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Vol. 66 Number 12
ÂŽ
DECEMBER 2019
SPECIAL REPORT SR2 | Robotics Special Report: Why you need robots
SR2-SR8 GRIPPING COVER: Adaptive-shape robotic grippers can conform to radically different shaped objects. The octogonal shape molds around and grips the object. Learn more at SR6. Courtesy: Festo
INSIGHTS 4 | International: Make digital twins easier to implement for manufacturing industries 8 | Technology Update: Operations-driven matrix design 10 | Career Update: Three-step retirement plan for engineers NEWS
11 | Extend IT security to the plant floor, Robotics sales grow 12 | Ensure regulatory compliance with international codes, standards: 5 tips 13 | Hot topics in November, Online news 14 | Think Again: Ethernet for process and discrete devices
SR3 | Buying, specifying robotics: Exclusive research SR5 | Save jobs by getting robotic help for the dull, dirty, dangerous
SR8
SR6 | Grasp new robotic applications: Five ideal features for robot grippers SR7 | Start today with these six most-common collaborative robot applications SR8 | Robots eliminate inconsistencies, cut cycle time 50%
ANSWERS 25 | Industrial virtualization heads to the plant floor 27 | How to specify cut-tolength cable 29 | Employing PtD as the first line of defense against control panel electrical hazards
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INSIDE MACHINES
M1 | Seven things to know about OMAC M3 | 3 steps to a successful machine vision project
CONTROL ENGINEERING (ISSN 0010-8049, Vol. 66, No. 12, GST #123397457) is published 12x per year, Monthly by CFE Media, LLC, 3010 Highland Parkway, Suite #325 Downers Grove, IL 60515. Jim Langhenry, Group Publisher/Co-Founder; Steve Rourke CEO/COO/Co-Founder. CONTROL ENGINEERING copyright 2019 by CFE Media, LLC. All rights reserved. CONTROL ENGINEERING is a registered trademark of CFE Media, LLC used under license. Perio dicals postage paid at Downers Grove, IL 60515 and additional mailing offices. Circulation records are maintained at 3010 Highland Parkway, Suite #325 Downers Grove, IL 60515. Telephone: 630/571-4070. E-mail: customerservice@cfemedia.com. Postmaster: send address changes to CONTROL ENGINEERING, 3010 Highland Parkway, Suite #325 Downers Grove, IL 60515. Publications Mail Agreement No. 40685520. Return undeliverable Canadian addresses to: 3010 Highland Parkway, Suite #325 Downers Grove, IL 60515. Email: customerservice@cfemedia.com. Rates for nonqualified subscriptions, including all issues: USA, $165/yr; Canada/Mexico, $200/yr (includes 7% GST, GST#123397457); International air delivery $350/yr. Except for special issues where price changes are indicated, single copies are available for $30 US and $35 foreign. Please address all subscription mail to CONTROL ENGINEERING, 3010 Highland Parkway, Suite #325 Downers Grove, IL 60515. Printed in the USA. CFE Media, LLC does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the material contained herein, regardless of whether such errors result from negligence, accident or any other cause whatsoever.
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control engineering
December 2019
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INSIGHTS INTERNATIONAL
Aileen Jin, Control Engineering China
Make digital twins easier to implement Move from vision to reality: It’s time to embrace digital twins for manufacturing. Benefits include more efficient digital transformations and more effective asset monitoring and performance.
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ew digital twin cloud applications and services with 4-D visualization and open programming ecosystem provide more opportunities and possibilities for manufacturing digital twins. Bentley Systems and its strategic partners announced the latest software and services of digital twins on Oct. 20 at Bentley’s Year in Infrastructure (YII) 2019 Conference in Singapore. After Bentley and Siemens launched the PlantSight cloud service in 2018, the two companies developed a new digital twin service for Capital Asset Lifecycle Management (CALM), which works within Siemens’ Teamcenter across the enterprise to advance and improve capital program decision-making. PlantSight and Teamcenter CALM are powered by Bentley’s iTwin Services, launched at YII 2019, using digital engineering content from building information modeling (BIM) design tools and multiple data sources, enabling 4-D visualization of digital twins, and logging of engineering changes along a project timeline, to provide an accountable record of who changed what and when. Different from PlantSight, which focuses on process indusJohn Sanins, direc- try operations and maintenance, the CALM software tor of strategic will benefit greenfield and brownfield discrete and channel at Bentley process implementations, including energy, consumSystems, and Torer goods, automotive and transportation industries. sten Beste, senior “It was created to address the challenges typically director enterprise faced across an enterprise’s greenfield and brownfield engineering of capital projects,” said Torsten Beste, senior director Siemens Industry enterprise engineering of Siemens Industry Software. Software, introWith the CALM software, manufacturing companies duced a new digital could consolidate asset data and weave a digital thread twin service for from project initiation and delivery into operations, to Capital Asset Liferealize greater efficiency through the lifecycle of capicycle Management tal assets. McKinsey & Company said 98% of mega(CALM) together projects incur cost overruns or delays, averaging a cost at Bentley’s Year in increase of 80% and delaying delivery by 20 months. Infrastructure (YII) Inefficiencies created in project delivery are passed 2019 Conference down to operators where they can exist for decades. in Singapore. Cour“Lost efficiency gives manufacturers a headache,” tesy: Aileen Jin, said Senthil Kumar, product lifecycle management Control Engineerbusiness consultant of Siemens Industry Software. ing China “CALM can help them make the digital transforma-
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tion, connect the process digital twin, plant digital twin and performance digital twin, and feed insights to continuously improve capital assets.” John Sanins, director of strategic channel at Bentley Systems, said, “By leveraging Bentley’s iTwin services and new simulation technologies, CALM can monitor and improve” performance and efficiency of users’ assets. “In the real world,” Sanins continued, “factories may have different data from disparate systems and different sources, including 1-D, 2-D, and 3-D design and engineering data from third-party computer-aided design (CAD), computer-aided engineering (CAE), and BIM tools. To maximize the user’s investment, we need to manage all this information on an enterprise level, and work within an ecosystem where we must be able to share and collaborate and exchange information in an open way.”
Open-source digital assets
The advantages gained by replacing decadesold, disconnected paper-based workflows and work products with open, live, trusted and evergreen digital twins are immense. Coupling that with an ecosystem of innovation through open-source platforms creates a force for change in infrastructure. Opensource is among the future digital-twin trends. ce
Aileen Jin is editor-in-chief of Control Engineering China. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com.
M More INSIGHTS KEYWORDS: Digital twin, asset management, digitalization Cloud-based software can help with digital twins. Asset management and asset utilization and efficiency can improve with digital twins. Companies more often talk about digital twins that implement them.
CONSIDER THIS Is it time to develop a digital twin execution plan?
ONLINE If reading from the digital edition, click on the headline to see: “Digital twin execution plan” www.controleng.com/magazine www.controleng.com/international www.controleng.com
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DECEMBER 2019
®
INNOVATIONS NEW PRODUCTS FOR ENGINEERS
M7 | New Products for Engineers: Multi-turn kit
encoder, Emergency stop switch series, Industrial cellular router See more New Products for Engineers at www.controleng.com/NPE.
BACK TO BASICS
39 | 10 industrial Internet terms you should know
NEWSLETTER: Industrial Networking
Control Engineering eBook series: IIoT Cloud Fall Edition Learn how the Industrial Internet of Things (IIoT) and the cloud are changing manufacturing in this helpful eBook. Learn more, register to download at www.controleng.com/ebooks.
We have upgraded our newsletter to deliver a better overall experience for our subscribers. Go to www.controleng.com/newsletters to learn more. • Workloads in the cloud for industrial manufacturers • Defining the details of a wireless network installation • Profit-driven operations require IT/OT integration • Using energy harvesting, radio technologies to power wireless sensors • IT/OT collaboration must drive digitalization. Subscribe at www.controleng.com/newsletters.
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. • IIoT Series: Part 4: Machine Learning • 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. Read the digital edition at www.oilandgaseng.com Global System Integrator Report Supplement to December Control Engineering and Plant Engineering Advice from automation and control system integrators with System Integrator of the Year for 2020, System Integrator Giants and more from system integrators www.controleng.com/GSIR 2020 System Integrator of the Year 21
| SI Giants 33
Edge Computing Solutions
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INSIGHTS
TECHNOLOGY UPDATE: ADVANCED CONTROL Allan Kern, P.E., APC Performance LLC
Operation-driven matrix design A multivariable control matrix has manipulated variables (MVs) on one axis, controlled variables (CVs) on the other axis, and models in the matrix that indicate a relationship between that MV/CV pair. Effective multivariable controllers use the right models for various control and optimization needs.
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atrix design practice refers to how control engineers go about designing the matrix at the heart of any multivariable controller. A multivariable control matrix consists of manipulated variables (MVs) along one axis, controlled variables (CVs) along the other axis, and models at various locations within the matrix, which indicate a relationship between that MV/CV pair (Figure 1). Designing the matrix consists of selecting the MVs, CVs and models which, for various control and optimization purposes, are wanted in the multivariable controller. “Large-matrix” design practice has been dominant (nearly exclusive) in industrial applications for the last 30 years. In large-matrix practice, a wide-ranging plant test is used to identify all related process variables and process interactions (models). An underlying principle has been more variables and more models yield a more complete solution, for both control and for optimization purposes. It has been routine for large-matrix practice to result in one large multivariable controller spanning an entire plant unit, with dozens of variables (sometimes more than 100) and hundreds of models (sometimes upwards of 1,000). A side-effect of this approach is most installed multivariable controllers in the process industry
Figure 1: Multivariable control matrix for an atmospheric crude distillation column, based on operation-driven design practice. The matrix is smaller than traditional crude column applications. It addresses primarily column pressure and product inferential quality control, which are often the most valuable objectives of this application – and often the ones found “unclamped” in existing large-matrix applications. Images courtesy: APC Performance LLC
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today are large, complex, fragile, costly, and challenging to own, operate and maintain. Moreover, the large-matrix approach has excluded smaller multivariable control applications that may be warranted based on more basic control and operation improvements, but which do not necessarily justify the high cost threshold of the large-matrix paradigm. In conventional multivariable control technology, the built-in optimizer always has been considered an essential piece, so most involved never questioned it. Instead, the search has looked for better ways to support and maintain the largematrix controllers. However, with insight from decades of experience, it is now possible to see alternative ways to build smaller and more efficient multivariable control applications to address operation and control needs without a built-in optimizer, and therefore without the side-effect of growing the matrix beyond its basic control and operation scope.
