarcsafe.com

How to Cast Your Vote VOTING FOR the Control Engineering 2020 Engineers’ Choice Awards program opens Oct. 10, 2019, and is hosted within the New Products for Engineers platform, www.controleng.com/NPE. Voting is only open to qualified subscribers of Control Engineering products (magazine—print or digital, enewsletters, white papers, etc.). Qualified subscribers are encouraged to vote in as many categories for which they are qualified based on technological advancement, service to the industry and market impact. Read more about voting eligibility via the program’s Official Rules, www.controleng.com/EngineersChoice.

Qualified voters, please register for a new user account or sign in to your existing user account within New Products for Engineers: www.controleng.com/NPE

2. Select “Product Voting” from the menu bar to arrive at the “Product Award Voting” page. Select “Control Control Engineering 2020 Engineers’ Choice Awards” to view the finalists in their categories and cast your votes.

3. Review, submit and/or edit your votes by Friday, Dec. 20, 2019. control engineering

October 2019

•

INNOVATIONS

Cast your vote at www.controleng.com/NPE.

ENGINE ERS’ CHOICE AWARDS • Rosemount 628 electrochemical toxic gas sensor, Emerson, www.emerson.com

• iQ Monozukuri Converting development software, Mitsubishi Electric Automation, https://us.mitsubishielectric.com/fa/en

• Vanguard WirelessHART toxic, combustible gas detector V1.2, United Electric Controls, www.ueonline.com

• Connected Components Workbench V12 machine development software, Rockwell Automation, www.rockwellautomation.com

• SCS 24Vdc P1SIL3 I safety relay, Weidmuller, www.weidmuller.com Software – Asset Management, Reporting • Wise-PaaS/DeviceOn IIoT device operations management application, Advantech, www.advantech.com

• AMS Inspection Rounds software, Emerson Automation, www.emerson.com • Dream Report V5.0 analytics software, Ocean Data Systems, http://dreamreport.net • SmartMonitoring field instrumentation management application, Siemens, www.usa.siemens.com

• DeltaV Live HMI, Emerson Automation, www.emerson.com

• Simatic Industrial OS V1.3 Linux-based operating system, Siemens, www.usa.siemens.com

• ThinManager V11.0 thin client management software, Rockwell Automation, www.rockwellautomation.com Software – Industrial Internet of Things Connectivity

• TwinCAT 3 Scope software with OPC UA integration, Beckhoff Automation, www.beckhoffautomation.com

• Prophecy IoT software, Godlan, www.godlan.com

• Loop-Pro PID controller tuning software, Control Station, http://controlstation.com

• Honeywell Forge for Industrial enterprise performance management software, Honeywell Process Solutions, www.honeywellprocess.com/en-US

• Movicon Pro.Lean V3.4 analytics software, Progea North America Corp., www.progea.com

• KEPServerEX V6.7 industrial connectivity software, Kepware, www.kepware.com

• Siplus CMS1200 condition monitoring software, Siemens, www.usa.siemens.com

Software – Control Design

• InduSoft Web Studio V8.1 + SP4, Aveva, www.indusoft.com

• Movicon.NExT V3.4 SCADA, HMI software, Progea North America Corp., www.progea.com

• Seeq R21 advanced analytical software for process manufacturing, Seeq Corp., www.seeq.com

• XLReporter V14.0 reporting software, SyTech, www.sytech.com

Software – HMI Software

• Simatic Automation Tool Software Development Kit, Siemens, www.usa.siemens.com

Software – Data Analytics

• PRiSM Predictive Asset Analytics asset management software, Aveva, www.aveva.com

• Smart Commissioning savings calculator, Emerson Automation, www.emerson.com

Software – Mobile Apps • CFSWorX connected field service mobile application, Iconics, www.iconics.com • Simatic Notifier mobile application, Siemens, www.usa.siemens.com • WIN-911 V4.19.17 alarm notification mobile application, WIN-911 Software, http://win911.com

READ MORE about the 117 finalists for 2020, see images, and, if eligible, cast your vote responsibly at www.controleng.com/NPE.

