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Vol. 67 Number 2

FEBRUARY 2020

ANSWERS 16 | Process control migration woes? 20 | Migration improvements help Alabama cotton gin increase yields

Control cabinet uses Profinet I/O, as shown during testing before commissioning. Courtesy: Design Automated Controls

INSIGHTS 4 | Technology Update: What kind of redundancy: Mirrored servers or edge devices? 6 | Application Update: Machine module provides software-supported product changeovers

22 | Six answers on industrial cybersecurity effectiveness 24 | Companies benefit from sharing cybersecurity efforts 25 | Integrating robots and drones in process plants and facilities INSIDE MACHINES

M1 | The future of the industrial and collaborative robot markets for 2020 and beyond M4 | Get the best robot investment M6 | Cartesian robots have value on the manufacturing floor M8 | Exoskeleton helps arm-based physical therapy M9 | Human impact: Role of workers with robotics

NEWS

12 | Utilities benefit from a risk-based approach to cybersecurity, Headlines online: sniff out pollution and toxic leaks; 3-D printing opportunities for manufacturing; Four ways embedded vision systems can enhance robots 14 | Think Again: Hot topics in Control Engineering for 2019

M10 | Mobile robot advantages M11 | AMR market sees record gains M13 | Autonomous mobile robots improve logistics M15 | Mobile robots are getting smarter and going new places CONTINUED ON PAGE 11: More about Engineers’ Choice Awards, automation design advice

CONTROL ENGINEERING (ISSN 0010-8049, Vol. 67, No. 2, 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 2020 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, PO Box 156000, Lincolnshire, IL 60009. Printed in the USA. CFE Media, LLC does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the material contained herein, regardless of whether such errors result from negligence, accident or any other cause whatsoever.

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control engineering

February 2020

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INSIGHTS

TECHNOLOGY UPDATE Mark T. Hoske, Control Engineering

What kind of redundancy? Advice helps in deciding between an industrial mirrored server or twin edge devices when designing a new computing system or control system architecture. Video gives three computing tips.

ontrol system architectures take many forms, and two high-availability opportunities for control system designers are a mirrored server and twin edge devices. How should someone choose between these architectures? Stratus representatives Jason Andersen, vice president strategy and business line management; John B. Vicente Jr. PhD, chief technology officer; and Stephen Greene, vice president global marketing, explained some similarities and differences in the two architectures. They made the comments to CFE Media and Technology publications at Rockwell Automation’s Automation Fair 2019.

Server or edge?

For a design in a more environmentally secure area, such as a control room or control enclosure, Stratus ftServer has two servers in one box, mirrored, for zero data loss if one side fails. These often are used in industries with high regulatory penalties for data loss of product quality or original information. These include food and beverage, pharmaceuticals, oil and gas and energy industries. Sales of edge devices has doubled in 3 years. The Stratus ztC Edge computing platform is a smaller, rugged form factor for use on a plant floor, on machines, and in other harsh environments, like a stone quarry. Stratus Edge devices can be ready to load applications within 30 minutes without experts. Security is built-in (a trusted platform module is used), and management and monitoring are included. Ports can be locked, a firewall is included, KEYWORDS: Edge computing, and penetration testing meets ISA cybersecurity industrial server standards in preliminary testing. How to decide between server Software offers virtualization, supervisory or edge computing control and data acquisition (SCADA), humanPre-packaged edge devices machine interface (HMI), database, and prevencan build-in security tive maintenance capabilities. Video offers three industrial The edge device has a web-based user intercomputing tips. face and is pre-packaged and pre-configured. A CONSIDER THIS system integrator said it can be integrated withHave redundant servers or in a day instead of a few days for other devicduel edge computing systems es or systems. The edge product includes two been among control architecture options? redundant devices, often placed apart. The Stratus experts said these edge devicONLINE es are designed to offer more capabilities than If reading from the digital an industrial PC (iPC). Greene added the zTC edition, click on the headline for more resources. Edge serves as a computing platform and not Stratus ztC Edge is a zero-touch, virtualized and selfprotecting computing platform, designed for industrial edge environments (top). Stratus ftServer is an integrated continuously available server platform. Courtesy: Mark T. Hoske, Control Engineering

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Video linked to this article online: Jason Andersen, Stratus vice president strategy and business line management, explains three tips to consider when choosing an industrial computing platform. Courtesy: McKenzie Burns, CFE Media and Technology

just a gateway communication device. The server is an assembled product and built organically to meet customer needs. While the server and edge platforms offer computing capabilities, the server is more costly than the smaller form factor machine, providing control room computing capabilities, as opposed to edge devices with a more finite capacity. As architectures progress, Greene suggested, more industries may get to “full enlightenment” of autonomous computing (also known as fog computing).

Video: Edge computing tips

In a 2-minute video, Anderson explained three tips about edge and server-based industrial computing. 1. Is it a secure system? Increasingly, edge devices are exposed to the cloud and outside services. 2. Where will data be processed? Systems are available to process data in a control room setting or on the edge, where the process is occurring. 3. Work with software partners to ensure the system runs well. It’s getting more difficult to find talent to program and maintain systems. They should be easy to install, use and maintain. ce

Mark T. Hoske is content manager, Control Engineering, CFE Media & Technology, mhoske@cfemedia.com. www.controleng.com

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INSIGHTS

APPLICATION UPDATE Frank Würthner, Beckhoff Automation

Machine module, softwaresupported changeovers Koch Pac-Systeme designed a labeling and grouping unit in a toothbrush packaging line with a transport system at its core.

machine builder embedded a highspeed linear motor transport system in a machine, adding speed and flexibility and saving space with the new design. Koch Pac-Systeme GmbH, headquartered in Pfalzgrafenweiler, Germany, specializes in building customer-specific blister packaging machines and systems. With extensive line design experience, the company’s engineers are able to stay flexible and implement each customer’s requirements. The packaging experts recently demonstrated their expertise with a complex new packaging line for toothbrushes. The transport system from Beckhoff Automation is designed to replace mechanical systems with software functionalities that make the line more compact and more flexible for faster product changeovers. Koch achieved a seamless, integrated and efficiently executed packaging process with custom-

ized equipment ranging from blister machines to product infeed and blister grouping modules to end-of-line packers. Customers received solutions that meet industry-specific requirements and are matched to the size and shape of the respective products. A line for packaging toothbrushes is controlled via automation software and processes up to 320 toothbrushes or 240 blisters per minute, showing off the packaging line’s flexibility. Project manager Gert Müller explained the functional scope and complexity of the line with a total length of 28 m. “At first, the line will be operated with two different formats for which the customer uses two different foil thicknesses,” he said. “What makes the line so attractive is its superior flexibility, because an automatic foil width adjustment feature allows the customer to use different foil sizes to produce additional blister sizes in the future. After the blisters have been formed, the toothbrushes are supplied via a high-speed pick-and-place (HSPP) system that uses a camera to control their position. “Next, another HSPP places the cardboard backing and uses ultrasonic spot sealing to keep it in place for the actual sealing process. A laser system applies a code to the back of the card that is verified downstream via a camera system. After the blisters have been separated in a punch station, they are transferred via a two-axis portal to the central labeling and grouping unit before another HSPP system groups and transfers them to a cartoning machine. The packaged blister packs are then transferred to the customer’s downstream packaging steps.”

Transport system adds efficiencies

A total of 24 movers with light, 3D-printed blister grabbers travel along an 11-meter-long XTS circuit between one HSPP system, the laser labeling system and the second HSPP. All images courtesy: Beckhoff Automation

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control engineering

Müller explained how the labeling and grouping unit is an example of Koch’s expertise in developing innovative solutions. “We installed a circuit that is 11-m long and equipped with 24 movers with special carriers for single and twin blisters. When the product changes, only the carriers have to be switched out,” he said. Since this is a very quick and easy process, setup www.controleng.com

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APPLICATION UPDATE The team responsible for the new Koch Packaging Line for toothbrushes (left to right): Wolfgang Braun, global account manager at Koch; Jürgen Welker, director automation and technology at Koch; Jonas Rauser, machine installer; Frank Würthner, industry manager, packaging Technology at Beckhoff; Bernhard Michels, machine installer; Frank Helber, software programmer at Koch; Gert Müller, project manager at Koch.

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Each mover is mapped as a separate servo axis in TwinCAT to monitor and adjust each

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mover separately, for collision avoidance.

M More

changeover times are reduced considerably, added global account manager Wolfgang Braun. “The end customer wants to produce different formats with our packaging line, and therefore very fast and flexible format changeovers are required.” Jürgen Welker, director automation and technology at Koch, said there were two specific factors that convinced the company to use transport technology: The high throughput rate and the ability to adapt to various labeling speeds Welker also noted machine design-related benefits from the transport system. “The labeling and grouping unit, and therefore the entire line, would have been 2 m longer and much more complex due to the additional mechanical components that would have been required. It also would have been much less accessible for the operators to execute format changes.” Braun considered the flexibility and the ability to convert the line very quickly to be key benefits from the end customer’s perspective. “The original plan called for a conventional solution based on a so-called bucket chain. While it was designed to be width-adjustable, it quickly encountered limitations because of the constantly expanding product spectrum. A more expensive solution would have been to add a second bucket chain or even a split line with two separate packaging machines,” he said.

ANSWERS

KEYWORDS: mobile machinery, system integration Koch Pac-Systeme designed a labeling and grouping unit in a toothbrush packaging line with a transport system. PC and EtherCATbased technology helped the machine could operate efficiently without any challenges. The software functionality also answers the requirement for rapid product changeovers. ONLINE Read this article at www.controleng.com for more details from Beckhoff Automation.

CONSIDER THIS What benefits could your plant derive from a transport system? www.koch-pacsysteme.com

High flexibility, advanced software

The labeling and grouping unit integrates flexible motion sequences, according to Mül-

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February 2020

control engineering

ler. “Depending on the format, the two-axis system transfers eight or 12 blister packs to four or six movers. These movers then travel to the labeling station. Another HSPP system places the blister packs in multiple layers into the cartoning machine’s product chain in accordance with the outer packaging type. The system stands still for loading and unloading while the labeling process runs continuously,” Müller said. The software functionality also answers the requirement for rapid product changeovers, because each blister format has its own recipe, including the precise processing positions that can be selected with a mouse click. The machine module has two labeling devices. Depending on the format, the software tells the transport system where it needs to travel.

PC- and EtherCAT-based control

An industrial PC was able to control the 24 movers precisely. The control cabinet PC was able to control two HSPP systems by handling the systems as additional TwinCAT NC tasks. Both HSPP systems also were equipped with servo drive technology. “TwinCAT software provides all necessary functionalities,” Welker said. “The fact that each mover is mapped as a separate servo axis in TwinCAT is hugely advantageous for us. That way, we can monitor and adjust each mover separately, which is convenient and safe due to integrated higher-level functions like collision avoidance. And to top it all off, there is the exceptional performance of EtherCAT. The controller makes full use of EtherCAT’s extreme speed, particularly where the communication with the many servo drives in the system is concerned.” ce

Frank Würthner, business management packaging, Beckhoff Automation. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com. www.controleng.com

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FEBRUARY 2020

Continued from page 3

INNOVATIONS NEW PRODUCTS FOR ENGINEERS

44 | 2020 ENGINEERS’ CHOICE WINNERS Upgrade, innovate, accelerate: Best automation, control and instrumentation products in 29 categories. See more New Products for Engineers at www.controleng.com/NPE.

Images on cover and above courtesy: Cognex, Epson, Kepware, Opto 22, Siemens, United Electric and Weidmuller.

BACK TO BASICS

61 | Automation design advice: Create smarter products

Control Engineering eBook series: Robotics winter edition Impact of robotics can be felt on many manufacturing floors. There’s more to the robot, however, than what you see. Learn more and register to download. www.controleng.com/ebooks/

Get automation product design, system integration, and application advice from some of the 2020 Engineers’ Choice winners.

NEWSLETTER: Information Control We have upgraded our newsletter to deliver a better overall experience for our subscribers. Go to www.controleng.com/newsletters to learn more. • Revamped HMI provides better process control, operator compliance • Modern controllers ease upgrades • Learning about the automation engineer • Many-core technology fills in the blanks for advanced machine control • Smart factory controllers bring security, connectivity.