Operation-driven matrix design Operation-driven matrix design can reveal important automation opportunities that have previously remained “below the radar” of large-matrix practices. (See “Low altitude radar: Smaller multivariable control.”) It differs from optimization-driven design in key ways. It often results in smaller multivariable controllers, rather than one large controller, with fewer variables and models. When concerns arise regarding a variable’s importance, its efficacy for control, or the reliability of its models, it is often left out of the matrix. Leaving it out errs on the side of reliability. Keeping it errs on the side of optimization. The overarching goal of operation-driven matrix design is automation, not optimization, and such a design strives to include only necessary, reliable, and worthwhile parts. In operation-driven matrix design, groups of related single-loop controllers are identified, based on frequent (often highly coincident) changes to setpoints, outputs or modes. This activity represents manual open-loop multivariable control being carried out by the operating team. The objectives are to: www.controleng.com
1. Automate these manual multivariable control scenarios to capture the well-known intrinsic benefits of closed-loop vs. open-loop control 2. Relieve the operating team of repetitive control loop micro-management, thereby allowing more time to play a proactive process oversight role. Operation-driven design does not strive to include all related variables and models. It often focuses on the ones already used in existing manual multivariable control operating practices and procedures. It automates established proven procedures and captures the experience and skill of the operating team regarding which MVs are suitable and reliable for controlling which CVs. Using automation to capture operator skills is an important criteria that large-matrix practice often neglects in favor of greater optimization.
Where does this leave optimization?
Optimization belongs in the business layer, based on access to site-wide information, ability to bring a variety of planning, scheduling, blending and modeling tools to bear, and the appropriate execution time frame, which is typically daily and not in real time. Common practice is performing daily updates to the (optimized) site-wide production plan and handing it down via the operating chain of command, usually starting with the “morning meeting.” This raises questions about the conventional multivariable control built-in optimizer in the control layer. In the control layer, multivariable control needs to execute at high frequency because process values are subject to real-time changes. However, optimization normally does not need to execute at high frequency because optimization normally does not change in real time. This makes the control layer optimizer redundant and unnecessary, even as it contributes significantly to the high cost and maintenance of conventional multivariable control applications (second only to model maintenance).
Low altitude radar: Smaller multivariable control
Many smaller multivariable control applications have remained “below the radar” of the largematrix multivariable control paradigm, but the exact nature of these applications and a method to identify them has never been proposed — until now. A simple technique for spotting these applications is to use a console activity log to reveal the controllers that require the most operator intervention in the form of setpoint, output or mode changes (Figure 2). A safe assumption is most of these “bad actors” are effectively in a manual multivariable control scenario, wherein operators must frequently adjust groups of related controllers to keep related process
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Figure 2: Operation-driven multivariable control application “low altitude radar” spotlights potential multivariable control applications that have remained “below the radar” of large-matrix practice. Like previous industry-wide initiatives to address loops-in-manual and bad-actor alarms, this simple technique identifies multivariable open loops that can be closed to capture the well-known benefits of closed-loop vs. open-loop control and operation.
variables within constraint limits and (to the extent possible) at optimum target values. [Note: the term “optimum target values” refers to how remaining MV availability (after constraint control) is utilized, and does not necessarily mean the value comes from a real-time optimizer, which in fact it often does not.] This manual open-loop activity can be automated — these multivariable loops can be closed — by deploying an operation-driven multivariable controller to capture closed-loop control benefits vs. open-loop control. This same technique has successfully been used in industrial applications twice in recent memory: Once to address loopsin-manual (as opposed to multivariable loops in manual) and once to address KEYWORDS: Advanced control, multivariable control “bad actor” alarms. In each case, this technique was used Multivariable control can optimization targets to show the extent of the problem, and pursue without having its own optimizer. then measure progress towards best This is already (has long been) practice target metric values. Accord- the norm throughout process ing to EEMUA 191, Alarm systems — a control. guide to design, management and pro- By focusing on control and curement, operators should not have operation needs, rather than optimization, matrix design can more than one alarm per 10 minutes. be streamlined, leading to more However, there’s no best practice guide- efficient and reliable multivariable line for controller interventions per controllers. hour. This also has remained below the All optimization will likely reside in the business layer (as radar — until now. ce
M More INSIGHTS
Allan Kern, P.E., is owner, president, and control engineering consultant at APC Performance LLC. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com.
most always does), rather than in the control layer, where it is redundant and problematic.
CONSIDER THIS Are you updating your multivariable control implementations to close more loops?
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INSIGHTS CAREER UPDATE Bill Keen, Keen Wealth Advisors
Engineer retirement plan: 3 steps A three-step plan can help engineers begin engineering retirement planning with a checklist.
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ngineers face challenges when it comes to retirement planning, but they can lower risk by approaching it as an engineering project. Engineering industries ebb and flow, with firms laying people off in one division while another is thriving. The Health and Retirement Study from ProPublica found 56% of employees over age 50 were laid off at least once or forced to leave jobs before they were ready. Some engineers leave because they’re unable to appropriately diversify the personal wealth they have invested in their company’s employee stock ownership plan (ESOP). Others leave due to changes in leadership, or for health reasons — either personal illness or to become a caretaker. Preparation helps engineers arrive at retirement, like any engineering project. A three-step plan can help engineers begin engineering retirement planning with a checklist, an ESOP discussion and an additional consideration after the three steps are completed.
1. Engineering a retirement plan
To get an idea of current status, start with your assets: property (such as a home), ESOP, 401(k), IRA, Roth IRA, bank and savings accounts, trust accounts, social security, pension plans, etc. Then, take stock of liabilities: mortgage, consumer debt, college or small business loans for children. Check to see if the sum of liabilities are higher than anticipated. During this assessment, remember social networks and reputation are huge assets during the next phase of life, whether it’s consulting, mentoring or working part-time. KEYWORDS: Engineering retirement, retirement ESOPs, common in the engineering world, planning include three key points: Engineers can look at A. Also contribute to a 401(k) retirement retirement as an engineering plan to provide diversification. Don’t rely on project. an ESOP alone, even if it worked in the past. If Assess retirement spending possible, maximize 401(k) contributions. as part of the plan. B. Know how the ESOP plan works. Revisit and update the retirement plan. Study ESOP details such as when ESOP shares may be diversified, what is the vesting CONSIDER THIS schedule, what investment options are availRetirement: If you fail to able outside of the ESOP shares, how forfeiplan, you may plan to fail. tures and reallocations work for former and ONLINE current employees, etc. If reading from the digital C. ESOP timing is everything. Upon retireedition, click on the headline ment, ESOP investors may be forced out of for more resources. www.controleng.com/magazine this privately-owned security. Also consider liquidity. With an ESOP, the stock is privateSearch “Career Update” at www.controleng.com. ly held and valued annually or quarterly by an
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outside party. Timing will affect a retirement date and the ability to liquify assets.
2. Engineering a spending assessment
Reassess spending data abut two years from retirement. This information is needed to have an idea of the money needed each month during retirement. Some engineers have this data handy; others have created a rhythm and know the approximate range of monthly spending that’s worked for them for a while. If this data isn’t handy, look at the last two years of spending. Be as granular as possible to determine where the money goes monthly. Doing this exercise with a spouse or life partner ensures couples agree on finances. Adjust for expected changes after retirement.
3. Engineering retirement timing
Set an ideal retirement date after assessing assets, liabilities and spending. Those levers tell when retirement is affordable. Then set a date when to begin enjoying the next phase of life. A common question during retirement planning is to ask: “When is the best time to retire from a financial standpoint?” Many thoughtful answers result, but never the right one. The best time to retire? Never. From a financial standpoint, it’s always going to be better to work longer, save more and delay spending down assets another year. There comes a crossover point for every person where another year working isn’t worth another year of earnings. Then it is time to retire. Another common question is, “When should I start planning for retirement?” In an ideal world, as soon as working begins to create the longest possible glide slope. Ten years should be the minimum for planning. Remember: the chosen date could be changed by circumstances beyond anyone’s control. Working with a decade-long time horizon, it will be easier to make decisions, and last-minute scrambling may be less. For those behind on planning, it’s never too late to begin making smart decisions.
How a retirement checklist will change
Life will change before retirement, especially if planning begins 10 years out. Update the checklist regularly, and when the day comes, a stabilized approach and smooth landing will be more likely. ce
Bill Keen is founder and CEO of Keen Wealth Advisors; Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com. www.controleng.com
INSIGHTS
Digital edition? Click on headlines for more details. See news daily at www.controleng.com
NEWS
Extend IT security to the plant floor The convergence of information technology (IT) and operations technology (OT) can make manufacturing operations more streamlined and efficient. Getting there, though, is a challenge in of itself. This has become one of the major challenges for manufacturers, and while it isn’t as fraught as it used to be, challenges remain. Eric Knopp, business manager for Rockwell Automation, said, “The cybersecurity threat is real in manufacturing. And it’s costly not just from a production standpoint, but from a public relations standpoint,” in the presentation “The Next Phase of the IT/OT Integration: Extending IT Security to the Cell/ Area Zone of the Plant Architecture,” at Automation Fair at McCormick Place in Chicago.
Security challenges, networks
There are many security challenges in industrial environments, but two of the most notable, Knopp said, are a lack of visibility and insecure design. “In the IT space,” Knopp said, “every-
thing is structured. In the OT space, it’s very common that the networks are thrown together as you go. As a result, the first step many customers have to take is determine what is and isn’t on the network. You can’t move forward if you don’t have an idea of what assets you have.” With insecure design, it’s about a lack of segmentation. Knopp said that while customers have gotten good with the IT/ OT separation with the firewall, there are still problems horizontally on the OT level. “Do you have your machines segmented in such a way so a bad actor doesn’t have access to the whole breadth of the network when they access one controlled or machine?” Knopp said.