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Electric Actuators

Rotary Actuators

Open loop performance. Closed loop control. input #27 at www.controleng.com/information

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

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

Get digital. Now! Engineering with the Handling Guide Online

Finding the right handling system couldn’t be quicker or easier: Configure and order your standard handling system in just three steps with the Handling Guide Online. All systems are delivered fully tested and assembled. Try out the new software tool today! www.festo.us/hgo input #28 at www.controleng.com/information

Finally, an I/O solution we can milk for all it’s worth. Sealevel is an American-owned designer and manufacturer of critical communication products, I/O and industrial computers. With more than 30 years of experience and over 250 standard products, our forte is using in-house engineering to create custom adaptations for our partners, precisely matching their application requirements. Industrial automation. It’s where Sealevel got its start. Let’s start something together. input #29 at www.controleng.com/information

The SeaLINK® 2402 USB serial I/O adapter provides USB connectivity to legacy or non-USB compliant devices.

SEALEVEL.COM

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Ignition 8 will revolutionize the way you control your industrial processes.

877-295-7057 Acromag.com/CE

Discover more at: inductiveautomation.com/ignition

Input #100 at controlengineering.hotims.com

Input #101 at controlengineering.hotims.com

Input #102 at controlengineering.hotims.com

Input #103 at controlengineering.hotims.com

Input #104 at controlengineering.hotims.com

Input #105 at controlengineering.hotims.com

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October 2019

control engineering O&GEng-CE 2017-06_TRGuide_MediaShowcase2x4_MII.indd5/17/2017 1 2:23:54 PM

www.controlengineering.com

MEDIA SHOWCASE FOR ENGINEERS Your place for new products, literature, Apps, Videos, Case Studies and White Papers. FIBER OPTIC SOLUTIONS

Factory Automation: RS232/422/485/Profibus/Modbus/Bacnet/Tnet Industrial Ethernet (LAN): 10/100/1000 Mbps SCADA: Modem/Multiplexers/Point to Point/Multidrop Video/Audio/Data: CCTV Systems/Robotics Optical Hubs & Repeaters USB Modems Extended Temp. Range & Ruggedized Products

Toll Free 866-SITech-1 Phone 630-761-3640 Fax 630-761-3644 www.sitech-bitdriver.com

Input #106 at controlengineering.hotims.com

Input #107 at controlengineering.hotims.com

Statement of Ownership, Management and Circulation 1. 2. 3. 4. 5. 6. 7. 8. 9.

Publication Title: CONTROL ENGINEERING Publication Number: 813-430 Filing Date: 9/27/19 Issue Frequency: 12x, monthly Number of Issues Published Annually: 12 Annual Subscription Price: USA $165 CAN $200 MEX $200 INTL $350 Complete Mailing Address of Known Office of Publication (Not printer): CFE MEDIA, LLC 3010 Highland Parkway, Ste #325, Downers Grove, IL, 60515 Complete Mailing Address of Headquarters or General Business Office of Publisher (Not printer): CFE MEDIA, LLC 3010 Highland Parkway, Ste #325, Downers Grove, IL, 60515 Publisher: Jim Langhenry, CFE MEDIA, LLC 3010 Highland Parkway, Ste #325, Downers Grove, IL, 60515, Editor-in-Chief: Mark Hoske, CFE MEDIA, LLC 3010 Highland Parkway, Ste #325, Downers Grove, IL, 60515 Editor: Chris Vavra, CFE MEDIA, LLC 3010 Highland Parkway, Ste #325, Downers Grove, IL, 60515 10. Owner: CFE MEDIA, LLC 3010 Highland Parkway, Ste #325, Downers Grove, IL, 60515, Jim Langhenry and Steve Rourke, CFE MEDIA, LLC 3010 Highland Parkway, Ste #325, Downers Grove, IL, 60515 11. Known Bondholders, Mortgagees, and Other Security Holders Owning or Holding 1 Percent or More of Total Amount of Bonds, Mortgages, or Other Securities: None 12. Does not Apply 13. Publication Title: Control Engineering 14. Issue Date for Circulation Data Below: September 2019 15. Extent and Nature or Circulation

a. Total Number of Copies (Net Press Run): b. Paid and/or Requested Circulation:

Average No. Copies Each Issue During Preceding 12 Months:

Actual No. Copies of Single Issue Published Nearest to Filing Date:

34,763

34,581

34,247

34,167

(2) Paid In-County Subscriptions Stated on Form 3541. (Include advertiser’s proof and exchange copies)

(3) Sales Through Dealers and Carriers, Street Vendors, Counter Sales, and Other, Non-USPS Paid Distribution

(4) Paid Distribution by Other Classes of Mail Through the USPS

(1) Paid/Requested Outside-County Mail Subscriptions Stated on Form 3541. (Include advertiser’s proof and exchange copies)

34,305

34,225

d. Free or Nominal Rate Distribution (By Mail and Outside the Mail)

c. Total Paid and/ or Requested Circulation [Sum of 15b, (1), (2), (3), and (4)-**

(1) Outside-County as Stated on Form 3541

(2) Free or Nominal Rate In-County Copies Included on PS Form 3541

260

206

(3) Free or Nominal Rate Copies Mailed at Other Classes Through the USPS (4) Free or Nominal Rate Distribution Outside the Mail (Carriers or other means) e. Total Nonrequested Distribution [Sum of 15d (1), (2), (3), and (4) f. Total Distribution [Sum of 15c and 15f] g. Copies not Distributed

260

206

34,565

34,431

198

150

h. Total [Sum of 15f and 15g]

34,763

34,581

i. Percent Paid [15c divided by 15f times 100]

99.24%

99.40%

a. Requested and Paid Electronic Copies

34,353

36,536

b. Total Requested and Paid Print Copies (Line 15c) + Requested/Paid Electronic Copies (Line 16a)

68,568

70,761

c. Total Requested Copy Distribution (Line 15f) + Requested/Paid Electronic Copies (16a)

68,918

70,967

d. Percent Paid and/or Requested Circulation (Both Print & Electronic Copies) (16b divided by 16c x 100)

99.62%

99.71%

16. Electronic Copy Circulation

17. Publication of Statement of Ownership: Publication Required. Will be printed in the October 2019 issue of this publication. 18. I certify that all information furnished on this form is true and complete. I understand that anoyone who furnishes false or misleading information on this form or who omits material or information requested on the form may be subject to criminal sanctions (including fines and imprisonment) and/or civil sanctions (including civil penalities). James M. Langhenry (signed), Owner

www.controlengineering.com

control engineering

October 2019

•

INNOVATIONS

BACK TO BASICS

Mark T. Hoske, Control Engineering, Kevin Parker, Plant Engineering

Control engineering: Basic terms explained Understand the terminologies that comprise control engineering and what they mean for engineers.

nderstanding basic terms helps when investing in processes and technologies related to control engineering and the design, integration, implementation, maintenance, and management control, automation, and instrumentation systems, components, and equipment.

Control systems Control systems help factories produce quality goods safely and efficiently. Open-loop control includes a human. Closed-loop control is automated. A control loop involves a measurement (sensors), decision (logic device), and actuation (changes the process), which is repeated until optimized. Networks and software connect the three.

‘

Control systems help factories produce

’

quality goods safely and efficiently.

Programmable logic controllers (PLCs) and programmable automation controllers (PACs) are industrial computers to control production systems. Edge computing and embedded systems control machines and processes and help humans make smarter decisions. Dedicated controls or single-loop controllers make a specialized set of decisions about a control system. Proportional, integral and derivative (PID) are process tuning parameters; advanced process control (APC) software improves decisions about processes. Distributed control systems (DCS) and supervisory control and data acquisition (SCADA) are types of control systems.