CFE Edu: Pre-register for our new course on motors, drives Pre-register for our upcoming course, “Introduction to Motors and Drives,” starting March 16, and learn about topics such as how motor sizing impacts efficiency and maintenance, understand motor repair processes, review repair best practices to maintain and improve efficiency, and more. Other featured courses include: • IIoT Series: Part 4: Machine Learning • IIoT Series: Part 3: Edge, Fog and Cloud Learn more at: https://cfeedu.cfemedia.com/courses/motors-and-drives

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

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

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control engineering

February 2020

•

INSIGHTS

NEWS

Utilities benefit from a risk-based approach to cybersecurity Because of the increased sophistication ing events. I think there has been a strong of attacks, utilities need to embrace a risk- focus on compliance, and while complibased approach to cybersecurity to match ance is good because it is prescriptive, it the existing basic-level of compliance. lifts the middle and it helps a majority of The idea utilities need to embrace and organizations develop a baseline of secuutilize a risk-based approach comes on rity. You still need a risk-based approach the heels of the revelation of the deni- to keep up with the evolving cyber threat.” al of service attack sPower, a Utah-based Vulnerability of critical infrastructure to renewable energy supplier, suffered in cyber attacks has potential to cause severe March 2019. They were the victim of financial, environmental and infrastructure an attack that involved exploitation of a damage: 64% said sophisticated attacks are known vulnerability a top challenge, and in Cisco firewalls. 54% expect an attack Utility digitalization “What we saw in on critical infrastrucMarch was in one has created an increasingly ture in 12 months. third of the country, “What is haphyper-intelligent, supergrid operators lost pening in the utilvisibility,” said Leo ity space is the connected attack surface. Simonovich, Siemens energy sector is going vice president and through a fundamenglobal head of industrial cyber and digital tal transformation with digitalization of security. power production and the introduction While the producer did not suffer an and switch out with traditional fossil genoperational issue, it did lead to a denial of eration for renewables and what that has service (DoS) which led to communication done is created an increasingly hyperoutages between the organization’s control intelligent, super-connected attack surcenter and the field devices at various sites. face,” Simonovich said. “In many ways it is a Catch-22. On one hand, there is the DoS attack brownfield with digital bolted on top. The North American Electric Reliabil- On the other hand, we have this digitally ity Corporation (NERC) said in Septem- native, renewable landscape that is distribber 2019 the security flaw impacted the uted and decentralized.” web interface of firewalls, and the result “We wanted to understand what does was a DoS attack, which caused the appli- risk look like in this energy transition and ances to reboot. The communication out- what are the readiness levels and what are ages occurred over a period of 10-12 hours the solutions they are thinking about? and each lasted for less than five minutes. We found these are a major challenge for Simonovich was responding to a many utilities,” Simonovich said. report entitled, “Caught in the CrossThe utility industry is also seeing the hairs: Are Utilities Keeping Up with the increased sophistication of attacks. Industrial Cyber Threat?” sponsored by “They are grappling from attacks that Siemens and conducted by the Ponemon are sophisticated, with many coming Institute. In the study, 56% of respondents from nation states, and many of those reported at least one shutdown or opera- attacks being potent causing shutdowns, tional data loss per year, and 25% ended safety events and environmental inciup impacted by mega attacks, which are dents. Only 42% are ready to address this frequently aided with expertise developed new cyber risk frontier and only 31% are by nation-state actors. able to respond when an incident does “There is a real sense of awareness of happen. Those statistics are troubling.” the challenge,” Simonovich said. “ResponThe smaller utilities, Simonovich said, dents are recognizing they are unable to are particularly vulnerable and strugdetect, and they are experiencing damag- gling to address this because they don’t

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control engineering

have the staff. There are four issues facing them: 1. Visibility challenge 2. Lack of humanpower or resources 3. Ownership, who owns operations technology (OT) cyberspace in the utility area 4. How to address nation state attacks. The midsized utilities, Simonovich said, need some assistance. He offered three basic best practices to get them moving in the right direction: • Know what you have • Assign dedicated personnel to OT • Create an incident response plan. Gregory Hale is the founder of ISSSource, a CFE Media content partner. This content originally appeared on ISSSource.com. Edited by Chris Vavra, associate editor, CFE Media, cvavra@cfemedia.com. See also pages 22 and 24 in this issue.

Headlines online Top 5 Control Engineering articles January 13-19 See the most-viewed stories of the week. Cooperative research and development agreement for additive manufacturing AddUp Group, a provider for metal additive manufacturing (AM), and the U.S. Department of Energy’s (DOE) Oak Ridge National Laboratory (ORNL) agreed to advance laser powder bed fusion (LPBF) technology. Make collaborative robots safer for human interaction Industrial HMI migrations: Help with Microsoft Windows 7 expiration Microsoft Windows 7 expired on Jan. 14, and system integrators can provide migration assistance to lower cybersecurity risk. Cybersecurity program launched at Arizona State University Trilogy Education launched a cybersecurity boot camp in partnership with ASU. www.controleng.com

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INSIGHTS THINK AGAIN

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

Hot topics for 2019 Review the top stories to help today... and tomorrow.

ot Control Engineering topics posted in 2019 include engineering salaries and career tips, object-oriented programming, rate-predictive control, Internet of Things (IoT) communications, and engineering career tips among the most-visited Control Engineering articles during 2019. See the top covers in 2019 as chosen by Michael Smith, Control Engineering creative director, on the topics of integrating design and simulation, knowing information and operational technologies, and robotic advances. Think again about 2020 at www. controleng.com/2020articles and contribute your expertise to next year’s hot topic list.

Top 10 in 2019

The articles posted during 2019 at www.controleng.com with the most clicks during 2019 follow. This metric favors those posted earlier in the year. 1. Control Engineering Career and Salary Survey, 2019, May 22: Engineers are getting paid more; fewer expect to get increases in 2019. Top factors for determining job satisfaction are feeling of accomplishment, technical challenge, and financial compensation. 2. Leverage object-oriented industrial programming, April 5: Plants and equipment are assembled from objects, so controls architecture should be too. 3. What is rate-predictive control?,

M More INSIGHTS

Engineering interaction: See all 2019 covers at www.controleng.com/magazine. See top 10 Control Engineering articles posted prior to 2019 and hot topics for November and December.

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February 2020

March 26: Advanced control: A new nonPID control algorithm, rate-predictive control, is adaptive to changes in process gain. 4. MQTT’s role as an IoT message transport, Jan. 7: Messaging queuing telemetry transport’s role as an IoT message transport derives from a simple design. 5. Choosing and managing an engineering career: 7 things to know, July 31: A well-managed engineering career means a lifetime career outside the rut. Apply these seven tips. 6. The future of IIoT software in manufacturing, Jan. 11: Understand how to use data distribution service, time-sensitive networking, and OPC Unified Architecture for advanced manufacturing applications. 7. IIoT-ready technologies improve machine controls, April 2: Industrial Internet of Things technologies have the potential to improve user applications. 8. Shift in control system technologies, design, Sept. 11: Project execution using a process control system highly integrated virtual environment melds software and networking to uncouple control applications from the physical. 9. Benefits of digitizing reality for workers in manufacturing, July 10: Digitizing reality helps workers thanks to technology advances. 10. Connect I/O systems with the IIoT, Oct. 3: I/O systems bridge the gap to connect the IIoT. ce Mark T. Hoske is content manager, Control Engineering, mhoske@cfemedia.com. Traffic ranking based on analytics of www. controleng.com performed by Chris Vavra, associate editor. Cover analysis by Michael Smith, creative director.

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

Editorial Advisory Board

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

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input #9 at www.controleng.com/information

ANSWERS

MIGRATING CONTROLS Lynn Njaa, Maverick Technologies

Process control migration woes?

Use front-end loading on the project and ask these 10 questions about migrating from a legacy distributed control system (DCS).

W Process control systems and distributed control systems should be upgraded to increase productivity over time. Courtesy: Control Engineering, CFE Media and Technology

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hat manufacturer doesn’t cringe at the thought of migrating legacy control system technology? Most control systems were installed or updated in the late 80s and 90s and are overwhelmingly fragmented and fraught with challenges. Taking a wait-and-see approach is no longer a viable option, as manufacturers face new standards and regulatory compliance mandates, along with disparate and obsolete systems requiring hard-tofind original equipment manufacturer (OEM) spare parts and higher support costs. Compounding these challenges are associated safety and cybersecurity risks in operating and maintaining legacy systems. With all the new innovative technologies on the market, it’s a good time to reevaluate processes and systems and look at opportunities to improve operational efficiency and performance to stay competitive. For many manufacturers, tackling a project of this magnitude with limited bandwidth and resources is no easy feat. It’s also not easy deciding whether to replace systems piecemeal or start over with new systems. Upfront planning and a qualified team are key to moving into the execution phase of an upgrade or migration project for a distributed control system (DCS), process control system (PCS), or programmable logic controller (PLC)-based system.

Plan and execute

First, before deciding on which upgrade or migration path to take, it is important to take a holistic

February 2020

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look at the entire facility’s operations. Regardless of a facility’s size, a solid plan from conception of the migration through startup must be considered for a successful project. A disciplined approach helps to define a scope that aligns with business goals and objectives and to outline facility requirements. This front-end loading (FEL) engineering effort helps ensure an execution plan and schedule are in place to keep the project(s) on time and on budget. It also supports defendable control system solutions to determine the best platform, identify and define any risks, and provide accurate and justifiable cost estimates. The result is a successful project execution plan with a functional platform in place for operational efficiency and profitability.

Engage a qualified DCS migration team

Where bandwidth and resource limitations are an issue, engaging third-party control system specific experts up front and using them throughout the project will increase the project’s success. Experienced guidance will pay dividends if obtained during the conceptual phase of the migration. Waiting to engage an external partner later in the project means many aspects of the scope will already be defined based on assumptions made up front that may or may not have included an all-inclusive view of the entire site’s needs. Changing these decisions late in the project will result in higher costs and schedule delays compared with getting them set correctly during the initial FEL phase. A platform-independent partner will deliver unbiased practical experience working on a variety of manufacturing processes and technologies. This qualified team of experts will utilize best practices and successfully help lead the project through the execution and implementation phases. It is best to work with a team early in the FEL stage to avoid delayed schedules and higher costs later. Additionally, an ideal partner is one who is in it for the long haul and knows what is needed to improve performance moving forward. Continuous improvement initiatives are beneficial, especially once all is up and running smoothly. With these initiatives in place, manufacturers can optimize processes and increase operational safety and efficiency. To keep an ongoing competitive advanwww.controleng.com

input #10 at www.controleng.com/information

ANSWERS

MIGRATING CONTROLS tage, manufacturers can consult with their trusted partner to help incorporate these initiatives as part of the overall long-term plan.

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KEYWORDS: Distributed control

system (DCS), migration, controls upgrade Migrating control systems requires extensive planning. Efficiency and cybersecurity risks increase as systems expire. Ask the right DCS migration questions.

CONSIDER THIS Don’t migrate after it’s too late.

ONLINE From the digital edition, click on the headline for more on: - Piecemeal or rip and replace? - Key to a successful DCS migration www.controleng.com/magazine

1. Is there evidence new technology could improve output? 2. Is there an existing installation base of new technology within the site that could be built or expanded upon? 3. How is the relationship with the existing OEM? 4. Does the current equipment allow for modern security? 5. Does the existing system have the modern amenities for ease of maintenance and engineering? 6. Does the existing system have the modern amenities for ease of future innovations? 7. Does the existing system have the necessary memory and space for expandability?

are beneficial, especially once all is

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Ten questions for DCS migration

To help choose a DCS migration path, consider the following 10 questions to help steer the overall project:

Continuous improvement initiatives up and running smoothly.

8. Is the legacy system so old and antiquated that it would be easier to start over, especially if increased output could increase profitability? 9. Have the risks for both migration paths been identified, and a cost put to them? 10. From a conceptual perspective (FEL1 ±50%), which would cost more — piecemeal or rip and replace — and why? A trusted, unbiased third-party partner can address all these factors, offer professional guidance and help brainstorm the pros and cons of an upgrade or migration. ce Lynn Njaa is a senior consultant for Maverick Technologies’ DCSNext solution. Maverick Technologies is a Control Engineering content partner. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media, mhoske@cfemedia.com.

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input #12 at www.controleng.com/information

ANSWERS

MIGRATION

Nelly Ayllon Lazo, Profibus Trade Organization

Continuous improvements increase cotton gin yields A cotton gin facility in Alabama upgraded its industrial network to better manage its increased production while running optimally for long periods of time.

he cotton gin facility owned by Milstead Farm Group Inc. in Shorter, Ala., requires a production process that can run at optimum levels 24 hours a day, six days a week, until all the growing season’s cotton is in bales. When Milstead Farm Group first started processing loose cotton into bales (ginning), it produced 15,000 (500 lb.) bales a year. Their volumes have increased over the years, topping 65,000 bales in 2018. As a result, production rates have had to increase to achieve those numbers. Increasing production demands required better equipment and more finely tuned process controls, a more powerful programmable logic controller (PLC) and local input/output (I/O) rack at the end of the 2017 ginning season, and installing a new Profinet communications backbone after the 2018 season.

Working against the clock Because the factory can only run three months out of the year, there’s no question the factory’s primary mission must be to get the maximum yield out of its raw materials. The cotton gin facility owned by Milstead Farm Group requires a production process that can run at optimum levels 24 hours a day, six days a week, until all the growing season’s cotton is in bales.

Cotton ginning facility When Milstead Farm Group first started ginning, it wasn’t able to pro-

Exterior view of Humidifier control cabinet. An old PLC was replaced with Profinet I/O (Siemens ET200S) so the control logic could be integrated into the Gin control system. This was done mainly to provide operator control and monitoring from the Main Gin Console. All images courtesy: Design Automated Controls

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duce what it can now. Investing in new equipment and maintaining existing systems has pushed production from 25 bales an hour in 1998 to 50 bales an hour. This has required tighter process controls, PLC and I/O updates, and communications upgrades. “By investing in these technologies, we’re able to provide our customers with a better return on their crop,” said general manager Joey Scarborough. “One thing we’re seeing at Milstead and across the ginning industry is a large push for more process controls. As gins try to increase capacity to be more efficient, controls often have to be relied on to get it done.