IT, OT cases: 3 ways to merge
Co-presenter Paul Didier at Cisco said IT and OT can help each other, citing three use case examples. 1. Monitoring flows and anomaly detection. Didier said this is the first step in the process. IT monitors traffic lows and detect anomalous traffic behav-
Robotic sales show overall growth
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he Robotic Industries Association (RIA), part of the Association for Advancing Automation (A3), today announced that North American robot unit orders are up 5.2% through the third quarter, compared to 2018 results. So far this year, North American companies have ordered 23,894 robotic units, valued at $1.3 billion. Looking at third-quarter results only, North American companies ordered 7,446 robots, valued at $438 million. Units ordered and revenue are both up 1% in the quarter compared to 2018. The largest driver of the year-to-date growth in units ordered was an increase in orders from automotive OEMs at 47%, followed by plastics and rubber at 15%, and food and consumer goods at 4%. “We continue to see improvement in the robotics market,” said Jeff Burnstein, president of A3 and RIA, in a press release. “At this time last year we saw a dip in orders of around 15%, so it’s encouraging to see a recovery through the third quarter. We hope to end the year strong and see growth in 2020 as well.” Orders from non-automotive customers also remain near record numbers, which is a good sign for the overall health of the robotics industry. – Edited from an RIA press release by CFE Media. RIA is part of the Association for Advancing Automation (A3), a CFE Media content partner. See the Robotics Special Report in this issue.
www.controleng.com
There are many security challenges in industrial environments, but two of the most notable are a lack of visibility and insecure design, which can cause many problems for companies. Courtesy: Chris Vavra, CFE Media and Technology
ior so the source can be identified. “You need to do this before you implement anything,” Didier said. “This is about discovering the network, and who’s talking to who for context.” 2. Cell/area zone segmentation. This requires visibility of industrial automation and control systems (IACS) in the production environment. “It’s relatively easy to manage, but they require previous knowledge of who’s talking to who. Once they’ve been written, it’s easy to implement in a relatively simple matrix,” he said. 3. On-demand remote access. This allows OT to manage access as defined by IT security. A specific asset in the machine being serviced must be accessible to the machine building over a remote virtual private network (VPN). There’s no dependency on IT to enable access during the maintenance window, which reduces downtime. While a full convergence might not be happening anytime soon, there are many steps manufacturers can take to make the process easier. Chris Vavra is associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.
M More ONLINE
Read this article online at www.controleng.com for more information, including software-defined strategy.
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INSIGHTS
NEWS
Five tips to ensure regulatory compliance with international codes, standards Navigating the stages of designing, manufacturing and commissioning for any international project is challenging, and an often-overlooked area that poses a significant risk is international codes and standard compliance. Take, for example, an amusement ride where the design is done in one country, parts built in another, and the installation is planned for multiple destinations. Even though the design is meant to be identical, the final installation sites may dictate the need for compliance on various codes and standards. What can be done to prevent a rejected product on-site? Consider these five steps. 1. Target market analysis: Understand national versus international product certification requirements. Codes and standards for an identical product can change depending on the
country. One critical step early on in the project should be to perform a market assessment. The target markets (national, international, hazardous or nonhazardous) should be very clearly identified in the scope of work. For example, a product for the European market may only require self-declaration whereas the same product for the North American market requires third–party certification. 2. Educate the team. The key to a successful project should always be a standard-based design. Educating the team about target markets, applicable codes and standards, and designing with those guidelines in will save time and money. 3. Engage local authorities during the preliminary design phase. The biggest challenge when approaching a design-based approach is how to pick the relevant standards. Engaging local regula-
tors early, during the preliminary design or even concept design phase, can prevent a headache later on. 4. Perform pre– and mid-design site visits. Most companies focus on design, procurement, manufacturing and shipment phases, leaving installation as an afterthought. Meeting site inspectors in person and learning their certification process is crucial during the commissioning phase. 5. Complete the documentation. Another source of project delay is poor documentation. For international projects, having proper documentation is even more important for quick customs clearance and on-site regulatory approval. Amreen Grewal is a professional engineer for Hedgehog Technologies; this originally appeared at www.csemag.com.
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Control Engineering hot topics, November 2019
H
ot topics in Control Engineering, for November 2019, included the Engineers’ Choice finalists, control system migration, information and the cloud, profit-driven operations, the future of industrial automation, and others. These are based on the top 10 most-read articles online in Control Engineering November. 1. 2020 Engineers’ Choice Finalists: The official ballot is open for voting for Control Engineering North American print and digital edition subscribers, until Dec. 20 at www.controleng.com/NPE. 2. Opening your options: Control system migration: Aging process control systems (PCSs) create nine major problems. 3. How information ascends to the cloud for greater utilization. 4. Profit-driven operations require IT/OT integration: Maximizing process plant profits requires integration. 5. Future of industrial automation: discern the possibilities, potential. 6. Interoperability and how to sustain it: Vocabulary and concepts for the age of analytics. 7. PLC tag and address naming conventions. 8. Eight IIoT project tips: Consider these eight expert Industrial Internet of Things (IIoT) implementation tips. 9. Safety tips on SCCR for industrial control panels, industrial machinery. 10. Five factors to smart instrumentation in Industry 4.0. Chris Vavra, associate editor, CFE Media and Technology, cvavra@cfemedia.com.
Headlines online Top 5 Control Engineering articles Nov. 18-24 Articles include the Engineers’ Choice finalists, control system technologies and control system migration, industrial automation, and information ascending to the cloud. Machine vision can improve random bin picking Random 3-D bin picking is a developing robotic skill. See us at these upcoming events... A3 Business Forum, Jan. 13-15, Orlando, www.a3automate.org ARC Industry Forum, Feb. 3-6, Orlando, www.arcweb.com 2020 Marketing to Engineers, CFE Media and Technology, April 27, Chicago; www.cfemedia.com control engineering
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INSIGHTS THINK AGAIN
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Ethernet for process and discrete devices Separate efforts aim to extend Ethernet to process and discrete devices. Standards can promote interoperability for devices and software if standards are specific enough.
E
thernet communication efforts are moving to economically extend the protocol to devices, one for process control devices using existing two-wires often in place in many applications, and the other for discrete applications.
compatible with most communication protocols, including industrial Ethernets, such as ODVA’s EtherNet/IP, PI’s Profinet, and Ethernet Technology Group’s EtherCAT. Latency is virtually nonexistent, Festo said: “Scan cycles for a mix of both valve terminals and Advanced Physical I/O are below one millisecond Layer for industrial and are expected to approach Ethernet microseconds.” The I/O has a The Advanced Physical theoretical upper limit of 500 Layer for industrial EtherI/O modules with 164 ft (50 net consists of IEEE P802.3cg m) between modules. A future 10Mbits single twisted pair safety implementation is under Mark T. Hoske, long reach Ethernet (from Content Manager consideration. IEEE Task Force; approved With 19 active projects, Nov. 7) plus Power on Sinstudy groups, and ad hoc efforts gle Twisted Pair plus an Intrinsically underway, think again about helping safe frontend (both from APL Industry future Ethernet communications promote Partners R&D project). The goal is to interoperability, as work in the IEEE 802.3 update industrial Ethernet specifications Ethernet Working Group continues. ce in 2020 (FieldComm Group, ODVA and PI). First infrastructure and field devic- Mark T. Hoske, content manager, Control es are expected in 2021. Companies Engineering, CFE Media and Technology, involved so far include Endress+Hauser, mhoske@cfemedia.com. Pepperl+Fuchs, Rockwell Automation, and Samson, to bring interoperability, Ethernet communications, and hazardous area protection to field instruments. See more details with this article online.
Discrete Ethernet communications
Extending the discrete Ethernet side, Festo’s CPX-AP-I Remote I/O, launched in October, extends performance of mixed valve terminals and I/O systems and is
M More INSIGHTS
See images with this online. Search for the headline at www.controleng.com or click through the headline at www.controleng.com/magazine. www.ieee802.org/3/
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High-speed communications extend the reach of Ethernet protocols, as Festo showed at Automation Fair by Rockwell Automation. Courtesy: Mark T. Hoske, Control Engineering
control engineering
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, Associate 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
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www.controleng.com/EAB Doug Bell, president, InterConnecting Automation, www.interconnectingautomation.com David Bishop, president and a founder Matrix Technologies, www.matrixti.com Daniel E. Capano, president, Diversified Technical Services Inc. of Stamford, CT, www.linkedin.com/in/daniel-capano-7b886bb0 Frank Lamb, founder and owner Automation Consulting LLC, www.automationllc.com Joe Martin, president and founder Martin Control Systems, www.martincsi.com Rick Pierro, president and co-founder Superior Controls, www.superiorcontrols.com Mark Voigtmann, partner, automation practice lead Faegre Baker Daniels, www.FaegreBD.com
CFE Media Contributor Guidelines Overview Content For Engineers. That’s what CFE Media stands for, and what CFE Media is all about – engineers sharing with their peers. We welcome content submissions for all interested parties in engineering. We will use those materials online, on our website, in print and in newsletters to keep engineers informed about the products, solutions and industry trends. www.controleng.com/contribute explains how to submit press releases, products, images and graphics, bylined feature articles, case studies, white papers, and other media. * Content should focus on helping engineers solve problems. Articles that are commercial or are critical of other products or organizations will be rejected. (Technology discussions and comparative tables may be accepted if non-promotional and if contributor corroborates information with sources cited.) * If the content meets criteria noted in guidelines, expect to see it first on our Websites. Content for our e-newsletters comes from content already available on our Websites. All content for print also will be online. All content that appears in our print magazines will appear as space permits, and we will indicate in print if more content from that article is available online. * Deadlines for feature articles intended for the print magazines are at least two months in advance of the publication date. Again, it is best to discuss all feature articles with the appropriate content manager prior to submission. Learn more at: www.controleng.com/contribute
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CONNECT WITH THE GLOBAL ROBOTICS COMMUNITY A ROBOTIC INDUSTRIES ASSOCIATION MEMBERSHIP GIVES YOU: •
Access to thousands of robot suppliers, end users, system integrators, researchers, and industry leaders
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Educational opportunities to grow in your career
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JOIN RIA TODAY Visit robotics.org for more information (734) 994-6088
SPECIAL REPORT
ROBOTIC S Exclusive research and more
Robots can save jobs in dangerous environments Grasp new robotic applications: Five ideal features for robot grippers Start today with these six most-common collaborative robot applications Robots eliminate inconsistencies, cut cycle time 50% Is training addressing the risks? Exclusive Robotics Research Report summary, advice 9% ƂPF WPCEEGRVCDNG UCHGV[ TKUM CUUQEKCVGF YKVJ TQDQVU 56% don’t think those involved with robots get enough safety training 4% of respondents said a robotic safety risk isn’t being addressed Robots boost throughput and quality; optimize robotic investments today with more online: Research Report; eBook; Robotics page; Webcasts on creating TQDQV URGEKƂECVKQPU YGNFKPI VQQNKPI CPF TGVWTP QP KPXGUVOGPV COVER IMAGES from left: At Darex in Oregon, a collaborative robot erects a box, placing the product into box, and pushes it through the tape sealer, courtesy Universal Robots; A new gripper designs allow robots to grasp, move, sort, and pack a wider diversity of products (radial gripper shown), courtesy Festo; Fanuc robot at Fabtech, courtesy Chris Vavra, CFE Media and Technology.