Information management Info management is the translation of data into information, and its delivery to people who need it at the right times. Human-machine interface (HMI) and operator

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October 2019

CONTROL ENGINEERING

interface (OI) help humans monitor, change, control and manage the state of a process. Product lifecycle management (PLM) software evolved from computer-aided design. PLM can update information through a product’s life, aiding control design. Manufacturing IT (information technology) and manufacturing execution systems (MES) improve production and bridges production planning systems and the plant floor. Industrial PCs (IPCs) are personal computers hardened for use in industrial environments.

IIoT, Industrie 4.0 Industrial Internet of Things (IIoT) and Industry 4.0: IIoT brings IT standards to industries. Industry 4.0 uses advanced technologies to make manufacturing smarter. Mobility: Portable and handheld computers allow humans to make mobile decisions more quickly and efficiently and safely at an appropriate distance. Asset management enables more effective maintenance on a wide range of devices and systems. Virtualization, cloud, analytics: Virtualization segments computers. Cloud architectures run apps or storage separate from the source computer. Analytics software turns data into info.

Discrete manufacturing Discrete manufacturing makes individual things of a certain number. Mechatronics combines mechanical and electronic engineering. Machine safety uses devices, systems, and procedures to lower risk to humans, equipment, and products in a production environment. Motors and drives: Motors transform electrical and magnetic energy to motion. Drives control the motion of motors and other actuators. Discrete sensors and machine vision: Discrete sensors measure presence, proximity, distance, vibration, direction, motion, and other parameters. Machine vision uses sensors and software to see. www.controleng.com

Robotics: Industrial robotics use sensors, actuators, programming, and networks to perform dull, dirty and dangerous work with precision, repeatability and speed. Computerized numerical control (CNC) and motion control: A CNC uses special computers and software to control and manage machine tools. Motion control decides movement.

Networking and security

â&#x20AC;&#x2DC;

A control loop involves a measurement (sensors), decision (logic device), and actuation (changes the process), then it repeats until optimized. Networks

â&#x20AC;&#x2122;

and software connect the three.

Networking and security: Industrial networks runs software protocols over physical media to connect sensors, computers, actuators and systems. Security lowers industrial risk. Cybersecurity uses technologies and procedures to protect devices, computers, systems and networks from unwanted intrusion. Ethernet is an IEEE standard that defines communication protocol and medium. Ethernet has multiple standard variants for industrial networking of devices, computers and systems. Wireless technologies and methods: Communicating though the air may enable lower-cost networking than wired connections. Many wireless standards serve various applications. Other networks: Associations and manufacturers have created many sensor networks, device networks and computer networks for industrial communications. Input and output (I/O) devices communicate measurements about the state of a process.

System integration

Process manufacturing

Mark T. Hoske, content manager, Control Engineering, mhoske@cfemedia.com; Kevin Parker, content manager, Plant Engineering, CFE Media and Technology.

Process manufacturing makes (often fluid or gaseous) products in a continuous flow or batch process, of a certain amount. Data acquisition (DAQ) can gather measurements that can be analyzed to help understand a process. Simulators and optimizers use computer programs to improve processes without the commitment of physical resources. Diagnostics and asset management: Diagnostics assess the current state of a process and may involve the identification of root causes. It helps with predictive maintenance of assets. Process safety uses devices, systems, and procedures to lower risk to humans, process or batch equipment and products in a production environment. Process sensors and actuators: Process sensors measure temperature, pressure, level, flow, and other parameters. Process actuators (valves, pumps, heaters, fans, mixers, and others) change a process.

www.controleng.com

System integration connects devices and systems, often with computers, software and networks, to optimize throughput. System integrators for automation and controls design and integrate computerized control systems for industrial machines, manufacturers or facilities. Project management: Work processes are often organized into projects that can be planned and coordinated. Energy efficiency: Measuring and optimizing energy use is important in a time of constrained resources. Energy and power are essential to all forms of work and require attention to technologies, safety, standards and best practices. Workforce development teaches human resources with in-person or online training. Engineers require frequent training to remain useful and up to date in their professions. ce

M More INNOVATIONS

KEYWORDS: Control engineering, basic terms Control engineering is more easily understood when related terms are defined. Smart investments in control engineering processes and technologies help with optimization. Efficiently integrating technologies helps. CONSIDER THIS Engineers often have multiple names for similar things. Has your organization agreed-upon terms to help new hires?