Upgrading the network The latest network upgrade project had two goals: first was replacing an obsolete PLC on an existing piece of equipment that provides moisture control to the air, which is then fed to the cotton as it moves to the bale press. The second was to provide an interface to a new piece of equipment that was purchased to supplement the moisture unit, which didn’t have sufficient capacity to deal with the increased production output. Cotton is priced according to several characteristics including moisture content. In addition to providing additional moisture during baling, the facility also uses air dryers to dry the cotton when it comes in from the fields, where it may have been stored for many weeks. Summer droughts, such as the one experienced in 2019, can make achieving the right moisture balance complicated. David Adams, a system integrator for Design Automated Controls, who has worked with Milstead since 2006, was on a tight timeline to complete the project between May and September, before the start of the 2019 ginning season. “We needed to decide which hardware we would use, determine how much of the I/O needed to be replaced, and how much could be moved to the human-machine interface (HMI) we planned on adding to the machinery we were updating,” he said. “The first step in the project was actually taken at the end of 2017 ginning season, when we www.controleng.com

Cotton modules as they come into the Gin on the Module Feeder. The conveyor takes them into the Module Feedworks which pulls apart the compacted cotton.

The heart of the process, these three gin stands remove the seed from the cotton. Prior to arriving at these the cotton has had all trash from harvesting removed as well as the moisture content has been adjusted to as close to ideal as possible.

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Modernization included tighter process controls, PLC and I/O updates, and communications upgrades.

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proposed replacing the existing PLC and local rack with a PLC and local rack that uses the modules as is. This ensured we would have spare parts available in case of breakdowns.” “Profinet was added to provide a means to network the two controllers in the plant without adding to the existing Profibus system,” Adams said. “It was also chosen to allow for future upgrades, especially for the five aging HMIs that reside on the Profibus network. As they are replaced by Ethernetbased HMIs in the coming years, they will reside on the Profinet network.”

Seamless step-wise migration

While many machines in the facility are still running with the Profibus protocol, they interface seamlessly with the control system. The new CPU that’s been installed has onboard Profibus and Profinet interfaces, which made installation and commissioning very efficient, and has the memory capacity to support the existing code after conversion. Profinet I/O also replaced the I/O for the controls for an existing piece of equipment Since Milstead Farm is continuously improving equipment and process controls, Profinet’s ease

www.controleng.com

Interior view of Humidifier control cabinet with Profinet I/O (Siemens ET200S). This view was taken during testing before commissioning and final cleanup.

of expansion and installation, as well as higher data transfer rates, were factors in the switch to the new network. It only required 200 feet of cable to install Profinet to service the new I/O and controller. “A sideline of this project and the PLC upgrade is to provide more and better troubleshooting tools from the HMIs to assist operators and maintenance personnel,” Adams said. “They need to be producing finished product instead of working on the machines. The in-depth status-of-operation capabilities that will be added to the HMIs will assist them in troubleshooting problems, which will reduce downtime and lead to increased productivity and a lower operating cost.” ce

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KEYWORDS: Profinet, programmable logic controller, Ethernet A system integrator deployed a Profinet industrial network to improve a food supplier’s operations. The Profinet network helped streamline communications, implement more effective energy management, and optimize operational efficiency. The network upgrade will provide the food supplier with $125,000 of utility savings per year. CONSIDER THIS What benefits can a Profibus industrial Ethernet network provide to your company?

Nelly Ayllon Lazo, technical marketing director, PI North America. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media, cvavra@cfemedia.com. control engineering

February 2020

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ANSWERS

CYBERSECURITY

Massimiliano Latini, H-ON Consulting

Six answers on industrial cybersecurity effectiveness Industrial automation cybersecurity has a lot of confusion and questions. Learn about changing trends and effective best practices for operations technology (OT) providers.

Domain knowledge of operational technology and automation need to be considered for industrial cybersecurity. Courtesy: H-ON Consulting

â&#x20AC;˘

hile cybersecurity is brought up more frequently, it doesnâ&#x20AC;&#x2122;t very often refer to infrastructure or industrial automation control systems security. Is the trend changing? Where and how should cybersecurity be addressed for operational technology (OT) applications?

while the PC screen is locked, waiting for a multifactor authentication (MFA) code. In that simple example, cybersecurity impacts safety. It is therefore necessary to ask first who can access the area and how to deal with it. OT cybersecurity cannot bypass the deep knowledge required for automation. This is why many companies are internalizing a dedicated OT security division.

1. How is cybersecurity for industrial automation?

3. What are the most effective OT security solutions available?

The interest in a subject like industrial cybersecurity, or OT cybersecurity, is growing among manufacturing companies globally. The reference to information technology (IT) cybersecurity is evident. Think about crypto-currencies and big players such as Google and Facebook. However, it is interesting to see increasing references to the OT field (for example, see the European NIS Directive or the Russian FSTEC legislation). In the IT environment, problems are mainly related to data confidentiality. For automation, a lack of cybersecurity seriously impacts the availability of production plants.

The world reference standard is ISA / IEC 62443, which defines the approach to the problem. This standard was created by a research group at ISA (International Society of Automation), later developed by IEC (International Electrotechnical Commission). The regulatory framework is still under review, but defense-in-depth approach of IEC 62443 series of automation and control systems cybersecurity standards is the most wellknown and globally recognized cybersecurity standards in the OT field. And so, starting from a risk assessment, IEC 62443 aims at developing a cybersecurity management system (CSMS), which is a system of cybersecurity procedures, that includes the security policies and responsibilities related to OT security, such as access or patch management.

2. Who should address OT cybersecu-

rity risk and protection?

There is a lot of confusion. Everyone talks about cybersecurity, but only a few solutions address automation systems. It is often erroneously thought the OT problem should be handled by the IT department, but actually, the two environments differ in approaches. Consider the example of the plant operator who must activate an emergency procedure,

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CONTROL ENGINEERING

4. How can a manufacturing company take over an OT cyber issue? IEC 62443 approach is systematic: clear processes lead to concrete results. It would not make sense to assess a system without having an upstream strategy. The starting point is defined by IEC as business rationale. Use the rationale as a tool to determine the potential critical issues on OT systems that impact the company, such as a stop to production or product contamination. Through business rationale one can quantify the seriousness of cyber-attack consequences. www.controleng.com

It is also useful to conduct a high-level risk assessment (HLRA), which is necessary to segment the network infrastructure and estimate what would happen if a cyber attack were successful. In relation to the seriousness parameters defined in the previous phase, the HLRA helps companies save resources by isolating single areas and performing an in-depth analysis about potential vulnerabilities. HLRA is followed by the lowlevel risk assessment (LLRA), also called detailed analysis, where, with the help of software for the detection of network information (architecture, software, protocols and existing vulnerabilities), one can perform a network scan and a vulnerability analysis.

5. On a technical side, what are the

most concrete OT security best practices for automation?

Start with segmentation, which means only traffic that is strictly necessary must circulate at layer 6 and 5 (the lowest level segment containing components and PLCs). If it’s not segmented with the help of a firewall or OPC UA (OPC Foundation Unified Architecture) protocols, network traffic may reach the most remote corners of a production plant. For this reason, network mapping must be always updated and

always clear. Finally, many devices on the market can help with cybersecurity, including managed switches, next-generation Wi-Fi access points, anomaly detection software, VPN servers and the cloud.

6. When is it possible “to be safe” from a cybersecurity point of view?

Never. No installation is ever safe from cybersecurity risk. Put in these terms it may sound shocking, but the point is a good dose of maintenance activities need to be carried out continuously to maintain a secure infrastructure over time. Only through periodical audits, through the repetition of further vulnerability analyzes, and thanks to the constant personnel training, is it possible to ensure OT protection will last over time. ce

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KEYWORDS: cybersecurity,

operations technology (OT) There is a lot of talk about cybersecurity, but there is confusion about what to do. IEC 62443 helps companies develop a cybersecurity management system (CSMS), which is a system of cybersecurity procedures. It is never possible to be safe; continuous efforts can minimize risks.

ONLINE Read more about cybersecurity under the “Networking and Security” topic on the Control Engineering homepage. www.controleng.com/ networking-and-security/cybersecurity

CONSIDER THIS What do you need to do to ensure OT protection will last on your plant floor?

Massimiliano Latini, research and special projects director and ICS cybersecurity manager at H-ON Consulting. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.

input #13 at www.controleng.com/information

ANSWERS

CYBERSECURITY

Matt Shipman, North Carolina State University

Companies benefit from sharing cybersecurity efforts A study from North Carolina State University finds that companies that disclosed cybersecurity risk management efforts before and after a competitor’s breach fared the best.

esearch finds that when one company experiences a cybersecurity breach, other companies in the same field also become less attractive to investors. However, companies that are open about their cybersecurity risk management fare significantly better than peers that don’t disclose their cybersecurity efforts.

Use voluntary report guidelines

“Previous studies have found evidence of this ‘contagion effect’ in the wake of cybersecurity breaches,” said Robin Pennington, an associate professor of accounting in North Carolina State University’s Poole College of Management. “However, to our knowledge, ours is the first to test the issue experimentally. We not only confirmed the contagion effect, but found that there are clear steps companies can take to reduce its impact. Specifically, companies would be well advised to implement the voluntary reporting guidelines from the AICPA on disclosing cybersecurity efforts.” KEYWORDS: cybersecurity, To explore issues pertaining to the behavioral research contagion effect, researchers conducted a Voluntary reporting can help study with 120 nonprofessional investors. cybersecurity efforts in several In the study, participants were given inforkey ways. mation about a fictional company, which Research at North Carolina State University saw that contagion we’ll call Company A. topped competition concerns. Some of the participants were also told Disclosing efforts before and briefly about Company A’s cybersecurity after a breach works out best risk management program. Participants for the public perception of the were then asked to give an initial assesscompany. ment of the attractiveness of investing in ONLINE Company A, as well as the likelihood of Read more about cybersecurity purchasing stock in the company. under the “Networking and Study participants were then told Security” topic on the Control that one of Company A’s peers was the Engineering homepage. victim of a cybersecurity breach. ParticCONSIDER THIS ipants were then asked to give a revised Are your cybersecurity efforts assessment of Company A’s attractiveadequately communicated inside ness and the likelihood of investing in it. and outside the organization?

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Participants were then given a news release from Company A. Some participants received a version of the release that included a reference to Company A’s cybersecurity risk management program. Study participants were then asked to give a final assessment of Company A’s attractiveness and the likelihood of purchasing stock in it. The researchers found that companies who disclosed cybersecurity risk management efforts before and after a competitor’s breach fared the best. “While the company suffers some decline in attractiveness after the breach, on average it suffers the least if it discloses its cybersecurity risk management program, in a way that is similar to the AICPA’s voluntary reporting guidelines,” Pennington said. The researchers also analyzed the study data to ascertain the impact of another effect, called the “competition effect,” which has previously been associated with cybersecurity breaches in archival research. In this context, the competition effect is when investors see a cybersecurity breach at one company as an advantage for that company’s competitors, making those competitors more attractive to investors.

Contagion over competition

“We did see evidence of the competition effect with some investors in our study, but on average the contagion effect overwhelmed the competition effect,” Pennington said. “Our study offers experimental evidence for both the contagion and competition effects, as well as their relative strengths. But I think the takeaway here is that there are very real advantages to voluntarily disclosing cybersecurity risk management efforts, as the AICPA suggests. This is not a purely theoretical exercise; it can affect your company’s appeal to investors.” ce

Matt Shipman, research communications lead, North Carolina State University. Edited by Chris Vavra, production editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com. www.controleng.com

ANSWERS

ROBOT INTEGRATION Penny Chen, Yokogawa

Deploying robots and drones in process plants and facilities Robots have long been used in discrete manufacturing and machine automation applications, and their use is now spreading to address process industry applications.

rocess plants need leaner and more efficient operations to cope with aging assets and workforces. Key technologies for reaching these goals are robots and drones. They can be used to enhance safety while improving productivity and operational efficiency, especially in hazardous environments. In general, robots and drones are better at performing routine tasks than humans, who typically prefer and excel at more creative uses of their talents. Routine tasks are boring for humans, and because of this natural characteristic, they sometimes skip routine safety procedures and ignore dangerous signs in the field. However, robots can be designed to execute these types of tasks without skipping steps. Robots and drones can relieve humans from working in hazardous environments, and perform some tasks humans are unwilling to do. Their capabilities allow them to perform more mundane and dangerous jobs and free up workers for higher-value activities. Robotics are not new to the process industries. For decades, they have been used in dangerous environments such as deep-water oil exploration, subsea inspection, and hazardous plant areas. Robots have been effective in these applications. They are highly specialized and expensive, but technology advances are addressing these and other issues.