SPECIAL REPORT: CONTROL ENGINEERING, PLANT ENGINEERING
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Buying, specifying robotics 2019 Robotics Research Report: Respondents to the Control Engineering and Plant Engineering 2019 Robotics Research survey identified use, trends, and purchasing habits of industrial robots and related hardware, software, peripherals, robotic safety, training, installation, integration, and maintenance.
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ndustrial robots and related hardware, software, peripherals, robotic safety, training, installation, integration, and maintenance were among topics covered in the 2019 Control Engineering and Plant Engineering 2019 Robotics Research survey. Summary survey results appear below; see the full research report at www.controleng.com/research and www.plantengineering.com/research. This is critical information for those interested in increasing throughput, quality and staying competitive. It’s not a question of if you’ll be buying and using the latest industrial robots, it’s a matter of when.
Robots, robotics, integration
About 70% of respondents buy or specify robots. Many other products and services include robot or vision sensors (64%); robot grippers (59%); robot software (52%); robotics as part of a larger machine system or workcell (50%), robot control panels and enclosures (49%). More than another dozen related products or services are noted.
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The diversity of robotic software, training, and components shows the need for a wider engineering effort when working on robotic specifications. More respondents are doing their own integration (45%) than hiring others to help (34%). It seems robot manufacturers, like other automation providers, are making their offerings easier to set up, program, and operate, perhaps because time to productivity has become a more important metric with demographic pressures and the skills gap. Robotics experts can help shorten that time, whether on staff or from a robotic system integrator involved in the project. Articulated robots are the most common robot type (72%). Other common types (double digits) include robots applied or modified for collaborative use, collaborative robots (by design, speed or force limiting), Cartesian robots, gantry robots, mobile robots, and selective compliant articulated robot arm (SCARA) robots. For open-source robot programming software, 27% said they use or would use; 31% said a control-
KEYWORDS:
Industrial robots, robotics research Robots, robotics, integration Purchasing, safety, training Robotic advice from survey respondents.
CONSIDER THIS How can robots increase your throughput?
ONLINE If reading from the digital edition, click on the headline for more resources. www.controleng. com/research www.plantengineering. com/magazine
www.controleng. com/webcasts
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Q: Which robotic devices, systems or services do you buy or specify? Check all that apply. (N=118) Seventy-one percent of respondents said they buy or specify robots, while 64% said they specify robot sensors or vision; 59% specify robot grippers; 52% robotic software; 50% robotics as part of a larger system; and 49% robotic control panels and enclosures. All graphics courtesy: Robotics Research Report, 2019, Control Engineering and Plant Engineering, CFE Media and Technology
December 2019
SPECIAL REPORT: CONTROL ENGINEERING, PLANT ENGINEERING
ler from a third-party manufacturer guides robot movement. Forty-seven percent of respondents have material handling/conveying applications; 34% said they have pick-and-place applications. Three types of machine vision are highlighted: machine vision, visible light (31%); machine vision 3-D (13%); and machine vision, infrared (10%). Machine vision can be involved in quality control, palletizing, pick-andplace, assembly and other applications.
Robotic safety, training
Q: What are reasons behind your next robot purchase? Check all that apply. (N=86) Sixtyfour percent of respondents said that the reasoning behind their next robot purchase was to increase throughput, and 52% said it was to increase quality.
Just 9% find unacceptable safety risk associated with robots; 4% of respondents said a robotic safety risk isn’t being addressed. More than half of respondents (56%) don’t think those involved with robots get enough safety training. Of that, 14% could use a lot more. Respondents were clear they’re not receiving enough robot safety training. Consultants provide the most training (54%), compared to other robotic trainers (24%), RIA-certified integrators (21%), RIA online (17%), and other robotic system integrators (13%). Depending on position, 53 to 70% receive a sufficient or above average amount of robot training; 17 to 36% receive minimal or poor training, with robot maintenance staff receiving the least of the four roles at 36% receiving minimal or poor training. Robot safety training varies according to position, with robot maintenance staff (36%) and robot operators (27%) as the two positions getting least training. Improvements are needed here.
their robot purchase, and 32% said “Maybe,” for a total of 75% that might switch vendors.
Robotic purchasing
Survey respondents’ advice
Just 12% have one or more predetermined robotics vendor. Extremely and fairly important decisions for purchase or specification include safety devices (88%), throughput (87%), avoiding downtime (86%), and quality (86%). Throughput (64%) and quality (52%) are the largest purchasing reasons. Financing and justification are top obstacles to purchasing (42% each). More than half expect their next robot purchase within a year. One-third of respondents said their next robot purchase is within the next six months; 4% within a year. Forty-three percent of respondents said they would be willing to consider a different vendor for
SPECIAL REPORT: CONTROL ENGINEERING, PLANT ENGINEERING
Q: What obstacles are there in your next robot purchase? (N=77) Forty-two percent of respondents said that financing and justification are obstacles in their next robot purchase; reliability, maintenance, safety and integration are the next obstacles; 9% foresee no obstacles.
Survey respondents were asked to provide robotic advice to peers. General robotic advice includes the following (see much more specific advice with this article online): Be familiar with your system. Ensure you understand the robot capabilities before you purchase. Robots are helpful if you get it right. Standardize. You need to have a geometrical mindset. ce
Mark T. Hoske is Control Engineering content manager, mhoske@cfemedia.com; Hemdeep Kaur is CFE Media audience database technician; and Amanda Pelliccione, CFE Media and Technology director of research. December 2019
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Robots: Dull, dirty, dangerous Robots can handle dull, dirty and dangerous jobs humans shouldn’t be doing. They can improve efficiency, reduce downtime and lower risk for humans.
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hen discussing the subject of automation, it’s common to hear someone say that robots will eventually take all the jobs. Is that true? Can robots do all the jobs? No. Robots are doing the jobs humans shouldn’t have been working on in the first place. These are known as the dirty, dangerous, and dull jobs.
Unsanitary, hazardous, repetitive jobs
Robots are doing the dull, dirty, dangerous jobs humans shouldn’t be doing in the first place, as shown at Fabtech, a metal forming, fabricating, welding and finishing event, in Chicago, in November. Courtesy: Chris Vavra, CFE Media and Technology
Dirty jobs are often unsanitary or hazardous work that can impact human health. Even though these jobs are unfavorable, someone has to do them. They include waste management, livestock nurturing, and mine exploration. The robot can take away the risk from humans and keep them safe from harm. One example is the need for sewer scrapers. When there a sewer pipe has a problem, a crew shuts it off, digs to access the pipe, then fixes the infrastructure. A robot can clean, map, and inspect pipes before the problems arise. Robots can collect data like distance, pressure, temperature, and composition to get visibility of pollutants, infectious diseases, and drug use. Dull, low-interaction, high-repetition jobs require very little human thought. They often include processes that have a sole objective of efficiency and output. Robots can work around the clock to streamline dull jobs. This saves businesses money and frees up human capital for tasks that have an element of variety and a need for critical thinking. With the growth of e-commerce, there’s an
increasing need for fulfillment centers. These centers must move a high volume of small, multiline orders to turn a profit. Workers must walk long aisles, find an item, scan it, put the item in a cart, and push the item back to the staging area. But robots can be used to increase order-to-delivery times, reduce errors, and minimize the burden on human workers. Dangerous jobs put humans in harmful situations. To prevent the loss of human life, robots can be used. They are able to measure and detect variables beyond human perception. Robots can defuse bombs, traverse distant planets, and inspect unstable structures. Robots are being used to inspect bridges. A high degree of expertise, risk, and cost is associated with bridge inspections by humans. Multi-rotor drones are able to completely remove humans from dangerous situations. They inspect hard-to-access areas with advanced speed and maneuverability. Humans still have plenty to do if robots take these dirty, dangerous, and dull jobs. Technology advances have brought change throughout the history of industry. Robots are no different. Humans are better off doing the variable, dexterous and cognitive work. Humans will be able to choose the work they’d rather do. Workers can gain knowledge and skills. This increases their value so that they earn a higher income and can live a more rewarding life. ce This article originally appeared on the Robotics Online Blog. Robotic Industries Association (RIA) is a part of the Association for Advancing Automation (A3), a CFE Media content partner. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.
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KEYWORDS: robotics, robots, machine safety Robots can handle jobs with safety or hazard concerns. As a result, humans can handle dexterous and cognitive work, which they are better-suited for. ONLINE See more on robots at www.controleng.com/robotics.
CONSIDER THIS What dull, dirty or dangerous tasks would you like to see robots take over soon?
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5 ideal robotic gripper features The ideal robotic gripper should be flexible for multiple applications and easy to use. Robotic grippers can help with their long-term data needs.
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rom 2014 through today, industrial robot sales have nearly doubled worldwide according to the International Federation of Robotics (IFR). Many industrial robots include an end-ofarm-tool (EOAT) for gripping. There are two broad classes of grippers — those that grasp and those that attach. Mechanical grippers grasp while vacuum-suction-cup and magnetic grippers use air pressure or magnetism, respectively, to temporarily attach the workpiece to the EOAT. Mechanical grippers are driven by electrics or pneumatics and are designed to grasp various parts having similar shapes and sizes. Two new classes of electric- or pneumatically-driven grippers are adaptive, which can conform to varied shapes; and soft, which can be used with fragile products (fruits, vegetables and other foods). Look for five qualities in a robotic gripper.
1. Easy to integrate with the robot
The ideal gripper will integrate with the hardware and software of the robot. This is one of the reasons robotics manufacturers now offer pre-integrated gripper programs. They want to lower engineering overhead and decrease time to market for their customers.
2. Easy to teach
An intuitive human-machine interface can make it easy to teach the gripper its functions. If it is difficult and time-consuming to configure a new motion then look for a better gripper.
3. Flexible
Shorter product lifecycles indicate the gripper will not be gripping the same things in the same way for long. In the collaborative sphere, it is mandatory that one gripper be able to grasp or attach to many items. Mechanical grippers grasp show a sectional view of a radial gripper. SPECIAL REPORT: CONTROL ENGINEERING, PLANT ENGINEERING
Soft grippers gently conform to delicate objects. Images courtesy: Festo
A high level of flexibility is often better in operations with frequent product changeovers. This is true for attachment, mechanical, adaptive and soft grippers. Flexibility is why so many research and development projects involve grippers that work like the human hand.
4. At least as good as an
application-specific gripper
Robots have been deployed in many unusual applications, and many application specific grippers have been produced. Determine if an unusual handling problem has been solved with an optimized gripper. If so, see if the gripper meets the ideal of being easy to integrate and teach, and is flexible.