ONLINE If reading from the digital edition, click on the headline for more resources. www.controleng.com/magazine See articles organized under topics at www.controleng.com. control engineering

October 2019

â&#x20AC;˘

Advertising Sales Offices ContentStream

Patrick Lynch, Director of Content Marketing Solutions 630-571-4070 x2210 PLynch@CFEMedia.com ®

Company

Page#

RSN

Web

ad index

ABB Motors & Mechanical . . . . . . . 9 . . . . . . . . . 6 . . . . . . . .www .new .abb .com/motors-generators Allied Electronics . . . . . . . . . . . . . C1, 7 . . . . . . . . 5 . . . . . . . .www .alliedelec .com Automation24 . . . . . . . . . . . . . 16A-16D, 27 . . . . 13 . . . . . . .www .automation24 .com AutomationDirect . . . . . . . . . . . . . C2, 1 . . . . . . . 1, 2 . . . . . . .www .automationdirect .com binder . . . . . . . . . . . . . . . . . . . . . . . . 47 . . . . . . . . 21 . . . . . . .www .binder-usa .com CONTEMPORARY CONTROLS . . . . . . . . . . . . . . . . . . . 40 . . . . . . . . 19 . . . . . . .www .ccontrols .com/machine Digi-Key ELECTRONICS . . . . . . . . . 12 . . . . . . . . . 8 . . . . . . . .WWW .DIGIKEY .COM DIGI . . . . . . . . . . . . . . . . . . . . . . . . . 31 . . . . . . . . 15 . . . . . . .WWW .DIGI .COM/WR54 Endress + Hauser . . . . . . . . . . . . . . 33 . . . . . . . . 16 . . . . . . .www .us .endress .com/prowirl-f200 EZAutomation . . . . . . . . . . . . . . . . . 28 . . . . . . . . 14 . . . . . . .www .EZAutomation .net Festo Corporation . . . . . . . . . . . . . . 59 . . . . . . . . 28 . . . . . . .www .festo .com Graybar . . . . . . . . . . . . . . . . . . . . . . 35 . . . . . . . . 17 . . . . . . .www .graybar .com ifm efector, Inc . . . . . . . . . . . . . . . . 21 . . . . . . . . 10 . . . . . . .www .ifm .com Inductive Automation . . . . . . . . . . . 15 . . . . . . . . . 9 . . . . . . . .http://demo .ia .io/engineering Maple Systems Inc . . . . . . . . . . . . . 26 . . . . . . . . 12 . . . . . . .www .maplesystems .com Moore Industries - Intl . Inc . . . . . . . 2 . . . . . . . . . 3 . . . . . . . .www .miinet .com OPTO 22 . . . . . . . . . . . . . . . . . . . . . . 5 . . . . . . . . . 4 . . . . . . . .www .opto22 .com Oriental Motor . . . . . . . . . . . . . . . . . 58 . . . . . . . . 27 . . . . . . .www .orientalmotor .com Phoenix Contact . . . . . . . . . . . . . . . 23 . . . . . . . . .11 . . . . . . .www .phoenixcontact .com/warranty RADWELL INTERNATIONAL, INC . . . . . . .Bellyband . . . . . . . . . . . . . .www .Radwell .com

AR, IL, IN, IA, KS, KY, LA, MN, MO, MS, NE, ND, OK, OH, SD, TX, WI, Central Canada

Bailey Rice (630) 571-4070 x2206 BRice@CFEMedia.com AK, AZ, CA, CO, HI, ID, MT, NV, NM, OR, UT, WA, WY, Western Canada

Iris Seibert (858) 270-3753 ISeibert@CFEMedia.com CT, DE, MD, ME, MA, NC, NH, NY, NJ, PA, RI, SC, VA, VT, WV, DC, Eastern Canada