Sensors, computing, connectivity

Advancements in sensing, computing, and connectivity technologies are leading the robotics revolution. Advanced sensing and microelectromechanical (MEM) technologies are making robots more functional, less expensive, smaller, and lighter. Smartphones helped in the development of advanced MEM technologies at low cost with a small form factor. This increased market adoption, and these technologies are being applied to improve robots and drones. The internet provided communication and cloud computing infrastructure, coupled with high demand for connected devices. Autonomous vehicle research

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Many different types of drones and mobile robots are being used to perform various tasks in process plants. Images courtesy: Yokogawa

and development allowed for high-priced technology testbeds fueled by vehicles to lower costs. Artificial intelligence made analysis of large data sets possible, and machine learning can be used to make decisions and take corrective actions in real time. The convergence of all these and other technologies has created space for innovation, with robotics one of the main beneficiaries.

Mobile robots, drones: How they help

In general, mobile robots and drones must perform two main functions. One is mobility, which requires a means of propulsion, along with multiple onboard sensors for guidance such as light detection and ranging, high-def cameras, infrared cameras, and others. This allows robots to move forward, backward, sideways, and in curved paths while avoiding obstacles, climbing stairways, and performing other necessary movements. It also allows drones to avoid obstacles in flight without the need for constant human monitoring and control. The second main function of robots and drones is related to the specific task and application. For control engineering

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KEYWORDS: Mobile robotics, process manufacturing, drones Robots can handle some dangerous applications. Integrating vast amounts of info is a challenge. The rise of artificial intelligence and machine learning make robots and drones smarter. ONLINE Read this article at www.controleng.com for more about robot integration. www.sprintrobotics.org

CONSIDER THIS What benefits could mobile robots and drones provide to your facility?

February 2020

â&#x20AC;˘

ANSWERS

ROBOT INTEGRATION example, robots use gas sensors to detect leaks, highdefinition cameras to read gauges, and infrared cameras to measure temperature. On rotating equipment, robots use microphones to detect abnormal noises and vibration sensors to detect excess movement. Drones use cameras to transmit video information to operators, and they carry payloads to remote areas.

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Some robots can be equipped with arms

Robots to inspect assets

Asset inspection and maintenance has been the first target application for able to turn valves, robotics in the process industries. The SPRINT Robotics Consortium is a userpaint structures, owned and -managed organization, with its main objective collaboration on a new push buttons, and industry-driven initiative to promote the development, availability, and applicaeven replace election of robotic technologies in technical inspection and maintenance of capitaltronic boards. intensive infrastructure. Early targeted application areas include the inspection of pipelines, storage tanks, and pressure vessels. Remote control robots are useful in these and other hazardous environments. A variety of robot form factors such as crawlers, snakes, drones, etc., are available, with each having unique capabilities designed for specific applications (Figure 1). Snake robots crawl in pipelines, carrying multiple cameras and LED lights, to perform visual inspection and ultrasonic measurement of pipe wall thickness. Snake arms inspect vessel interiors. Spider and honeybee robots can inspect pipeline interiors and exteriors. Drones perform upstream oil and gas industry inspection tasks such as locating leaks and detecting

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the presence of hazardous gases, and they are also used to inspect confined spaces in large vessels. Bike robots are also used to inspect vessel interiors. Crawler robots can move around plants and facilities to perform many of the same tasks as human operators making rounds. Dog and human form factor robots can perform simple repairs. These types of robots can be equipped with manipulating arms able to turn valves, paint structures, push buttons, and even replace electronic boards in cabinets. To achieve the highest levels of effectiveness, it’s necessary to deploy, maintain, integrate and coordinate the actions of these different robots.

Deployment and maintenance

Deploying robots in an industrial environment requires more than just purchasing and installing individual robots. Robots must be trained to perform specific tasks effectively, and they must be maintained and repaired. Each robot must be deployed based on its suitability for often hazardous environments, and best practices and regulations must be followed. For example, since most mobile robots for industrial applications are battery-based, recharging or battery swap is required every few hours. This simple task can become very complex if the robot is working in a hazardous area, where careful planning is required to achieve maximum efficiency while maintaining safety. Robot training is commonly required initially, whereby a general-purpose robot is programmed to perform a specific task, following either pre-designed routes or autonomously. Instead of generating lines of code to program robot operations, some manufacturers offer a training function. This allows users to deploy and guide a robot with a touch screen interface to create a robot trajectory, with robot programming automatically generated based on this user input.

Robot integration, coordination

A mobile robot management system can schedule and manage the wide variety types of robots and drones deployed in an industrial plant or facility, with integration made easier if robotics with open interfaces are purchased. Another important aspect of robot and drone deployment in the process industries is integrating vast amounts of information. Most robots and drones carry multiple cameras, with many types of sensors, which produce information that must be stored, integrated, and made available. Operators prefer one graphical interface to show an overview of multiple robots and drones, but also require the flexibility to deep dive into each sensor or camera (Figure 2). ce

Figure 2: Operators can safely monitor field conditions remotely using information provided by mobile robots and drones.

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Dr. Penny Chen is the principal technology strategist in Yokogawa’s marketing headquarters. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com. www.controleng.com

ANSWERS

INSIDE MACHINES AND ROBOTICS Jan Zhang, Interact Analysis

Industrial, collaborative robot markets: 2020 and beyond The industrial and collaborative market has a bright future ahead as companies look to make robots faster, smarter and more efficient. See three market trends and two technology trends for the 2020s.

he recent “big picture” story with industrial robots has been a slowdown in the market driven by poor market performance in China, as well as slowing general investment in the two main end-user markets: automotive and 3C (computer, communication and consumer) electronics. An interesting sub-story has been collaborative robots, where we’ve seen continued strong performance — 30% revenue growth in 2019. We are confident the overall industrial robots market slowdown is temporary and was driven by wider macroeconomics. The longer-term outlook for robotics is very positive due to a drive towards greater automation and an aging workforce in many countries. The industrial robot market will start to pick up from 2020 with collaborative robots having an even better year. Looking further ahead, the big tech trends affecting the industrial robot market most significantly will be machine vision and machine learning as well as mobility.

Three future robot market trends 1. Industrial robots In 2020 and 2021, we will see a rebound in the two biggest markets for traditional industrial robots: automotive and electronics, meaning there will be significant improvement in the industrial robot market. One thing driving long term growth is a trend for industrial robots to move into applications and markets they have not traditionally been used in. Another noticeable trend in industrial robots is toward smaller payload, entry-level, easyto-use variants. All this is driven by new technologies, by globally increasing labor costs and by competition from collaborative robots. Demand for these new “lighter” types of industrial robots is strongest from nontraditional markets such as logistics and food and beverage and, after 2021, a lot of the growth will be www.controleng.com

driven by these sectors. This was reinforced by a December 2019 visit to the IREX robotics show in Tokyo, where many robot vendors had dedicated logistics and food and beverage demos. 2. Collaborative robots The collaborative robot market is pretty exciting right now. One of the most interesting things is rather than taking market share from traditional industrial robots, collaborative robots are helping expand the overall robot market’s boundaries. This means traditional industrial robot vendors can enter the collaborative robots market without too much worry about cannibalizing their own sales. We are starting to see that with companies such as Fanuc and Yaskawa bringing new models of truly collaborative robots onto the market. Fanuc and Yaskawa have a more “industrial” take on the collaborative robot market, compared to the dedicated collaborative robot manufacturers who have dominated up until now. However, it seems likely they will ultimately find significant success with these offerings. The real competition in the collaborative robot market has only started; things are likely to get more competitive. 3. A regional view Regionally, the collaborative robot and industrial robot markets have several clear trends. The EU (and Japan) have a strong emphasis on safety; China prioritizes low At right: Fanuc’s new 10kg payload CRX-10iA and CRX-10iA/L reach 1,249 mm and 1,418 mm respectively. The collaborative robots have sensitive contact detection that allows them to work alongside people. Courtesy: CFE Media and Technology New Products for Engineers Database control engineeering

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INSIDE MACHINES AND ROBOTICS

Above: OnRobot’s VGC10 electrical compact vacuum gripper has two independently controlled air channels to act as a dual gripper with pick-up and release in the same action, increasing efficiency and reducing cycle time. No air supply is needed. Courtesy: CFE Media and Technology New Products for Engineers Database

costs and ease of use; the U.S. is pushing boundaries by taking collaborative robots out of the traditional industrial space and into new markets, such as the service industry. This may be partly because manufacturing is a smaller sector of the economy in the U.S. than China and Japan, or in key EU countries such as Germany. This means if robot companies want to sell their products, they have to look outside their core markets. It also may be down to culture: U.S. business culture is historically very open to risks, and to rapid innovation and change. Many of the new collaborative robot applications may fail, but it is possible U.S. customers may soon walk into burger bars and cafes staffed almost entirely by collaborative and industrial robots.

Two robot market technology trends A. Machine vision and machine learning In the long term, machine vision and machine learning are going to be among the most important technologies driving industrial and collaborative robot growth. A market being targeted by industrial robot and collaborative robot vendors is highly complex inspection, pick and place and sorting applications. Entry into these markets isn’t limited by the hardware, which is mostly advanced enough, but by software capabilities as applied to machine vision and machine learning. The implication is the robotics industry will come to be defined by its software. These trends were obvious at IREX, and it was particularly interesting to see more dedicated machine vision and machine learning companies had their own stands at the show. The way forward for these specialist companies is partnering with big robotics vendors. To some extent, this is already a visible trend, but it is likely going to grow radically. B. Mobility In recent years, e-commerce logistics has rapidly adopted industrial robot technology. What is interesting is that, despite being a late adopter of robotics (compared to sectors such as automotive) e-commerce logistics companies have rapidly moved ahead in some areas, merging robots with mobility technology in a way that has never been done by manufacturers. In part, this is because of the industry: it is simpler to adapt robots for mobility in e-commerce applications than it is in manufacturing applications. Growth in mobile robots for manufacturing applications is set to accelerate and

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Industrial robot and collaborative robot vendors are targeting highly complex inspection, pick and place and sorting applications aided by advances machine vision and machine

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be one of the big trends in the 2020s as more manufacturers increase their automation investments. At IREX, mobility demos were in almost every booth — with many specifically showcasing the possibilities of robot mobility for manufacturing applications. The technology is currently at the concept stage, but it won’t be long before robots are moving up and down production lines and moving raw materials and finished goods around factory complexes. Of course, this is not simple: it needs connectivity, Big Data and Internet of Things (IoT) technology to support it. In the end, it will be the big automation vendors who have the resources to integrate the systems and technologies into a coherent and viable market offering. As with machine vision and machine learning, many specialist, niche mobility companies will form deep partnerships with the industrial robot leaders to make this a reality. ce Jan Zhang, research director at Interact Analysis. Edited by Chris Vavra, associate editor, Control Engineering, cvavra@cfemedia.com.

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KEYWORDS: Robots, collaborative robots, robotics The industrial robot market will rebound in the 2020s and continue to grow. The collaborative robot market is going to grow, and industrial robot companies will become more involved. Machine vision, machine learning and mobile robots’ capabilities will grow. ONLINE www.controleng.com/robotics

CONSIDER THIS What do you think the biggest robotic development will be in the 2020s, and are you taking advantage? www.controleng.com

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INSIDE MACHINES AND ROBOTICS Mark Howard, EU Automation

Getting the best from your robot investment Investing in a robot for an automation project is an ongoing process and requires the user to perform risk assessments and get a clear picture of what the robot’s purpose is in the project.

anufacturers often turn to automation to perform a specific function or address a production line challenge, such as improving productivity or quality. When specifying automation equipment, manufacturers should focus heavily on the goal they want to achieve. Expanding beyond original business objectives or scope can add costs and delays. For those tackling automation projects, choosing the right robot, software, and tooling is a complex task, and the work doesn’t stop once the robot has been specified. Even if a manufacturer has chosen the right equipment, it doesn’t mean the automation project will be successful. There are numerous considerations to make about the operating environment, machine integration, and peripheral employees before the project begins.

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Seeing the bigger picture

KEYWORDS: robotics, robot

maintenance, robot safety Robots aren’t cheap, but they can deliver strong return on investment (ROI) for an automation project. Risk assessments need to be taken to ensure the robot and human can work without endangering each other. Manufacturers should also update their obsolescence management strategy when investing in robotics.

ONLINE View the robotics page at www.controleng.com/robotics for more stories on robotics.

CONSIDER THIS What is the biggest challenge or hurdle your company faces when it comes to choosing a robot?

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Typically, manufacturers take a cellular approach to production. At each stage, the product moves from one cell to the next, so the next step in the process can take place. However, automating one cell impacts far more than just one step in the production process. The first question to ask is, how will employees be affected? This can include thinking about the process itself, such as whether it will be automated or manual. If the automation displaces human workers, manufacturers should think about new roles for the employees and how to train members of the team how to operate and maintain the equipment. Only when factoring in the role of employees can manufacturers get a clear picture of how long return on investment (ROI) is expected to take. Employee buy-in is critical when

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implementing new automation technology. Poor internal communication can lead to employee’s panicking about losing their jobs, due to the misconception that robots steal jobs. Clearly explaining what changes will be made and why will help with this.