5. Supports data integration
For operations moving toward IIoT and Industry 4.0, grippers that provide operational data have an edge over those that do not. ce
Michael Guelker, product manager — cylinders and grippers, Festo. Edited by Chris Vavra, associate editor, CFE Media and Technology, cvavra@cfemedia.com.
Adaptive-shape grippers are able to conform to radically different shaped objects.
M More ANSWERS KEYWORDS: robotics, robot grippers Many types of robotic grippers fit specific applications. Regardless of type, a robotic gripper should be flexible and easy to use and integrate. Robotic grippers should support long-term data integration goals. ONLINE Read this article online at www.controleng.com for additional articles from this robotics special report.
CONSIDER THIS Which feature is most important to when choosing a robotic gripper?
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Collaborative robots: 6 ways
Six most common collaborative robot applications are pick and place, machine tending, packaging and palletizing, process tasks, finishing tasks, and quality.
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ANSWERS
KEYWORDS: Collaborative
robots Most-common applications Plug-and-play effectors ease set up.
CONSIDER THIS Have an easy first application?
ONLINE From the digital edition www.controleng.com/magazine click on the headline for more advice and links to: The ROI of collaborative robots Plug-and-play peripherals for collaborative robots Collaborative robots are now skilled welders, what’s next?
T
he field of collaborative robotics has expanded in 10 years and is the fastest-growing global industrial robotics market segment. Leading that expansion are six application areas: pick and place, machine tending, packaging and palletizing, process tasks, finishing tasks, and quality inspection. A collaborative robot (also known as a cobot) is a robot with the ability to safely work alongside human workers to complete a task. Technology accessibility through ease of deployment is similarly integral to the collaborative robot definition. Online, see more on each of the six applications and advice on how to implement a collaborative robot into the application, what accessories are required, and programming advice.
1. Pick and place: A pick-and-place task is one At Darex, a manufacturer of drill and knife sharpeners in Oregon, a UR5 handles the packaging cycle. Courtesy: Universal Robots
in which the robot is required to pick up a workpiece and place into another location and or orientation. The handling of the workpiece is the key action rather than any other process. In the simplest instance products will be presented to the robot in a uniform layout tray or pallet or on a conveyor in predictable position, where in more complex cases a vision system may determine product orientation. A pickand-place task is an excellent first collaborative robot
automation application because it's repetitive.
2. Machine tending: Machine tending is
another common application task. Machines being tended include computer-numerical control (CNC) machines, injection molding machines, laser engravers and metal-stamping presses.
3. Packaging and palletizing: Before any
product leaves a factory or facility, it is likely it needs some form of packaging before shipping. Packaging and palletizing tasks could involve packaging a product by placing it into a shrinkwrapping machine, picking packaged products from a conveyor and collating them into boxes, or placing these boxes onto a pallet for shipping.
4. Process tasks: For process tasks such as gluing, dispensing or welding, the key details are the same: The robot moves a tool through a fixed path while the tool interacts with the workpiece. In each of these process tasks, it takes a significant amount of time to train a new employee to control numerous variables required to attain an excellent quality finish. If this control can instead be copied directly from one robot to another, the process becomes more straightforward. 5. Finishing tasks: A finishing task requires the robot end-effector to apply a force across the surface of a workpiece to remove a certain amount of material. Polishing, grinding and deburring differ in amount, form and location of material to be removed, but the robot’s requirements are essentially the same. 6. Quality inspection: Quality inspection involves full inspection of a finished product, especially one that is the result of a precision engineering process, often requiring high-resolution images to be captured from many angles to confirm all of the surfaces and dimensions conform to the required specifications. ce Joe Campbell, senior manager, applications development, Universal Robots. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media, mhoske@cfemedia.com.
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Using robots for success How year-round automation eliminated inconsistencies on stock products and boosted output by cutting cycle time by 50%.
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pplication note: A custom robotic workcell using vision-guided robots helped increase consistency and throughput in a welding application with a 50% drop in cycle time.
1. Describe the project and goals.
A producer of wire partition products, WireCrafters LLC (Louisville, Ky.) sought to implement a custom robotic workcell to maintain consistent and cost-effective production of 20 stock Style 840 partition panels, optimizing production and meeting the seasonality of customer demand. The manual manufacturing of 20 stock Style 840 partition panels was difficult to maintain during peak seasons. The established MIG welding process for one-foot increment panels (ranging from 1- to 10-in. wide, in heights of 4- and 5-in.) required one to two skilled workers using a fixture table to complete all angle frame and mesh welds manually. While an effective method for fabricating stock partition panels, hiring temporary workers to help fill the uptick in seasonal demand for the product grew expensive, and the manual fabrication of the panels resulted in product variation for weld quality and lot sizes.
2. What automation was used?
The custom robotic solution featured six robots: four long-reach 20-kg payload capacity robots with power supply for welding, and two high-performance 50-kg payload capacity handling robots. To equip the system to detect variance in the weld target location, each welding robot was equipped with a 2-D vision system with vision application software and a camera. The combination of hardware and software enabled the robots to return critical X- and Y-axis information to the robot controller for the strategic management of required complex vision issues.
3. What were challenges?
Aside from the need for a robotic vision, the prime hurdle, perhaps, was the time spent waiting for technology to catch up to the concept the customer had in mind. In the 12 years spent searching and testing various technologies to help create smaller batch sizes and gain better inventory returns, the Industrial Internet of Things (IIoT) came to fruition, prompting the development of highly-capable and
SPECIAL REPORT: CONTROL ENGINEERING, PLANT ENGINEERING
Featuring six high-performance Yaskawa Motoman robots, this automated welding workcell robotically welds angle frame components and mesh to angle frames for the fabrication of stock partition panels, improving efficiencies and levelizing production at WireCrafters LLC. Courtesy: WireCrafters LLC
affordable robots, as well as the exact 2-D machine vision system needed to address the variance in weld target location.
4. Please share positive metrics.
Overall, implementation of the custom-designed automated panel welding system has improved efficiencies and leveled production. Cycle time for the manufacturing of stock panels had been reduced by 50%, and the workcell has eliminated seasonal production challenges, creating a consistent schedule to meet year-round customer demand. The workcell operates 20 hours a day, four days a week to maintain regular production. Fridays are used to fill extra demand when necessary. Requiring minimal personnel investment, only two operators are needed per 10-hour shift to manage the welding system and its subsequent part transfer. Robotic automation has delivered flexibility needed to adapt to market fluctuations, and it has contributed to the company’s strategy for future success. ce
Josh Leath, product manager, welding at Yaskawa America Inc. — Motoman Robotics Division. Edited by Chris Vavra, associate editor, CFE Media and Technology, cvavra@cfemedia.com.
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KEYWORDS: Robotics, grippers, robotic automation A robotic workcell maintains consistent and cost-effective production. Vision-guided robotics helped improve production consistency and make operations more efficient. ONLINE Read this article at www.plantengineering.com
for more photos and case study advice, with links to other robotic case studies.
CONSIDER THIS How can robotic automation improve operations at your facility?
December 2019
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ANSWERS
VIRTUALIZATION Vibhoosh Gupta, Emerson
Virtualization for the plant floor End users are comfortable with virtualization in information technology server rooms and desktops, and many similar benefits now can be realized with programmable logic controllers and programmable automation controllers.
C
ommercially available technologies are almost always applied at a quicker pace in the consumer and information technology (IT) space than their industrial counterparts. For instance, virtualization technologies have been commonplace within IT environments, most often in server-based applications, for many years. On the other hand, industrial automation operations technology (OT) applications lagged by several years in adopting virtualization. Today, virtualization has become mainstream for almost all OT products, practices, and applications, though it is still often used in computer-room environments. It is now common for OT system servers to host multiple virtual machines (VMs) for visualization, historian, redundancy and other uses. Automation engineers use desktop-based virtualization to quickly create instances of development and testing systems. Virtualization provides benefits for quickly deploying systems, optimizing resource usage and backing up configurations. The concepts and advantages of virtualization are commonly associated with PCs and servers, but they can be employed elsewhere. Recently, virtualization capability has been extended into more specialized and robust industrial programmable logic controllers (PLCs) and programmable automation controllers (PACs) used for process and machine automation. This creates more options for end users, such as enabling analytics closer to the source of data. It also provides other benefits including enhanced productivity, efficiency and security.
Virtualization concepts
A basic definition of virtualization is providing the ability to run more than one VM software operating system (OS) on one hardware platform, allowing one physical computer to be more utilized as many virtual computers. Each VM must operate independently. There are two types of virtualization, Type 1 and Type 2, depending on where the hypervisor is located. A hypervisor is the combination of hardware, firmware, and software running on the host machine and managing guest VMs. Type 2 virtualization, which may be called “hosted,” is used for desktop and server PCs, with the
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Figure 1: This figure depicts how a single Type 1 hypervisor manages two virtual OSs on an industrial controller, a RTOS for realtime control and a guest OS for edge processing. Images courtesy: Emerson
hypervisor running on top of a traditional host OS already operating on the hardware. This creates virtual “sandboxes” where multiple OSs can run simultaneously, but it adds latency due to the underlying OS. Type 1 virtualization, sometimes called “native,” utilizes a hypervisor running directly on the bare metal hardware without an underlying OS. The hypervisor partitions the hardware itself to each OS. This results in very low latency and jitter, which is ideal for real-time deterministic or time-sensitive applications. Type 1 offers greater performance than Type 2 because it has direct access to the hardware without delays due to a host OS system. Until recently, virtualization has not been practical or possible at the plant floor level. Now, the development of a new class of PLCs and PACs leveraging multiple processor cores and virtualization offers the ability to extend the same virtualization concepts down into the industrial controller, providing an integrated approach. A common class of industrial controller for typical automation applications is the PLC, which has used a dedicated processor and specific real-time OS (RTOS) to provide high-speed deterministic control. The challenge to virtualizing PLC functions is maintaining high-speed determinism. Today there are hardware advances common to the commercial PC world such as multicore processors and large memory. By using multicore technology and Type 1 virtualization, industrial controller platforms can run multiple OSs on the same procescontrol engineering
Figure 2: Industrial controllers capable of virtualization, such as Emerson’s Outcome Optimizing Controller (OOC), include multiple processing cores, digital communication ports, and support for parallel operation of a control RTOS and a general-purpose OS.