Julie Timbol (978) 929-9495 JTimbol@CFEMedia.com Account Manager

Robert Levinger 630-571-4070 x2218 RLevinger@cfetechnology.com International (outside U.S., Canada)

Stuart Smith +44 208 464 5577 stuart.smith@globalmediasales.co.uk

Publication Services

Jim Langhenry, Co-Founder/Publisher, CFE Media JLanghenry@CFEMedia.com Steve Rourke, Co-Founder, CFE Media SRourke@CFEMedia.com Laura Prochaska, Marketing Services Manager (773) 818-7771, LProchaska@CFEservices.com

Red Lion Controls . . . . . . . . . . . . . . 46 . . . . . . . . 20 . . . . . . .www .redlion .net

Kristen Nimmo, Marketing Manager KNimmo@CFEMedia.com

Sealevel Systems Inc . . . . . . . . . . . 59 . . . . . . . . 29 . . . . . . .www .sealevel .com

Brian Gross, Marketing Consultant, Global SI Database 630-571-4070, x2217, BGross@CFEMedia.com

SeeQ . . . . . . . . . . . . . . . . . . . . . . . . 37 . . . . . . . . 18 . . . . . . .www .seeq .com SEW-EURODRIVE, Inc . . . . . . . . . 11, C4 . . . . . .7, 31 . . . . . .www .seweurodrive .com spiroflow . . . . . . . . . . . . . . . . . . . . . 47 . . . . . . . . 22 . . . . . . .www .spiroflow .com Yaskawa America, Inc . . . . . . . . . . . C3 . . . . . . . . 30 . . . . . . .www .yaskawa .com

Michael Smith, Creative Director 630-779-8910, MSmith@CFEMedia.com Paul Brouch, Director of Operations PBrouch@CFEMedia.com Michael Rotz, Print Production Manager 717-766-0211 x4207, Fax: 717-506-7238 mike.rotz@frycomm.com

Inside Machines

Maria Bartell, Account Director, Infogroup Targeting Solutions 847-378-2275, maria.bartell@infogroup.com

Aerotech Inc . . . . . . . . . . . . . . . . . M3 . . . . . . . 23 . . . . . . .www .aerotech .com

Rick Ellis, Audience Management Director 303-246-1250, REllis@CFEMedia.com

Beckhoff Automation LLC . . . . . . . M4 . . . . . . . 24 . . . . . . .www .beckhoff .com Maverick Technologies . . . . . . . . M7, M8 . . . . . . 26 . . . . . . .www .mavtechglobal .com/the-graveyard-shift

Letters to the editor: Please e-mail us your opinions to MHoske@CFEMedia.com or fax 630-214-4504. Letters should include name, company, and address, and may be edited.

WAGO Corp . . . . . . . . . . . . . . . . . . M6 . . . . . . . 25 . . . . . . .www .wago .us

Information: For a Media Kit or Editorial Calendar, go to www.controleng.com/mediainfo. Marketing consultants: See ad index.

REQUEST MORE INFORMATION about products and advertisers in this issue by using the http://controleng.com/information link and reader service number located near each. If you’re reading the digital edition, the link will be live. When you contact a company directly, please let them know you read about them in Control Engineering.

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October 2019

control engineering

Custom reprints, electronic: Marcia Brewer, Wright’s Media, 281-419-5725, mbrewer@wrightsmedia.com

www.controleng.com

Always the Right Move

One Choice for All Controlling a robot arm, a servo axis, a VFD drive or a custom robotic mechanism is all the same task for an MP3300iec machine controller. It uses familiar IEC61131-3 and PLCopen programming to operate them all, and will even allow you to substitute one motion device for another without reprogramming. Looking for motion control that can change and grow as readily as your machines do? Move to the MP3300iec by contacting your Yaskawa representative.

Yaskawa America, Inc.

Drives & Motion Division

1-800-YASKAWA

yaskawa.com

input #30 at www.controleng.com/information

For more info: http://go.yaskawa-america.com/yai1335

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 #31 at www.controleng.com/information