Performing risk assessments

Robots commonly perform tasks that are unsafe, repetitive or hazardous for humans. Therefore robots have the potential to improve health and safety, provided the manufacturer conducts a thorough risk assessment. The risk assessment should cover the equipment and its environment, such as the cell the robot is operating in. Possible hazards include trapping and crushing and, depending on the gripper attached to the robot, electric shocks, burns, or exposure to hazardous substances. By identifying what risks apply, the manufacturer can put control measures in place to reduce the likelihood of each hazard. Occupational Safety and Health Administration (OSHA) provides guidelines and regulations for employee safety. OSHA draws on the Robotic Industries Association’s (RIA) ANSI/RIA R:15.062012, which provides guidelines for manufacturing and integrating robots safely. There also may be more specific requirements depending on the type of equipment, for example, electrical equipment may be covered by EN 60204-1, which lays out the requirements for enclosures, isolators and actuators. The manufacturer may also have to make physical changes to a building, for example if machine emissions mean different ventilation is required.

Collaborative robot safety

There are additional safety standards around collaborative robots. Traditionally, industrial robots are caged so no human could enter the area while the robot is active. Collaborative robots have been marketed to suggest they are able to www.controleng.com

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Robot risk assessments consider possible hazards including trapping and crushing and, depending on the gripper attached to the robot, electric shocks, burns, or exposure to hazard-

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work side by side with humans. However, this can only be determined by a risk assessment of the application. ISO/TS 15066 2016 EN gives additional guidance specific to collaborative robots. This includes defining the spaces around a collaborative robot, so safe operations happen in each area. Manufacturers may want to consider certain collaborative robot safety features, such as safety-rated monitored stop, which means the robot will stop when it detects when a human has entered the collaborative workspace. Once best practices for integrating, setting up and operating new equipment have been established, it is vital to communicate it to the team. By ensuring staff have a complete understanding of the machinery, the manufacturer reduces the risk of injury. Training can cover processes, procedures and personal protective equipment (PPE).

Maintenance best practices

Though it may seem early days, it is worth considering maintenance at the outset. For a robotic project to generate ROI, it needs to be up and running. Downtime is expensive. Manufacturers can either purchase equipment that comes with connectivity included or add sensors themselves to measure equipment performance. The data can be analyzed in real-time and used to make decisions. Predictive analytics, for example, will help to flag when equipment is about to break, so maintenance engineers can act in advance.

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Companies need to know exactly what a robot’s purpose is when selecting one for an industrial automation project to help ensure a good return on investment (ROI). Shown is a Yaskawa robot at Fabtech 2019 at McCormick Place in Chicago. Courtesy: CFE Media and Technology

That said, machines do break. When investing in robotics, manufacturers also should update their obsolescence management strategy, to be prepared in case of a breakdown. Forming a relationship with a reliable supplier means manufacturers can safeguard themselves against potential losses from unplanned downtime — particularly when a costly robot investment is involved. While investing in robotics is not cheap, they can help automation projects deliver good (ROI), provided all relevant factors are taken into account. ce Mark Howard is North America country manager, EU Automation. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com. control engineeering

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INSIDE MACHINES AND ROBOTICS Sandro Quintero, Festo

Cartesian robots have value on the manufacturing floor Cartesian robots offer space and cost savings, wide dynamic range, and are simpler compared to other industrial robots.

artesian robots might not fit anyoneâ&#x20AC;&#x2122;s image of an industrial robot. However cantilevered and gantry Cartesian robots offer several advantages in many applications compared to six-axis, selective compliance assembly robot arm (SCARA) and parallel robots. The most important of these advantages include greater workspace utilization, high dynamic range, simplicity and low cost. Ask most plant engineers what they highly value in new automation systems and the answer will likely be its small footprint. In many plants, space is at a premium, making workspace utilization crucial. Most robot workspaces can be visualized as either a two-dimensional plane such as a planeshaped workspace of a circuit board, or a three-

Figure 1: A large Festo Cartesian robot efficiently palletizes shipping cases in a box-shaped workspace. All images courtesy: Festo

Figure 2: Contactless high-speed handling: the Cartesian high-speed H-gantry for photovoltaic applications is 30% faster than any conventional Cartesian handling system while procurement costs are comparable.

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Figure 3: Festo Handling Guide Online enables the design of a Cartesian robot with a quote and a CAD file in as little as 30 minutes.

Figure 4: Festo ELGC and EGSC actuators ensure fast assembly of Cartesian robots.

dimensional box with X, Y, and Z dimensions, such as a shipping case with bottles or a loaded pallet. The ideal robotic implementation uses the plane or box workspace with a minimum of footprint outside the workspace. This is where Cartesian robots shine. Cartesian robots are positioned on top of the workspace, exactly fitting over the X, Y, and Z axes. Contrast the Cartesian maximum utilization of the X, Y, and Z axes workspace with that of six-axis and SCARA robots, which operate within a sphere, not a box. Their footprints typically exceed the footprint of a workspace, which for most applications, is a plane or box. Adding to the excessive footprint is the requirement to place guarding on the floor around the perimeter of the sphere. The parallel robot also requires area around the workspace. Does the workspace most closely resemble a plane, box, or sphere? Answering this question will help plan for the smallest footprint.

Dynamic range in the workspace Cartesian robots are customized, scaled to the size of the workspace and the dynamic range required by the application. A large workspace with light payload will have lighter drives with less torque, which CONTROL ENGINEERING

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decreases expense. Six-axis, SCARA, and parallel robots are off-the-shelf products. The engineer has to find one closest to the need, which means a robot may not be optimum in cost or performance. In that example, the only other robot other than a Cartesian may be a much larger and heavier unit than the payload requires because it is the only unit with the necessary reach. Cartesians deliver high accuracy across the workspace; a six-axis robot loses accuracy at the farthest extent of its reach.

“Custom” may not add time, cost

The words “custom solutions” can bring up images of long lead times and expense. However, Cartesian robots are simple mechanisms consisting of various combinations of relatively low-cost axis. Some Cartesian vendors have developed online design tools that can lead to a completed design, a computer-aided design (CAD) file ready for delivery, and a quote within 30 minutes. Delivering an assembled robot or a kit may take only weeks. Of the major classes of industrial robots, Cartesians are at the low end in terms of cost, although each is custom-assembled from off-the-shelf products. Using off-the-shelf components, lowers repair and maintenance cost, as well. For customers purchasing kits rather than fully-assembled Cartesians, vendors offer off-the-shelf drives and axes

designed for fast assembly without adding mounting plates. Design tools help ensure plug-and-play functionality. For X, Y, and Z motion, a standalone control panel may not be necessary, which lowers cost and reduces footprint. For advanced motion applications, such as curvilinear motion required for laying adhesive, a standalone control panel with motion controller may be required, incrementally adding to the unit cost and footprint. Cartesian robots are simple kinematic solutions that are easy to maintain and repair.

A few concerns about Cartesians

Cartesians are not perfect for all applications, however. The upper limit in degrees of freedom for a Cartesian is generally three axes plus rotation. Cartesian robots cannot be used in washdown environments, and they require precise alignment and a flat mounting surface. Programming is required though some suppliers provide function blocks to help. When a robot application comes up, analyze the workspace, consider the dynamic and reach required, and the cost and simplicity of operations. Then determine if a Cartesian robot may be the right choice. ce

Sandro Quintero, product manager – electric automation, Festo. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media, cvavra@cfemedia.com.

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KEYWORDS: robotics,

Cartestian robots, motion control Cartesian robots have many advantages including greater workspace utilization, high dynamic range, simplicity and low cost. Cartesian robots are not ideal when a lot of freedom of movement is needed. Analyze the workspace and the application to determine if a Cartesian robot is the right choice.

ONLINE Read this article at www.controleng.com for more on Cartesian robots, and an application list and image.

CONSIDER THIS What benefits could Cartesian robots provide in your plant?

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INSIDE MACHINES AND ROBOTICS Rohit John Varghese, Harmonic Bionics Inc.

Exoskeleton therapy Inside an exoskeleton, advanced robotics technologies help physical therapy patients regain arm movement. It’s a high-technology motion control application.

robotic exoskeleton is helping those with paralysis in arms to move, helping with physical therapy. It has 23 degrees of freedom (DoF) enabled by more than 50 sensors, sensing actuators, multiple processors and high-speed networking.

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KEYWORDS: Robotics, motion A robotic exoskeleton design helps with arm-movement therapy. Closed-loop torque-sensing actuators help with control. Industrial Ethernet networking.

CONSIDER THIS How can robotic advances save your manufacturing operations?

ONLINE If reading from the digital edition, click on the headline for more on project challenges and resolutions, and more photos. www.controleng.com/magazine www.controleng.com/robotics See robotic research at www.controleng.com/research.

Please describe a robotics project, scope and goals.

Harmonic Bionics, Austin, Texas, developed the Harmony exoskeleton for the upper limbs to help people who have suffered a stroke or neuromuscular damage improve functionality and healing. Physical therapists use the device to assist patients in their rehabilitation. The goal was to maximize the range of motion of the human shoulder and the shoulder girdle on the hemiparetic arm (the arm impacted by the stroke). The exoskeleton had to fit with people of all shapes and sizes (it can be adjusted to fit more than 95% of the U.S. population.) It includes advanced actuator and controller technology that allows Harmony to customize gravity compensation, assis-

tance and resistance, as needed, for each patient.

What robotics and controls were used?

The device is a 23 DoF robotic exoskeleton with 14 degrees of closed-loop torque sensing actuators capable of impedance control. The remaining 9 actuators have position feedback for active size adjustment. The robot control system was designed from the ground up by Harmonic Bionics using the EtherCAT protocol to enable cycle times across distributed processors. For instrumentation, the device has more than 50 sensors. Each joint has two encoders, active load sensing, and motor feedback, in addition to other required miscellaneous instrumentation. The design team built out all of the motor control and communication electronics in-house with a closed-loop cycle time of over 2,000 Hz across distributed processors, in addition to custom designing the actuator module to enable closed-loop torque feedback for accurate and reliable torque and impedance control. This has enabled the level of performance therapists require.

Can you share some positive metrics?

Pilot research findings based on healthy and stroke subjects showing positive results were recently published at the International Stroke Conference. There is growing traction in the medical community on the need to bring this robotic technology into the clinical market as rapidly as possible.

What were lessons learned?

Harmony is an exoskeleton designed to assist patients with stroke rehabilitation and focuses on the shoulder. Courtesy: Harmonic Robotics

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Harmony will be a powerful tool to use as a modality to aide in progressing the stroke patient towards normalizing movement. Clinics are limited, and it sometimes takes years of therapy to become functional. The misconception is normal use and movement will be fully restored. The hope is to provide an adjunct to existing strategies in clinics and at home with the stroke population. Harmony helps make a therapist’s job easier to handle the patient’s upper limb paralysis and gives immediate feedback. ce

Rohit John Varghese is head of product development for Harmonic Bionics Inc. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media, mhoske@cfemedia.com. www.controleng.com

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INSIDE MACHINES AND ROBOTICS Nigel Smith, TM Robotics

Human impact of robotics Automation can increase demand and create more opportunity for employment.

ot every food manufacturer is an automation convert, despite the opportunities. The food manufacturing industry tends to fall into two camps: Those who see automation as an opportunity to improve processes and a smaller minority who perceive it as a threat to business. Considering the widespread data that proves the potential productivity rewards of automation, why are some manufacturers still hesitant? Common complaints revolve around reputation and fewer jobs for humans.

Robots and jobs and risk

There’s a common misconception that increased automation leads to fewer jobs for human employees — and some manufacturers are concerned investing in automation will reflect poorly on their brand. However, history proves this hasn’t slowed down the uptake of robotics and automation in the past. Nearly 500 years ago, Queen Elizabeth I denied a patent for an automated knitted machine. The argument was the equipment would deprive young women of employment. Regardless of the denial of patent, factories adopted the machine anyway, in a bid to increase productivity. This productivity boom resulted in higher profits and greater opportunities for employment, with these factories employing four times as many workers a century later. Automation improves the working environment for employees by reducing the likelihood of injuries. According to the Health and Safety Executive, a U.K. government agency for workplace safety, over 30% of injuries reported in the food and drink industry are related to manual handling. That’s a striking figure, considering approximately 120,000 people working in the sector are injured each year. Many of the injuries are related to packaging, boxing and unboxing. Manual handling-related injuries include accidents that occur when packing products, pushing wheeled tacks, and stacking or unstacking containers such as boxes and crates. Such tasks are easily automated. Take bin picking as an example. Using a sixaxis robot with advanced 3D vision software, the bin picking process becomes fully automated with cycle times as fast as 0.7 seconds. Without automation, human operators would be required to manually pick items from the box and place them onto

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the next part of the manufacturing process. This is Automation can a seemingly safe task, but it carries manual handling help food industry workers increase and repetitive injury risks. Automation has been applied to help with robot- productivity and ic box-opening solution. One such system can auto- lower risk. Courmatically measure the size of every case or box that tesy: TM Robotics comes into the facility and automatically find the programmed cut lines. The machine is capable of cutting up to 750 boxes per hour without requiring a human employee to handle a blade. By safely automating this process, food manufacturers can decrease the chance of employees being cut or injured by a blade while on the factory floor. More automated processes lowers the likelihood of injuries. Automation has been an essential part of manufacturing since the first six-axis robots were introduced to automotive production in the 1960s. Since then, a growing number of sectors have embraced the KEYWORDS: Robotics, food processing, productivity technology, including food processors. Robotics can lower risk of injuries As automation and robotics become and create jobs. more affordable and accessible, we’re likeBin picking and box opening ly to see an even more widespread indusrobots decrease human injuries. try acceptance from food manufacturers. CONSIDER THIS Automation skeptics and enthusiasts alike Are you concerned competitors need to ensure their facilities do not get are looking at automated left behind with efficient robotic impleefficiencies that you are not? mentations. ce

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Nigel Smith is managing director of TM Robotics, a distributor of six-axis industrial robots and partner of Toshiba Machine. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com. control engineeering

In the digital edition, click on the headline for more on How will human roles change? www.controleng.com/magazine www.controleng.com/robotics See robotic research at www.controleng.com/research.