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VIRTUALIZATION
Control remains the inner loop
sor, including a RTOS for control which will experience little to no effect on the determinism and speed (Figure 1). A second Linux guest OS can be used for other edge processing. As the number of available cores increases, even more OSs can be deployed. For edge-located controllers, the possibility of running multiple OSs is a dramatic shift (Figure 2). The primary concern is maintaining a robust RTOS for control functionality, as with PLCs, so the automation functionality is not compromised. A secondary OS, operating as supplemental to the RTOS, provides more computing options. The two OSs must be independent and maintain ability to interact. The concept of running two OSs in an edge-located industrial controller can be further explained in terms of an “inner” and an “outer” loop, which may be familiar to users of cascaded process control loops. In this case, the inner loop is the RTOS VM for control, while the outer loop is a standard OS VM for added functions. The inner loop could monitor a process flow KEYWORDS: Virtualization, input, perform the proportional-integralPLC, PAC derivative (PID) calculations, and comVirtualization can deploy mand the control valve output. The outer systems, optimize resource loop can advise the inner loop regarding usage and back up configurations on the plant floor. the optimal flow rate, but it will not impact There are two types of inner loop operation otherwise. virtualization: Hosted and native, Another way of explaining the inner which can be used depending on and outer loop concept is an analogy specific plant-floor needs. related to navigating a car. The inner loop Virtualization future-proofs is represented by the driver’s direct attendesigns and saves them from committing to expensive tion to drive the vehicle to its destination, hardware replacements. while the outer loop could be the car’s dashboard navigation system providing ONLINE supplementary information. Read this at www.controleng.com for more on virtualization and cloud The inner loop is mission critical and services. must carry on operations without fail, even if the outer loop has a problem. On the CONSIDER THIS other hand, the outer loop is valuable, but What benefits would your plant floor see from virtualization? not essential, to basic system operation. Figure 3: Using virtualization, Emerson’s OOC uses a real-time “inner” loop for direct control, which can be advised by a general purpose “outer” loop where advanced optimization can be performed.
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PLCs provide the specialized functionality, robust packaging, and input/output (I/O) connectivity necessary to automate equipment and processes. These devices have gained processing power and networking capabilities to interact better with higher-level systems, with more advanced versions often called PACs. PLCs and PACs still have dedicated roles. PLCs and PACs use many types of programming languages; ladder logic is the most popular. A basic measurement of PLC performance is how fast the controller can scan through the ladder logic, typically measured in milliseconds. All other overhead tasks must be handled so a deterministic scan time is preserved. The OS from a PC is not a good candidate for millisecond control because it must handle many overhead tasks such as graphics and user interface. A controller-based VM with PLC or PAC functionality requires using an RTOS to provide features needed for inner-loop PLC functions without performance-sapping features.
In the outer loop
Since control functionality remains essentially the same, the real advantage to controller virtualization is the addition of an outer-loop Linux VM carefully integrated in a cooperative manner. This VM can do anything a dedicated PC could, but at a lower cost, and packaged in a more compact form factor, with no need to integrate a PC to the controller. It is unnecessary for industrial users to take advantage of the extra OS right away, as they could use a virtualized controller for the basic PLC functionality. Many users are finding a general-purpose Linux OS at the edge can enhance applications by running machine learning elements; performing analytics; communicating to the cloud; using messaging queuing telemetry transport (MQTT) or some other publish-subscribe model to exchange information; executing optimization calculations to inform the controller VM; driving a local display; and serving web pages. These functions have required upstream computing resources. Users benefit from the efficiency of implementing these functions out at an edge-located OS, because they are taking advantage of locally available processing power and acting on the data as close to the source as possible. This removes layers of computing and streamlines networking usage. The ability to drive a local display or directly serve web pages out of the controller are examples of this. When implemented properly, an outer loop VM lets users safely perform processing at the edge closer to the source of data, which unloads upstream networking and processing requirements. ce
Vibhoosh Gupta is a portfolio leader, Emerson’s Machine Automation Solutions business unit. Edited by Chris Vavra, production editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com. www.controleng.com
ANSWERS
WIRE AND CABLES Jim Krebs, AutomationDirect
Specifying cut-to-length cable Those seeking to improve manufacturing and fabrication flexibility can purchase cut-to-length cables to save time and money.
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very automation system — whether on an original equipment manufacturer (OEM) skid, installed in a test lab, or built in the field — uses significant amounts of wire and cable. These conductors are placed into many types of functional service, mechanical operations and environmental conditions. The right cables are needed on hand at the right time. Designers often try to minimize cable and wire types and colors required to simplify ordering and stocking and reduce waste. This can be a challenge, especially for multi-conductor cables because they come in so many types. Consolidation efforts can end up costing more because certain cables may be over-specified with more conductors or increased size, for the sake of reducing quantities of makes and models. Unused cable on the shelf, wasted during installation, or over-specified drives up raw material costs. For these reasons, many manufacturers are shifting some or all cable needs to suppliers offering cutto-length cables. Cut-to-length services can supply the exact cables needed for applications. It also gives end-users, system integrators, or machine builders the chance to test alternates, all while minimizing costs.
Determine cable type
Modern automated equipment uses cables for power, discrete and analog input/output (I/O) signals, and data/networking connections. These cables may be installed in raceway systems, open on the equipment, or arranged to accommodate motion for robotics and similar applications. Installations may be exposed to sunlight, water, washdown, chemicals or extreme hot or cold temperatures. Here are a few common categories of cables, generally arranged from largest in diameter to smallest: Power tray cable; variable frequency drive cable; heavy duty flexible power cable; flexible portable cord (service cord); continuous flexing motors supply cable; flexible control cable; continuous flexing control cable; control and signal cable; instrumentation cable; sensor/actuator cable; data cable (RS-232/422, RS-485); and continuous flexing industrial Ethernet cable. Each cable has characteristics making it suitable for its intended service (Figure 1). Sometimes the NFPA 70: National Electrical Code (NEC), which has many designations, may mandate certain cable types for applications. Other times, the work site may have
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requirements exceeding basic products that would otherwise be acceptable. Generic industry naming conventions and terminology also can confuse. When designers specify cables, they need to consider the construction, conductor materials, conductor ampacity, voltage loss due to impedance, insulation materials, shielding methods, voltage ratings, environmental ratings, conductor color codes and other factors. Communication cables, in particular, can have complex construction and technical details that must be specified (Figure 2). Premium performance characteristics also may be desirable or required for an application. This is true for cables that flex or move in operation or are subjected to extreme temperatures. A basic cable will function as needed but can eventually fail. A premium performance cable incorporates improved materials and methods of construction so it can last longer in operation. Premium performance costs more initially but can deliver savings over time. With many variables and products on the market it may be tough to choose the best fit. This variety also makes it hard for manufacturers or installers to adequately stock.
Figure 1: Even a basic cable type, such as flexible portable cords, come with numerous jacket type rating, conductor count, and conductor gauge options. Images courtesy: AutomationDirect
Reducing cable leftovers in stockrooms
When it comes to using cables, the business-asusual approach calls for keeping a stockroom full of any cable used in the past, just in case it is needed in the future. Most cable purchasers try to focus on a few cable type selections meeting most application needs and stock spools of those styles. control engineering
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WIRE AND CABLES Even so, many have an inventory with multiple spools of abandoned or out-of-date cables on the shelf. Different designers may call for new and specific cables without checking stock. With cut-to-length cable services, end users, machine builders, or system integrators can obtain what they need, when they need it. Prior to placing a order, verify proper cable type availability; delivery time; and pricing.
The conventional next step would be checking stock, spooling lengths, and ordering new or resupply cables as needed. With cut-to-length methods, technicians make the same take-off but use it to order what’s needed. They can receive materials delivered within a day or two. This can represent a convenience, especially when fast delivery times transform cable suppliers into a virtual stockroom.
Making the cut, certification
Those exploring cut-to-length cable services will want a supplier to stock the widest possible selection of cables. While certain cables may become a standard order, the cut-to-length route provides flexibility to change or improve selections over time, without waste. A valid concern is time to delivery. Any cut-tolength supplier must demonstrate it has the means and methods in place to receive orders, make the necessary cuts, package the product, identify it, and ship it promptly. If availability and delivery of cut-tolength cables can be assured, the final matter is cost. Buying bulk cable on the spool is always where the best price will be found, but only on a simple dollar per foot basis. Significant savings can be realized when users buy only what they need from a cut-to-length supplier, minimizing waste and stocking efforts. Some suppliers recognize the shift KEYWORDS: Cut-to-length toward cut-to-length services and are taicable, National Electrical Code loring work practices to meet customer Cut-to-length services ensure cable purchasers can obtain the demands. Users should watch out for supcables needed for an application. pliers that may impose excessive cut fees Many different cable types exist or inflated shipping charges, which make with a variety parameters. the cut-to-length approach less attractive. Cut-to-length cables also need Cut-to-length cables also can help instalUL certification so suppliers and lation technicians in the factory or the end users know cable origins. field. Designers may know how to specONLINE ify cables, but may not understand field Read this article online at installation geometry and lengths needed, www.controleng.com for more so they rely on the installers. information about cables and benefits for manufacturers. Designers can specify cables and the to/from targets of each. Installation techCONSIDER THIS nicians are well versed in routing and What is the biggest finishing the cables and can perform a consideration for your company when choosing a cable? take-off to determine the required length. Figure 2: Data and communication cables in particular have many options for capacitance and shielding, all of which must be carefully specified to meet application requirements.
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When a cable supplier wants to offer cut-tolength services, it must take several important steps in facilities and procedures. Establishing an online order-taking system makes it easy for users to choose needed cable types and lengths and makes the experience convenient. The cable supplier also must configure a work area at its facility with personnel trained to fulfill the orders. The work must be tracked to ensure quality. One thing prospective cut-to-length cable customers may not know is Underwriters Laboratories (UL) requires traceability of a cable back to its manufacturer; surface printing on the cables alone isn’t enough to fulfill this requirement. A certified label must be affixed to the spool or cable shipping package from the manufacturer. When a cable is respooled into smaller quantities (when processed for cut-to-length), every spool must be provided with the original traceability information using special certification labels. This process is defined by UL as “Processed Wire – Respooled.” A cut-to-length cable supplier should be certified as a re-spooler so it can apply UL labels to the product that has been processed during cutting operations. The label verifies that the original cable was UL-certified. The supplier should track the master reels by lot number so it can provide a customer or the UL inspector with information about a particular cable, including manufacturing date. For OEMs and field installers, the normal way of doing business often involves standardizing and buying in bulk. When many varieties of detailed products are necessary, this isn’t always the best approach. Electrical and control cables used for industrial equipment and installations come in many configurations so lend themselves to customer cut-to-length operations. A supplier offering cut-to-length services must offer a comprehensive stock of cable, fair prices, and streamline online ordering and delivery methods. The supplier also should be UL-certified for cut-to-length operations. With these pieces in place, customers may find that cut-to-length cables represent the best value. ce
Jim Krebs is a technical marketing engineer at AutomationDirect. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com. www.controleng.com
ANSWERS
CONTROL PANEL DESIGN: ELECTRICAL SAFETY Martin Kronz, Panduit
PtD: First defense against control panel electrical hazards Prevention through design (PtD) can help manufacturers keep workers safe from electrical hazards, which remains one of the most common dangers they face daily. Do you use the five-point hierarchy of risk?
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marter electrical designs for industrial equipment control panels lower risk and improve safety. In 1979, the National Fire Protection Association (NFPA) released the first version of the NFPA 70E Standard for Electrical Safety in the Workplace. Today, Occupational Health and Safety Administration (OSHA) statistics show exposure to electrical hazards remain the sixth-most common cause of workplace fatalities overall and the third-most common cause in construction. Similarly, the Electrical Safety Foundation International (ESFI) found that from 2003-2017 the highest numbers for nonfatal electrical injuries were in construction and manufacturing. Despite efforts to create awareness of electrical hazards and implement electrical safety programs that establish training and work procedures, electrical incidents continue to occur and workers are suffering the consequences. Prevention through design (PtD) can help workers with awareness and safety. The goal of PtD is to prevent workplace injuries through designs that limit human exposure and interaction with hazards as much as possible. Best practice is to establish and verify an electrically safe work condition exists before performing work. Correctly de-energizing, verifying the absence of voltage, and complying with lockout/ tagout (LOTO) requirements requires the proper training, qualifications, and procedures. As plant operations evolve, personnel other than qualified electricians are interacting with electrical equipment when operating equipment. Tasks include updating firmware or programming, performing thermal scans, monitoring sensors, and performing non-electrical maintenance tasks. It is essential all personnel are aware of electrical hazards and these tasks are considered during the design phase so steps can be taken to mitigate potential exposure to electrical hazards. Performing absence-of-voltage verification
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with a portable test instrument is dependent on human input, interaction, and interpretation. Human error can and does occur even for experienced personnel. How can a worker safely perform these tasks in what’s potentially an electrically unsafe work environment? The need to maintain, monitor, and troubleshoot plant networks is increasing. This means it’s vital to use the best technology available to minimize direct access to potential electrical hazards.
Understanding the hierarchy of risk controls
Control engineers and equipment designers are the first line of defense against electrical hazards. Planning for safety throughout the equipment’s lifecycle needs to be top of mind when designing a workspace and selecting and installing equipment and safety technology. KEYWORDS: prevention A common challenge is: How do through design, PtD, electrical engineers develop a standardized solusafety tion that safeguards authorized personPrevention through design (PtD) nel from the energy source in electrical can help workers with awareness and safety. enclosures? PtD depends on understanding PtD depends on understanding of the of the hierarchy of risk controls hierarchy of risk controls. The hierarchy and knowing what is the most ranks risk control measures from most and least effective. to least effective: PtD, if used correctly, can
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• Elimination physically removes the hazard. • Substitution replaces the hazard with something non-hazardous or minimizes the hazard. • Engineering controls prevent access or act as a barrier between personnel and hazards.
control engineering
also improve productivity while minimizing direct and indirect costs.
ONLINE Read this article online at www.controleng.com for additional stories about electrical and worker safety.
CONSIDER THIS How many tiers of the hierarchy of risk controls is your company following and what could you be doing better?
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CONTROL PANEL DESIGN: ELECTRICAL SAFETY • Administrative controls attempt to change the way people work through training, procedure, policy and signage. • Personal protective equipment (PPE) can be effective in tandem with administrative controls, but does not eliminate the hazard. The process of verifying absence of voltage in many organizations relies primarily on the lowest two tiers of the hierarchy, administrative controls (including LOTO procedures, training and devices) and PPE. These methods are often the quickest to implement as they don’t require changes to existing equipment but are subject to human errors and may not be the most effective method to control exposure to hazards as a long-term solution. Between training, PPE replacement costs, and remaining potential for By automating absence of incidents, implementing these two tiers voltage verification and of controls alone may end up being completing the entire vermore expensive in the long run than ification process in 10 secdesigning a workspace with advanced onds, Panduit’s VeriSafe safety technology in from the start. absence-of-voltage-tester For example, PPE cannot prevent (AVT) enables plants to an electrical incident from happenwork faster, safer, and ing; it only limits exposure. The effecmore efficiently. Courtiveness of administrative controls tesy: Panduit depends on the type of hazards and how consistently the controls are followed. Both leave significant room for human error. Unfortunately, the most effective methods of risk control may not be feasible to implement. Eliminating electricity from an electrical enclosure is not an option. However, engineers can opt to implement substitutions that reduce shock hazards by replacing 120 V control circuits with 24 V. Exposed terminals also can be substituted with IP20-rated “finger-safe” terminals to prevent the risk of accidental contact with energized conductors. Engineering controls don’t eliminate hazards but can isolate personnel from them and reduce risk to “as low as reasonably possible.” Mounted on the outside of a control panel, a data access port provides access to electrical outlets and control panels without the need for personnel to open the enclosure itself. In the case of network troubleshooting, data access ports (also referred to as programing port or service port) or remote network access allows personnel the ability to check or change program parameters without having to open the door to the electrical enclosure.
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PtD can improve productivity, save costs by making processes more efficient, and minimize direct and indirect costs that
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come with incidents. PtD technology advances
When it comes to electrical hazards, engineering controls are more effective and reliable than administrative controls and PPE alone. Active engineering controls may still require human interaction, but they are less susceptible to human error. Data access ports, permanently mounted voltage indicators, voltage test portals, and automated absence of voltage testers are tools or technologies that can be used with the prevention through design methodology to help reduce exposure to electrical hazards in the workplace. When de-energized work is required, automated absence-of-voltage testers (AVTs) can make the verification step of establishing an electrically-safe work condition safer and more efficient. By verifying the absence of voltage before the electrical equipment is even opened, automated testers reduce exposure to potential electrical hazards. Automating the process also makes it less susceptible to human error.
Realizing the benefits of employing PtD
Innovations like data access ports and automated AVTs are making it viable to complement existing control procedures or replace less-effective ones. These technologies prove that welldesigned engineering controls protect workers without interfering with productivity. In fact, PtD can often improve productivity, save costs by making processes more efficient, and minimize direct and indirect costs that come with incidents that are a result of processes that rely more on human input. Safety innovations need to move as fast as the manufacturing industry is. Administrative controls and PPE can only go so far when it comes to mitigating risk from electrical hazards. If safety professionals want to see electrical hazards drop off OSHA’s list of top risks, PtD and engineering controls will be key to making that happen. ce
Martin Kronz, manager of prevention through design — OEM business, Panduit. Edited by Chris Vavra, production editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com. www.controleng.com
ANSWERS
INSIDE MACHINES John Kowal, B&R Industrial Automation
OMAC: Seven things to know The Organization for Machine Automation and Control (OMAC) addresses connectivity, manufacturing efficiency and best practices for global manufacturing.
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he Organization for Machine Automation and Control (OMAC) celebrated its 25th anniversary in 2019 and 15 years since the introduction of PackML (ISA TR88.00.02). The OMAC-developed automation standard ensures consistent machine states, modes and data transfer and retrieval. OMAC participants include end-user manufacturers, original equipment manufacturer (OEM) machine builders, system integrators, technology providers, and non-profit and government agency organizations. OMAC can help improve productivity for manufacturers in seven ways.
1. Increasing interoperability: A signifi-
cant driver of past and present OMAC initiatives is interoperability. PackML ensures functional interoperability and a consistent look and feel across plant floors by providing standard data definitions and consistent tag naming known as PackTags. These allow machines and devices from multiple vendors across multiple control platforms to exchange common information and specific data. PackML simplifies machine-to-machine (M2M) integration and makes troubleshooting, training and startup easier. The new PackML/OPC UA Companion Specification developed by OMAC and OPC Foundation combines the common data definition of PackML and OPC UA’s communication protocol to exchange data across a line and to enterprise systems. This boosts overall equipment effectiveness (OEE) and implements a crucial building block for OPC UA over time-sensitive networking (TSN).
2. New human-machine interface (HMI) and stacklight guideline: An OMAC mem-
ber working group developed an implementation guide to outline standardized representation of PackML in HMIs and stacklights for best practices in usability and design, with examples. Goals include improving efficiency, the ability to move operators from machine to machine with less training and less downtime. The draft guide will be on the OMAC website when final.
3. Standardizing overall engineering efficiency and OEE: An OMAC member working group is developing implementation
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guidelines for OEE to increase accuracy, ease of use and to standardize data handling and best practices. A PackML-enabled machine provides data that reflects certain machine states upstream and downstream, producing metrics on availability, productivity and quality.
4. OMAC and PackML benefits: OMAC member machine builders who have implemented PackML experience shorter engineering and commissioning times, easier troubleshooting, increased code reuse and higher quality. Axon, a ProMach brand, reduced build and debugging time by 40% after implementing PackML. About 80% of their code now is reusable. Mettler Toledo said PackML helped reduce engineering costs and design time. 5. OMAC collaborates: OMAC collaborates with other organizations to align efforts, including OPC Foundation, PLCopen, Weihenstephan, OpX, the Industrial Internet Consortium, NIST, and others. PackML is part of the first universal User Requirements Specification (uURS) known as PackSpec, which is a template for technical specification of packaging and processing machinery. 6. Manufacturing workgroup: OMAC’s Manufacturing Workgroup focuses on ways to improve tooling and manufacturing processes, such as digital twin technology and real-time measurements.
7. 100% volunteer-led and mem-
ber supported: OMAC has almost 60
member companies in North America, Europe, Latin America and Asia. The foundation of OMAC’s success is the collective strength of its members and their commitment to advance manufacturing automation and efficiency. Knowledge, experience and financial support drive OMAC initiatives that make a difference. ce
John Kowal is marketing director, B&R Industrial Automation; edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com. control engineeering
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KEYWORDS: OMAC,
machine standards, OEM Interoperability for machines Industry groups collaborate Manufacturing efficiencies.
CONSIDER THIS Connectivity standards offer easier, more rapid connections and communications.