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INSIDE MACHINES AND ROBOTICS Christoph Wimmer, Omron Automation Americas

AMRs: Flexible, intelligent

Autonomous mobile robots (AMRs) are adding flexibility and spaceefficiency in industrial use, especially electronics and semiconductor industries.

Omron’s AMRs support a variety of payloads and shapes to enhance flexibility. Shown is an Omron LD Mobile Robot. Courtesy: Omron Automation Americas.

aterials transport in consumer electronics and semiconductor manufacturing is a challenge. To enable small-volume, highmix semiconductor production, for example, wafer cassettes must be transported in complicated orders with precise timing. Tasking human workers with transporting these items lacks efficiency; automating the process with inflexible conveyors or automated guided vehicles (AGVs) reduces system adaptability. New technologies are emerging as effective solutions to this issue. Today’s mobile robots automate materials transport without any of the complicating factors caused by AGVs. Best described as autonomous mobile robots (AMRs), these robots self-navigate throughout dynamic environments using the shortest viable pathways. Space-efficient and capable of delivering materials on precise timetables, AMRs optimize throughput and cut costs. With no need for factory modifications like floor magnets and navigational beacons, their implementation saves up to 15% of deployment costs compared with other strategies. A coordinated fleet of self-navigating mobile robots streamlines job scheduling by bundling pickup and drop-off locations into strategic groups. Capable of carrying the right products to the right place at the right time without pause, AMRs minimize unplanned time from missed deliveries and accidents.

AMRs: Workforce training, safety

By taking care of repetitive, error-prone tasks, selfnavigating robots reduce the likelihood of mistakes while freeing up the workforce to perform activities that require human ingenuity. In addition, AMRs help keep semiconductor manufacturing plants free from contamination by ensuring employees only enter workspaces where human ingenuity is needed. One semiconductor manufacturer was able to assign workers to other tasks and reduce training time because the AMR made it unnecessary for new recruits to learn transport processes. A manufacturer of liquid-crystal display (LCD) panels eliminated manual tray transport from buffering areas to cell stations with AMRs that carry 40 trays per day. This boosted efficiency by making sure the right product gets picked up and/or delivered at the right time.

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By taking on materials transport tasks, AMRs also help prevent work-related accidents that can be caused by heavy lifting, collisions or other workplace hazards. Where the robots assisted with sputtering machine maintenance, the safety improvement in was as important as the boost in productivity. By automating materials transport, workers are no longer exposed to these hazards.

System integrators and AMRs

When setting up a fleet of mobile robots, a system integrator who has an in-depth understanding of the particular AMR platform can design a system to fit the factory needs in a very short time. This saves the customer effort in design and engineering. Several of the listed examples involved a skilled integrator from the starting stage; the simulation of routing and job assignments were key to success. An AMR offers benefits for manufacturers in the consumer electronics and semiconductor industries. By automating materials transport needs with a flexible and reliable system, mobile robots ensure efficient floor space utilization, robust traceability, workforce optimization and help minimize risks to employees. ce

Christoph Wimmer is manager, semiconductor/electronics at Omron Automation Americas. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media, mhoske@cfemedia.com.

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KEYWORDS: Mobile robots, mobile autonomous robots, AMR Sensors help AMRs intelligently navigate. AMRs save space, cut installation costs, and add productivity. Workforce productivity, training, and safety can improve with AMRs. CONSIDER THIS Will AMRs deliver the next tier of productivity for your organization?

ONLINE If reading from the digital edition, click on the headline for more on AMR basics, space, installation costs, and photos. www.controleng.com

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INSIDE MACHINES AND ROBOTICS Michael Majchrzak, Control Engineering Poland

AMR market expands rapidly The market for autonomous mobile robots (AMRs) is growing fast, and there is a lot of demand globally for them in traditional automation, in non-automotive sectors.

utonomous mobile robots (AMRs) were a hot topic at the 3rd Forum Cobotyki in Wrocław, Poland, which had more than 300 participants, including Thomas Visti Jensen, CEO of Mobile Industrial Robots ApS. The growing AMR presence in manufacturing is matched by a growing demand. The overall market for AMRs in all sectors (aerial, ground and marine commercial and private) is booming, with the overall market expected to grow at 24% per year from $19B in 2018 to $54B by 2023, according to MarketsandMarkets Research. Jensen discussed his experience as the CEO of MiR and what the future of mobile robotics looks like, with Control Engineering Poland. Michael Majchrzak, Control Engineering Poland: MiR was one of the first companies to launch AMRs for industry and logistics. Did you do any market research before deciding to take the leap? Thomas Visti Jensen: Yes. When Niels (Niels Jul Jacobsen, founder of MiR), reached out to me to be the CEO, he asked me if I was ready for another journey. I started looking into the product and calling contacts in Germany, in the USA and so on, and I spoke with them about the product. Nobody really understood the concept. They would ask, “Where’s the market?” or “We don’t see any potential there,” or whatever. I had the same feeling, but I could see some potential in the flexibility that was inherent in the product and the fact that it was very easy to program, it was safe, and I knew that there were companies that were looking for a solution to automate logistics operations. MM: What about finding engineering talent, is that difficult in today’s quickly automating environment? TVJ: Everybody’s asking, “Is it difficult to find employees?” It’s not that difficult, thankfully, because there’s so much focus on engineering development in Denmark, and we now see a lot of foreigners willing to move to Odense (Denmark, the headquarters of MiR) because there’s a lot of exciting jobs there. I’m not saying it’s been easy, but it’s been relatively easy for us to find the good employees compared to the whole market situation as it is right now. MM: What sectors you are focusing on, and where do see the biggest potential for your products? TVJ: The main driver in the beginning was

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The opening presentation by Thomas Visti Jensen at the Forum Cobotyki 2019 in Wrocław, Poland. Courtesy: Control Engineering Poland

automotive producers and suppliers, as they were willing to invest in the technology. They were also the first sector to move into automation. After automotive came electronics, and then we saw fast moving consumer goods (FMCG) and now logistics. So this has been the development of the market. And of course, hospitals. Hospitals have a big potential in the long distances that are required moving medical equipment around buildings. Automotive is 35% of our revenue today. MM: Which regional markets are the most important for you, and how strategic are the markets in this region of CenKEYWORDS: mobile robots, tral and Eastern Europe? autonomous mobile robots, TVJ: For robotics, China is a very AMRs large market for all manufacturers. Over Mobile robots are a growing one-third of all robots produced go to market all over the world. China. In our case right now, about There is a lot of demand for mobile 10-12% of our sales go to China. The robots beyond the automotive and USA is our second largest market with automation sectors. more than 25% of sales. Europe is largest China, North America and Europe are among strong AMR markets. with over 50% of revenue. Eastern Europe is about 14% of revenue. We expect the ONLINE market for logistical AMRs to grow from Read this article online at about 100,000 installed base today to www.controleng.com for a link to the Control Engineering Poland more than 700,000 by 2022. ce

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Michael Majchrzak is with Control Engineering Poland. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com. control engineeering

interview, with more background on Jensen and his history with robotics and other topics.

CONSIDER THIS What technology advances will help expand mobile robots’ footprint in manufacturing?

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IIoT Cloud

Sponsored by: Universal Robots

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ANSWERS

INSIDE MACHINES AND ROBOTICS Ed Mullen, Mobile Industrial Robots (MiR)

AMRs improve logistics At Ford Motor’s body and stamping plant in Valencia, Spain, autonomous mobile robots (AMRs) improved logistics; humans work on more complex tasks.

hile robots aren’t new to Ford Motor Co., its 3.2 million-sq-ft factory in Almussafes-Valencia, Spain, has added autonomous mobile robots (AMRs) to its facility. The body and stamping plant makes 2,000 vehicles a day. Until 2018, workers had to manually deliver fresh industrial and welding materials to the different industrial robot stations within the massive facility, a repetitive and time-consuming task. Plant managers knew they needed to improve logistics and make employees available for more valuable tasks. Ford decided to purchase a flexible and collaborative mobile robot to deliver the spare parts to the manufacturing plant. The mobile robots avoid unforeseen obstacles, modify their routes or stop when necessary, and work safely alongside people and other vehicles. Ford equipped the AMRs with an automated shelving system with 17 slots to accommodate materials of different weights and sizes. To avoid errors, the opening and closing of these slots is automated, meaning operators in each area only have access to the materials assigned to them. “We programmed the AMR to learn the entire plant map, and this, together with the sensors with which it is equipped, means that it does not need any external help to circulate safely,” said Eduardo García Magraner, the plant’s engineering manager. Ford tested the first robot to see how it would operate in real time. García Magraner said, “It worked flawlessly and has become a very valuable member of the team. When the tests started, the operators were staring at the robot as it passed by. Now, they go on with their work knowing that the robot is smart enough to work around them.” The company introduced two other AMRs shortly after to transport more spare parts for production equipment from the warehouse to the production lines. “It was important... for the navigation of the robot, no external elements were needed, such as external beacons, magnets or tapes on the ground,” said Miguel Montaña, the facility’s analyst on maintenance control. “We simply mapped the test area, and the robot began to work. In an environment as complex as ours, that is very important.”

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Tests conducted by Ford show that one mobile robot frees up to 40-human hours per day, allowing workers to do more complex tasks. Courtesy: Mobile Industrial Robots (MiR)

For Ford’s employees, ease of use was also a major factor. According to García Magraner, “The robot is well configured so that it can be used by anyone even if they are not familiar with the world of collaborative mobile robots. The system is very user-friendly, as the three robots have their own routes throughout the extensive factory area.”

Mobile robot benefits

Tests conducted by Ford show that one mobile robot alone frees up to 40-human hours per day, allowing workers to dedicate themselves to more complex tasks. “We are... pioneers in the use of collaborative mobile robots for the distribution of industrial materials that allow us to be more efficient KEYWORDS: mobile robots, in our intra-logistics,” said Pepe Pérez, autonomous vehicles corporate communications manager at Ford Motor added autonomous mobile robots (AMRs) to its Ford Spain. facility in Valencia, Spain. Ford Valencia hopes to find other The AMRs they used were able AMR applications and expand to other to work seamlessly on the plant Ford facilities in Europe. The robots can floor and assist human workers. learn their way by themselves and interHaving a mobile robot frees act perfectly well with employees and up humans to work on complex tasks. forklift trucks or other moving elements with total safety, said Helios Alverez, the ONLINE plant manager. ce Read this article online at

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Ed Mullen is vice president of sales, Americas, Mobile Industrial Robots (MiR). Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com. control engineeering

www.controleng.com for links to more about AMRs.

CONSIDER THIS What benefits could your plant derive from AMRs and in what way?

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webcasts Control Engineering’s webcasts cover the latest engineering topics that affect your industry and operations. Join the expert panelists and attend our webcasts at your desktop or mobile device of your choice. Discover the latest on topics like:

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ANSWERS

INSIDE MACHINES AND ROBOTICS Laura Moretz, Robotic Industries Association (RIA)

Mobile robots are getting smarter and going new places Autonomous mobile robots (AMRs) are working alongside humans and providing help in applications such as hospitals and warehouses thanks to advances in mobility and mapping technology.

n warehouses, hospitals, and factories, mobile robots are doing tasks that can tax workers with repetitive stress injuries or fatigue. Autonomous mobile robots (AMRs) carry heavy loads in factories, deliver meals, medicine, and laundry in hospitals, and select and pick products off warehouse shelves for shipments. In some cases, AMRs can fill empty jobs that lack applicants, and in others, they work alongside humans. Robot manufacturers are incorporating better mapping systems into AMRs to create routes through the workplace, creating better sensors to protect people who work in the same space with AMRs, and finding optimal methods for recharging AMRs.

New hospitals and hotels plan on robots

In hospital environments, Aethon’s TUG carries meals, medicine, and linens. Peter Seiff, senior vice president for Aethon, said, “When you’re operating a hospital, it’s a miniature city in a lot of ways.” The patients have a lot of needs. Aethon programmed the TUGs to be personable and friendly when meeting people, using scripted phrases. The University of Pittsburg Medical Center uses 27 Aethon TUG robots. Seiff hopes architects and owners will plan for AMRs when they design hospitals and hotels and creating designs that optimize space for AMRs and humans. He said that as they employ robots, hospitals could eliminate laundry chutes and linen stor-

age closets if AMRs like TUGs take away old linens and deliver fresh ones. In addition, there’d be a gain in floor space. The TUG rarely needs human backup, but if it does, Aethon has a cloud command center that guides TUGs remotely and also updates software for the company’s 800 TUGs. Seiff said the command center allows Aethon to address 97% of any issues with the robots remotely and without on-site support.