ONLINE If reading from the digital edition, click on the headline for more resources. www.controleng.com/magazine
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A revolution in linear transport systems: XTS NEXTSTEP The XTS advantage circulatory movement flexible modular system individually movable movers
User benefits reduced machine footprint software-based changeovers improved machine flexibility increased throughput shorter time to market
www.beckhoff.us/xts Manufacturers around the world need to offer increasingly customized products – with machines that deliver reduced footprint and improved productivity. Available now in the U.S., the eXtended Transport System (XTS) from Beckhoff answers these machine design challenges and more. In combination with PC- and EtherCAT-based control technology, the XTS features a high level of design freedom for machine builders to develop game-changing concepts for product transport, handling and assembly. A stainless steel hygienic XTS version is ideal for use in the pharmaceutical and food industries. Take your next step in machine design with XTS: total freedom of installation position compact design integrates directly into machinery freely selectable track geometries few mechanical parts and system components input #10 at www.controleng.com/information
BRING YOUR MACHINE TO LIFE WITH CUSTOM DRIVES
ANSWERS
INSIDE MACHINES Ian Visintine, MartinCSI
3 STEPS: for
Aerotech can partner with you to design a custom automation solution for your specific application at a minimum price.
machine vision
In our concept machine below, Aerotech’s drive packaging can be customized to fit into the wasp body with special algorithms developed at the firmware layer for flight control.
Machine vision can add to a project’s quality and throughput.
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achine vision is a powerful tool that can be used to ensure the quality of a product, but it is often not trusted or even considered as a viable option due to bad experiences and unsuccessful projects. In most cases there are only a handful of reasons a vision project is unsuccessful; unrealistic expectations for a machine vision system, failure to properly analyze the application from the beginning, and letting a budget dictate the hardware instead of the requirements of the application. An unsuccessful project is not affected by one reason due to each one impacting another. If a project is unsuccessful, it is very likely it was due to one of these three reasons.
Aerotech can accommodate your custom automation controller needs by using our plug-in architecture for specific algorithms such as 2D bar code, interfaces to nonstandard sensors, signal outputs synchronized to servo sample time, and more. If you have a need for custom hardware or firmware in your drive package, contact Aerotech today.
1. Unrealistic machine vision expectations
Making sure there are realistic expectation for a machine vision application can be one of the easiest hurdles to overcome if the application is thought through and understood at the beginning. It is important to understand that not all vision systems are the same or capable of the same applications. Applications cannot be solved by using the favorite smartphone camera or a basic camera. Each application has specific needs that dictate the most important aspect of the vision system. If the application needs are not correctly identified or changed, it can be difficult and expensive to change the system’s capability once equipment has been purchased. Expectation that need to be set and not changed after the design phase would be; inspection location, speed of inspection, camera working distance (WD), field of view size (FOV), area of interest size and inspection tolerances. One of these changes could make the wanted inspection not possible or require expensive hardware change to allow the inspection to still be possible. Learn application needs by answering the following questions: What is being inspected? Where is it being inspected? How it is being inspected?
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Ethernet Connectivity Automation Controller
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Vision
2. Budget vs. application requirements
As with most projects, budget is a large limiting factor. However, when the budget for a vision project is not decided based on the application requirements, it is the greatest contributor to a vision project not going well or failing to meet expectations. The cost of vision equipment can vary a lot; so can the results of the same equipment selected. If equipment is only being selected based on cost, there is a possibility it will not be able to perform as needed. Some might assume a low-end $2,000 camera can conduct a part presence inspection on a small bolt because it is being done on a similar bolt size in another part of the plant. As a result, the budget was based on the equipment used previous-
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INSIDE MACHINES ly. The mounting location between the two applications, which are significantly different, was not considered. The hope is it got caught during the proof of concept and would not cost any money. A similar application was already being done in the plant, so it was assumed a proof of concept was not needed for the new application. If the budget does dictate what equipment will be used, then it is important to understand what is important for the application and have realistic expectations of what the equipment can accomplish.
3. Failure to properly analyze the
application from the projects’s start
Once an application has been conceived, had expectations set, and had some initial planning started, it is time to test equipment and verify what can accomplish the application. Verification should always be done so the calculation on paper and the idea of the application can be verified prior to buying equipment or installing the system. The easiest way is conducting a proof of concept by simulating actual inspection conditions or mocking up equipment at the inspection location during production. If done properly, this will verify all parts of the vision system. If the users conducts the proof of concept offsite, it is important to test by reproducing actual inspec-
tion conditions as much as possible with actual parts. If the proof of concept is done improperly, it could lead to using the wrong equipment or not compensating for a potential pitfall. During proof of concept, verify working distance, field of view, equipment resolution, lensing, lighting, and inspection parameters. ce Ian Visintine is senior project engineer, MartinCSI. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media, mhoske@cfemedia.com.
M More ANSWERS
KEYWORDS: Machine vision Set realistic expectations for a machine vision project. Ensure proper budget for the project. Consider the application from the start. CONSIDER THIS Have you considered machine vision? These tips help.
ONLINE If reading from the digital edition, click on the headline for more resources. www.controleng.com/magazine See related New Products for Engineers in the machine vision product category at www.controleng.com/NPE
INNOVATIONS
NEW PRODUCTS FOR ENGINEERS
Emergency stop switch series
Industrial cellular router
Advantech’s ICR-3241 is a 4G industrial cellular router and gateway and is designed to connect IP or serial devices to a cellular network. Industrial M2M and IoT applications include industrial PCs, HMIs, meters, UPS systems, and more. It offers LTE Cat.4 upload speeds of up to 50 Mbps, download speeds of up to 150 Mbps, and powerful 802.11ac MIMO Wi-Fi providing ample bandwidth for highdata demanding applications using high-speed PCs, tablets, or surveillance devices. The device has two SIM readers protected by metallic cover for carrier failover redundancy. As an addition the router is ready to use internal eSIM. Advantech, www.advantech.com
Input #200 at www.controleng.com/information
Multi-turn kit encoder
Posital’s Hollow-Shaft kit encoders feature an open-center form factor that makes them ideal for motor, drive or robot joint installations where it is necessary for the measurement device to fit around a central shaft or centrally mounted structures, cables or pneumatic tubing. These encoders offer high precision (18-bit electronic resolution and an accuracy of ±0.02 degrees), plus higher tolerance for dust, moisture and minor misalignment than traditional optical encoders. Based on capacitive measurement technologies, they are compact and are available with 30 and 50 mm central openings. Their multi-turn measurement range is enabled by a rotation counter and keeps an accurate count of revolutions. Posital-Fraba, www.posital.com www.controleng.com
Machine vision can add to a project’s quality and throughput. A machine vision project can be successful by defining expectations, basing a selection on needs and conducting a proof-ofconcept. Courtesy: MartinCSI
Apem’s EC series emergency stop switch has an integrated connector for easy mounting. Available with solder lug terminal or a connector for easy integration, the EC series has a standard 22 mm diameter bushing. This ergonomic emergency stop switch is vibration-resistant and ideally suited for use on material handling, AGVs and off-road vehicles. The mounting makes the connection between the switch and the cable bundle immediate. The limited under-panel depth and 22 mm diameter bushing makes it the ideal emergency stop switch for applications where compact design is required. The EC series is front panel sealed up to IP65 and qualified to the latest international standards EN 60947-5-1 and EN 60947-5-5. Apem Inc., www.apem.com Input #201 at www.controleng.com/information
Input #202 at www.controleng.com/information
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PRODUCT & LITERATURE SHOWCASE
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INNOVATIONS
BACK TO BASICS: INDUSTRIAL INTERNET Industrial Internet Consortium (IIC)
10 industrial Internet terms you should know The Industrial Internet Consortium (IIC) released its Industrial Internet Vocabulary Technical Report V2.2. See 10 terms IIC thinks you should know and see a link for more definitions.
T
he Industrial Internet Consortium (IIC) released v2.2 of the Industrial Internet Vocabulary Technical Report, which provides Industrial Internet of Things (IIoT) industry guidelines on vocabulary, architectures, security, analytics, connectivity and business strategy. IIC vocabulary definitions can be replaced for existing terms in use to ensure clarity for all readers. The report includes a new definition for digital twin and eliminates virtual entity in favor of digital representation. Other terms added to the report include physical entity and physical entity of interest, describing a physical object, such as factory equipment that could be monitored or that is already being monitored by an IoT system. IoT sensor and IoT actuator also were added — both IoT devices but with dissimilar definitions. “We update the Vocabulary Technical Report annually with new terms that align with key IIoT trends,” said Bob Martin, co-chair of the IIC Vocabulary Task Group, IIC Steering Committee Member, in a press release. “This year the report focuses on digital twins — software replicas of physical devices that run simulations of systems and leverage IoT, AI [artificial intelligence] and analytics technologies.” The IIC plans to continue to revise the IIC IIoT Vocabulary Technical Report with definitions for new IIoT terms; 10 definitions that will have major implications for manufacturers that deal with the IIoT, have been highlighted: 1. Digital twin — Digital representation, sufficient to meet the requirements of a set of use cases note: in this context, the entity in the definition of digital representation is typically an asset, process or system. 2. Digital representation — Information that represents attributes and behaviors of an entity 3. Physical entity — Entity in the physical world that can be the subject of sensing and/ or actuating
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4. Physical entity of interest — Physical entity that is the subject of sensing and/or actuating 5. Stakeholder — Individual, team, organization or classes thereof, having an interest in the system of interest 6. IoT sensor — IoT device that observes one or more properties of a physical entity and converts those properties into information 7. IoT actuator — IoT device that can change one or more properties of a physical entity in response to received information 8. Semantic interoperability — Interoperability such that the meaning of the exchanged information can be understood by the participating systems 9. Syntactic interoperability — Interoperability such that the formats of the exchanged information can be understood by the participating systems 10. Security policy — rules, directives and practices that govern how assets, including sensitive information, are managed, protected and distributed within an organization and its systems, particularly those which impact the systems and associated elements. ce
- Edited with information by the Industrial Internet Consortium (IIC) by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com. The IIC is a CFE Media content partner. control engineering
M More INNOVATIONS
KEYWORDS: Industrial internet,
digital twin, Industrial Internet of Things Industrial Internet Consortium (IIC) vocabulary definitions help ensure clarity for all readers. A digital twin is a digital representation, sufficient to meet the requirements of a set of use cases. Security policy focuses on directives and practices that govern how assets are managed, protected and distributed.
ONLINE Learn more definitions from the IIC at www.iiconsortium.org/vocab/index.htm
CONSIDER THIS Can uniform vocabulary save time and reduce confusion among engineers and others?
December 2019
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Let’s Get Connected Introducing the GA800 Variable Frequency Drive
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input #14 at www.controleng.com/information
Stop paying twice! Problem: Inefficient drive systems create heat. And, hundreds of drives = a ton of heat. So, you pay for energy twice - first to convey the product and second to cool the air. Time to switch gears‌ Solution: MOVIGEARŽ Mechatronic drive from SEW-EURODRIVE. It combines an IE4 motor, gearing, and advanced electronics into one highly efficient unit minus all of the heat. Now that makes a ton of cents!
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