AMRs help with worker shortages

Jason Walker, the CEO and co-founder of Waypoint Robotics, believes the need for AMRs is growing because employers can’t find enough workers to hire. Walker said, “Our value proposition is: ‘Let’s take the people you’ve already got who you know and trust and love, and let’s give them better tools.’” Waypoint’s AMRs are ready to work soon after they arrive on a loading dock. They don’t need weeks of attention from engineers to get up to speed. They can drive through a factory once and make a map that will guide its future move-

Swift is an autonomous mobile manipulation robot (AMMR) that works like a human order picker, moves through inventory aisles, finds the right products, picks them into a tote, and then transports that tote downstream for packaging and shipment. Courtesy: Robotic Industries Association/IAM Robotics www.controleng.com

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ANSWERS

INSIDE MACHINES AND ROBOTICS Waypoint is selling Enzone to other companies, he said. “The reason we want to do that is to create an ecosystem and a standard in the robotics community where we all use one type of wireless charging system. I’d rather create a bigger pie than hoard the piece I’ve got.”

Future AMRs will slowly build on current success

Autonomous mobile robots intelligently navigate grocery and other retail stores using a point cloud created by a Kaarta mobile 3D scanner as master map. This 60,000-sq-ft store 3D map was scanned in less than one hour with a Kaarta Stencil system. Courtesy: Robotic Industries Association/Kaarta

ments. Waypoint’s Vector, which has payloads of 300 pounds and 600 pounds, and MAV3K, which carries up to 3,000 pounds, can move materials efficiently. MAV3K can “move pallets and large material loads, and it’s great for mobile manipulation with really big arms,” Walker said, but it’s not a forklift, and so it doesn’t work alone. The future for AMRs involves heterogenous fleets of AMRs, Walker said. “We’ve built our systems so that they are easy to integrate and are interoperable with all kinds of third-party external systems.” He envisions AMRs from multiple manufacturers working together to complete jobs. Through a partnership with Wibotics, Waypoint has adopted a wireless charging method called EnZone which uses radio frequency at multiple sites within a workplace. “As long as you get the receiving antenna within about an inch of the transmitting antenna, it will charge at full power, and it will do it all day long.”

MAV3K is a 3,000-lb capacity, industrial strength, omnidirectional, autonomous mobile robot. Courtesy: RIA/Waypoint Robotics

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CONTROL ENGINEERING

Tom Galluzzo, the founder and chief technology officer of IAM Robotics, says that IAM focuses on helping companies to pick, pack, and ship longtail inventory in warehouses, that is, items stocked in small amounts. IAM’s AMR, Swift, locates merchandise, uses Flash to read the SKUs, grasps the package, and moves it. It is controlled by the Swift Link server, which integrates with the existing warehouse management server. IAM Robotics’ first client was Rochester Drug, a large cooperative of pharmacies that needed automation to fulfill orders at night to be delivered the next day. Galluzzo says IAM Robotics is working “with everyone from fortune-five level retailers to two major health and beauty corporations that work internationally.” Galluzzo expects that “as robots need to become more complex, there might be a slow down as far as implementing them.” With the current technology, AMRs have the potential to do up to 80% of the thinking, he says. “That frees up a person to do higher value critical thinking for operations.”

Robots perform better with fast, accurate maps Kaarta, founded in 2015, creates 3D maps in real time. Kevin Dowling, CEO, said, “We’re essentially answering two questions for robots. One is: What is around me? Which is the map? And then, where am I? Which is its location.” He said customers use Kaarta software for AMRs in retail and factory environments. “We’re a thin part of the full stack but a very important part.” In addition, the company’s Contour software was used recently in the six-part National Geographic documentary series “Buried Secrets of WWII.” Some clients in the construction industry use a Kaarta device mounted to an AMR with legs to map difficult terrain. Data is uploaded to Kaarta’s cloud where it is processed. Kaarta can create a map for robots to use, or the software can be within the robot. In addition to attaching a Kaarta system to an AMR, it can be attached to a handheld device and walked through a space to create a map. Dowling said, “A large Wal-Mart takes about three hours to fully scale. There is some post-processing afterwww.controleng.com5

ward, but the onsite time is reduced.” The system can also be attached to a drone to create a map.

Remote controls keep humans in control

In 2018, Fort Robotics, formerly part of Humanistic Robotics, separated its operations to focus on refining and marketing remote safety controls for AMRs. Daria Duda, the director of product marketing at Fort, said the company designed the Wireless E-Stop and Safe Remote Control System to prevent dangerous AMR interactions with humans. The company sells the controls in construction, agriculture and warehousing markets. “There’s always going to be a need for a human to stay in control of automation or mobile robotic machine,” she said. The remote control technology can be within existing remotes, or it can be a separate control. As to Fort’s vision for the future, she said: “We want to keep things broad to gauge where the market is going and what industries are moving faster than others.”

AMR advances, better collaboration

Mobile robots have developed the ability to lift,

carry, pick, pack, sense obstacles, and stop to avoid collision. Increasingly, mobile robots from different manufacturers work collaboratively to complete tasks, and developers continue to build on existing skills. As AMRs become more able, doing most of their own thinking, humans will continue to supervise them. Developers will build on existing strengths and improve robot collaboration. ce

M More ANSWERS

KEYWORDS:

Mobile robots, AMRs Autonomous mobile robots (AMRs) can work alongside humans and improve on operations if they’re given the space and the ability to operate. Mobile robots can be programmed to map and navigate tight spaces such as grocery and retail spaces. Mobile robots are increasingly being developed to work collaboratively and build on existing skills.

Laura Moretz is contributing editor for the Robotic Industries Association (RIA) and Robotics Online. RIA is a not-for-profit trade association dediONLINE cated to improving the regional, nationSee additional articles from the RIA in the “robotics” section under the al, and global competitiveness of the discrete manufacturing tab on North American manufacturing and serwww.controleng.com. vice sectors through robotics and relatCONSIDER THIS ed automation. This article originally What applications would you use appeared on the RIA website. The RIA mobile robots for and how would is a part of the Association for Advancthey be beneficial? ing Automation (A3), a CFE Media content partner. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media & Technology, cvavra@cfemedia.com.

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2020

ENGINEERS’ CHOICE AWARDS

Spotlight on Innovation Best automation, control, and instrumentation products in 29 categories.

he 33rd annual Control Engineering Engineers’ Choice Awards shines a light on 29 categories of control, instrumentation and automation products, revealing the best of those introduced in 2019 as chosen by the Control Engineering print and digital audience. Review the winners and honorable mentions here to see if their innovative solutions can help resolve one of your most pressing problems. Also, join us in congratulating these technological innovators. Let them know you learned about their solutions in Control Engineering, and tell them what problems you need solutions for next. Their continuous improvement ensures that manufacturers, machine builders, and automation system integrators can achieve the levels of agility, efficiency, and effectiveness necessary to compete—and win—in today’s global economy. A total of 117 finalists from 57 companies were listed on the ballot for evaluation. Automation professionals from

Control Engineering’s subscriber lists—all of whom are responsible for or influence technology purchases, or have hands-on day-to-day interaction with the technologies in each category—then voted to identify the products they felt were the most exceptional based on technological advancement, service to the industry, and market impact. The result is a short list of Engineers’ Choice Awards winners and honorable mentions in 29 categories. A total of 1 grand winner, 29 winners and 28 honorable mentions were named for 2020. Control Engineering staff extends appreciation to all who nominated products and took the time to vote. Find more product innovations at www.controleng.com/NPE in the New Products for Engineers Database. The 2020 Engineers’ Choice Awards will be presented to the winners on April 27, 2020, in Chicago. Amanda Pelliccione is the project manager of events and awards programs for Control Engineering, CFE Media, apelliccione@cfemedia.com.

Engineers’ Choice Awards Index: 1 Grand, 29 Winners, 28 Honorable Mentions PTV terminal block, Phoenix Contact EZTouch EZ7 HMI/PLC operator interface, EZAutomation Simatic IPC1047 industrial PC, Siemens groov EPIC edge programmable industrial controller, Opto 22 Wise-710 Industrial Internet of Things gateway, Advantech UniStream PLC, Unitronics DataMan 370 fixed-mount barcode reader, Cognex Simogear KS adapter, Siemens Sinamics G120X drive, Siemens Sinamics S210 servo drive, Siemens XTS linear transport system, Beckhoff Automation Sipart PS100 electropneumatic valve positioner, Siemens VT6L all-in-one 6-axis robot, Epson America DA30D protocol converter, data acquisition system; Red Lion Controls 50 PROmesh P20 Ethernet/PROFINET switch, Indu-Sol GmbH 52 Simatic DP ET 200eco PN distributed fail-safe peripheral module, Siemens 52 ECT-DIN 2-wire output-loop powered isolator, converter; Moore Industries 45 45 45 46 46 46 46 48 48 48 48 50 50 50

52 Simatic RF615 compact UHF-RFID reader, Siemens 52 MD high-density sub-metering platform, Siemens Smart Infrastructure 53 PROtop high-end range power supply, Weidmuller 53 Sitrans P320/420 pressure transmitter, Siemens 53 Simatic PCS neo V3 distributed control system, Siemens 53 Simatic RF1000 access control badge reader, Siemens 54 Vanguard WirelessHART toxic, combustible gas detector V1.2; United Electric Controls 54 Dream Report V5.0 analytics software, Ocean Data Systems 54 Connected Components Workbench V12 machine development software, Rockwell Automation 54 Seeq R21 advanced analytical software for process manufacturing, Seeq Corp. 55 InduSoft Web Studio V8.1 + SP4, Aveva 55 KEPServerEX V6.7 industrial connectivity software, Kepware 55 CFSWorX connected field service mobile application, Iconics 56 Honorable Mentions

READ MORE ONLINE, including how to enter, at www.controleng.com/EngineersChoice.

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2020 Engineers’ Choice

GRAND AWARD

Hardware – HMI, Operator Interface, Thin-Client

Hardware – Industrial PCs, CNCs

EZTouch EZ7 HMI/PLC operator interface

Simatic IPC1047 industrial PC

EZAutomation

T PTV terminal block

Phoenix Contact

he Grand Award—first introduced with the 2017 program—is bestowed upon the product that received the most overall votes in the 2020 program. This year’s Grand Award recipient is the PTV Terminal Block from Phoenix Contact. The PTV terminal block with side wire entry connection combines the clarity of screw connection with the ease of push-in connection. This enables clearer wiring and eliminates bending of wires in confined spaces. The design also allows for much clearer marking of both the terminal block and wire. The PTV features clearly arranged wiring without bending radii, and a time-saving conductor connection, thanks to tool-free pushin direct connection technology. The connection principle and conductor routing are simple to understand. The PTV terminal block is compatible with CLIPLINE complete standard accessories, simplifying inventory requirements.

he EZTouch EZ7 HMI/ PLC operator interface has bifurcated the HMI in two parts: the front end and the back end. With the EZ7, there is no longer a need to have a panel cutout, only a ¾-in. hole with a grommet is needed to pull through an HDMI cable to connect the two. The front end and back end are stud-mounted to the control panel. The front end takes less than 2 minutes to replace without disconnecting any cables from the back end, which also allows a screen size upgrade, from 7 in. to 12 in. www.ezautomation.net Input 201 at www.controleng.com/information

Siemens

he Simatic IPC1047 industrial PC’s dual socket mainboard features Intel Xeon E5 processors, up to 2TB DDR4 RAM and high-performance graphics cards and GPUs. With its six PCIe slots (x8 and x16) and the powerful power supply unit, this rack PC can be flexibly used for many different applications. The rugged industry design and the dimensioning for 24/7 operation make the Simatic IPC1047 an ideal computer for production-related applications placing superior requirements regarding the computing and graphics performance. www.usa.siemens.com Input 202 at www.controleng.com/information

www.phoenixcontact.com/us Input 200 at www.controleng.com/information

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2020

ENGINEERS’ CHOICE AWARDS

Industrial Internet of Things Connectivity – Edge Controller

Industrial Internet of Things Connectivity – Gateway

Machine & Embedded Control – PLCs

Machine Vision, Code Readers

groov EPIC edge programmable industrial controller

Wise-710 Industrial Internet of Things gateway

UniStream PLC

DataMan 370 fixed-mount barcode reader

Opto 22

he groov EPIC edge programmable industrial controller is an embedded Linux, real-time controller with gateway functions. The groov EPIC processor provides control, connectivity, data handling, and visualization at the edge of the user’s network and is ideal for Industrial Internet of Things (IIoT) applications or any automation application. Programming options include flowcharting, secure shell access for C/C++ or other custom programs, or any familiar IEC 61131-3 compliant language and the CODESYS Development System. Users can combine any of these languages for control with many of the other software tools available in groov EPIC in order to do everything users need to on a single edge device.

Unitronics

Advantech

he Wise-710 Industrial Internet of Things gateway is an open platform with Cortex A9 processor that equipped with three RS-232/485 serial ports, two 10/100/1000 Ethernet ports, and four DI/DO in order to be an ideal solution to connect legacy equipment to the new mesh networks. All collected data to the cloud is secured by key encryption technology from an embedded security chip. With its rich I/O and wide operating temperature design, the gateway plays a role as PLCside protocol converter and data logger for multiple industrial applications. www.advantech.com Input 204 at www.controleng.com/information

he UniStream PLC is based on UniStream hardware and UniLogic software that enhances the flexibility to control all capabilities required by a user’s machine or process application. A multi-function controller that matches a vast range of application requirements, the UniStream PLC provides users with advanced communication support, including Industry 4.0, and introduces a unique concept in Virtual HMIs. The PLC stores and runs the program logic as well as the HMI user application within the PLC itself. This brings a unique advantage: users can view and operate their machine, or access their process via any mobile phone, PC, or remote display device.

Cognex

he DataMan 370 fixedmount barcode reader solves the challenging direct part mark (DPM) and label-based multi-code, multi-symbology applications using Cognex’s decoding algorithms, a multi-core processor, and integrated lighting. With twice the performance and power of conventional readers in the same class, the DataMan 370 delivers superior read performance for the broadest range of applications, including high-speed lines; difficult-to-read parts; small codes; multi-code, multisymbology applications; and multi-sided scan tunnels. www.cognex.com Input 206 at www.controleng.com/information

https://unitronicsplc.com Input 205 at www.controleng.com/information

www.opto22.com Input 203 at www.controleng.com/information

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| AT11-14USA |

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 â&#x20AC;&#x201C; 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 #16 at www.controleng.com/information

2020 WINNER

2020

ENGINEERS’ CHOICE AWARDS

Motion Control

Motion Control – Drives

Motion Control – Drives, Servo

Motion Control – Linear Transport

Simogear KS adapter

Sinamics G120X drive

Sinamics S210 servo drive

XTS linear transport system

Siemens

he Simogear KS adapter allows machine builders to add Simotics motion control servo motors to Simogear gearboxes—including helical, helical bevel (2 and 3 stage), helical worm and parallel shaft—to create Simogear servo gear motors. The KS adapter replaces the former KQ, KQS, K8 and KF adapters for simpler engineering and ordering. The resulting servo gear motors are more compact and have a zero-backlash coupling that simplifies mounting. Sizing and selection are available in the Siemens DT Configurator. www.usa.siemens.com Input 207 at www.controleng.com/information

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Siemens

he Sinamics G120X drive can be used with any standard or synchronous reluctance motor and a wide choice of circuit breakers, motor starter protectors and fuses. It’s compact design with an integral DC choke improves harmonics and EMC performance, eliminating the need for a line reactor that also allows integration into smaller spaces, like motor control centers. A Class 3C3 coating enables operation in harsh environments where corrosive gases are present. The G120X offers a comprehensive range of built-in application-specific functions for pumps and fans to ensure improved energy efficiency.

Siemens

he Sinamics S210 servo drive is capable of a full range of safety integrated functions, including Safe Stop 1, Safe Limited Speed, Safe Direction, Safe Brake Control and Safe Brake Test. In conjunction with a failsafe controller and failsafe network, all drive-based safety functions can be activated via PROFIsafe protocol over PROFINET. The 22-bit safety encoder on the Simotics 1FK2 servo motor easily connects to the S210 drive with the One Cable Connection, which includes the motor power and brake signal for simple installation. www.usa.siemens.com Input 209 at www.controleng.com/information

Beckhoff Automation

he XTS (eXtended Transport System) linear transport system offers paradigm-shifting capabilities for motion control and mechatronics by combining the advantages of proven rotary and linear drive principles into a modular platform. With its compact and flexible design, the advanced mechatronic system can reduce machine footprint up to 50%. The XTS revolutionizes drive technology and promotes innovative, globally competitive machine concepts. Movers can accelerate, brake, position and synchronize themselves on the fly with automatic collision avoidance provided by TwinCAT 3 software.

www.usa.siemens.com

www.beckhoffautomation.com

Input 208 at www.controleng.com/information

Input 210 at www.controleng.com/information

control engineering

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The next level of innovation in control panel wiring PTV: Push-in Technology with side-entry wiring New PTV terminal blocks from Phoenix Contact combine the fast, simple, and reliable connection of Push-in Technology with the compact and clearly visible sideentry wiring orientation of a common screw connection. This new technology unites the ease-of-use of Push-in Technology with the clear marking capabilities and standard wire routing of screw connections, giving you the best of both worlds. For additional information, call (800) 322-3225 or visit www.phoenixcontact.com/PTV

ÂŠ PHOENIX CONTACT 2020

input #17 at www.controleng.com/information

2020

ENGINEERS’ CHOICE AWARDS

Motion Control – Pneumatics

Motion Control – Robots, Robotics

Network Integration – Data Acquisition

Network Integration – Ethernet Hardware, Switches

Sipart PS100 electropneumatic valve positioner

VT6L all-in-one 6-axis robot

DA30D protocol converter, data acquisition system

PROmesh P20 Ethernet/ PROFINET switch

Siemens

he Sipart PS100 electropneumatic positioner can be initialized quickly at the touch of a button, automatically adjusting itself to the attached valve. If required, it is possible to optimize the positioner for a specific application with just one further touch of a button. Just as some cameras feature portrait, sport or night mode, the positioner can be set to different modes for precise and fast adjustment, open/close operation and other applications. These functionalities save time, cut the costs of commissioning, and increase the return on investment. The Sipart PS100 is fitted with a large, easy-to-read display that allows users to see the status of the device at a glance.

Epson America

he VT6L all-in-one 6-axis robot is ideal for simple parts transfer applications such as machine-tool and injection molding load/ unload, pick-and-place, dispensing and simple assembly projects. The all-in-one design with built-in controller saves on valuable factory space while its SlimLine structure, featuring a compact wrist pitch, enables access to hard-to-reach areas in confined spaces. This innovation opens a world of application opportunities due to its incredible price and ease of use. Many applications that were too costly to implement with standard 6-axis robots, are now possible.

Red Lion Controls

he DA30D protocol converter and data acquisition system is designed to act as a nexus for next-generation industrial data collection and management. Built-in MQTT connectors accelerate Industrial Internet of Things projects with point-and-click simplicity, while the embedded OPC UA server functionality eliminates the need for separate system hardware to gather and exchange data with upstream systems. The optional SQL queries capability simplifies activities like quality control, production scheduling, and batch and recipe management.

Indu-Sol GmbH

he PROmesh P20 is a full managed Ethernet/ PROFINET switch that is designed to be used directly after the controller. Four of its 20 ports are conducted as SFP slots that offer an additional level of flexibility because the corresponding SFP modules are available in a wide variety of copper and optical fiber versions. Due to increasing networking, new demands are being made on data security and access rights. This is why the PROmesh P20 has a router function that allows users to separate devices connected to the switch from the rest of the network.

www.redlion.net

www.indu-sol.com

Input 213 at www.controleng.com/information

Input 214 at www.controleng.com/information

https://epson.com Input 212 at www.controleng.com/information

www.usa.siemens.com Input 211 at www.controleng.com/information

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PROtop power supplies

The power boost for your production environment High performance, when you need it Ideal for Machinery

Ideal for Power

• High pulse reserves for starting motors quickly and safely

• 30% space-saving

Innovative DCL technology

Integrated ORing MOSFETS

• Excellent peak load reserves up to 600%

• Extremely reliable triggering of circuit breakers

• Direct parallel redundancy without an external diode module

• Reduced installation and wiring effort

2020 WINNER

Let’s connect. www.weidmuller.com/protop input #18 at www.controleng.com/information

2020

ENGINEERS’ CHOICE AWARDS

Network Integration – I/O Systems

Network Integration – Signal Conditioning

Network Integration – Wireless

Power – Energy, Power Protection

Simatic DP ET 200eco PN distributed fail-safe peripheral module

ECT-DIN 2-wire output-loop powered isolator, converter

Simatic RF615 compact UHF-RFID reader

MD high-density submetering platform

Moore Industries

Siemens

he Simatic DP ET 200eco PN distributed fail-safe peripheral module is a compact PROFINET IO device in the degree of protection IP65/66 respectively IP67. For indoor use only. The fields of application of the failsafe ET 200eco PN F are derived from its special properties. A robust design and degree of protection IP65/66 or IP67 make the ET 200eco PN F distributed I/O device particularly suitable for use in harsh industrial environments. The compact structure of ET 200eco PN F allows its operation in confined areas. The easy handling facilitates efficient commissioning and maintenance.

he ECT-DIN 2-wire output-loop powered isolator and converter features a solid metal housing that stands up to the continuous, daily rigors of process control and factory automation applications. The thin, 15-mm wide aluminum housing is general and hazardous area approved, has RFI/EMI protection and an operating temperature range of -40 to 85°C. The narrow design allows more isolators to fit in cabinets and field enclosures where installation space is a premium. www.miinet.com Input 216 at www.controleng.com/information

www.usa.siemens.com Input 215 at www.controleng.com/information

Siemens

he Simatic RF615 compact UHF-RFID reader features an overall footprint approximately 1/4th of previous Siemens readers, allowing for use in more confined areas. The reader provides increased manufacturing and production traceability through accurate and reliable radio frequency identification (RFID) tag reads. Features of the Simatic RF615 include internal and external antennae for increased flexibility and accuracy, a user-friendly web browser configuration for fast and easy commissioning and diagnosis, multiple communication protocols supported (Ethernet TCP/ IP, PROFINET, EtherNet/IP, PROFIBUS), external LED lighting to indicate accurate reads and current status, and an operating temperature range of -25 to 55°C.

Siemens Smart Infrastructure

he MD high-density sub-metering platform is a combination of networked electrical submetering instruments and advanced BACnet and Modbus protocol electrical power sub meters. These meters are compatible with all building management systems, being approved as a BACnet Testing Labs certified smart sensor (B-SS) device. The MD-12HD provides 12 CT inputs; equivalent to four 3-phase meters. The MD-48HD provides 48 CT inputs; equivalent to 16 3-phase meters. The MD high-density sub-metering platform is optimized for use in equipment rooms, multifamily housing, data centers and other high metering load measurement areas. https://usa.siemens.com/ buildingtechnologies Input 218 at www.controleng.com/information

www.usa.siemens.com Input 217 at www.controleng.com/information

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February 2020

control engineering

www.controleng.com

Power Supply, UPS

Process control – Process Sensors, Transmitters

Process Control Systems

Safety – Machine Safety

PROtop high-end range power supply

Sitrans P320/420 pressure transmitter

Simatic PCS neo V3 distributed control system

Simatic RF1000 access control badge reader

Weidmuller

he PROtop high-end range power supply features dynamic current limiting (DCL) technology for the most demanding of applications. With DCL technology, PROtop offers dynamic controlled output for the reliable triggering of circuit breakers and powerful motor starts. With an MTBF higher than 1 million hours, operational temperature range of -40 to 70°C, impact resistance of 30g and approvals ATEX and Class 1 Div. 2, PROtop covers all demands of a permanent and efficient power supply. PROtop is equipped with an integrated redundancy O-ring, reduces potential failure points, saves space and increases installation performance.

Siemens

eatures of the Sitrans P320/420 pressure transmitter include an advanced display, showing the device’s measurements and status at a glance. The setup is convenient and intuitive thanks to a large LCD with clear text and icons, four-button menu navigation, and a quick start wizard. The instrument’s remote safety handling via Simatic PDM saves time during SIL commissioning: rather than manually configuring each individual device across a facility, operators can program transmitters from the control room. The transmitter has increased proof test intervals over other devices, significantly lowering maintenance costs by allowing for testing periods of up to 15 years.

www.weidmuller.com

www.usa.siemens.com

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Input 220 at www.controleng.com/information

Siemens

he Simatic PCS neo V3 is an innovative distributed control system (DCS) that brings benefits to engineers and operators in the form of mobility, usability, and collaboration. By leveraging web-based technologies, users can access the control system from any device, such as laptops or tablets, without installing local DCS software and licenses. The system opens up opportunities in engineering by allowing multiple users to work on the same project at the same time from any location. The intuitive user interface has one common workbench for all DCS applications to facilitate efficient engineering for both new users and experts. www.usa.siemens.com Input 221 at www.controleng.com/information

Siemens

ith the Simatic RF1000 access control badge reader, Siemens provides an RFID-based solution that enables simple and versatile implementation of electronic authorization management. Existing employee ID provides the basis for identification, which increases user friendliness and minimizes costs. The Simatic RF1000 allows realization of finely-graded access concepts, documentation of processes or storage of user-specific instructions to be stored— according to the customerspecific application. Features include increased HMI and machine security and traceability, a compact footprint and integrated antenna, USB or RS232 communication options, an external LED light to indicate accurate reads, and operating temperature range of -25 to 55°C. www.usa.siemens.com Input 222 at www.controleng.com/information

www.controleng.com

control engineeering

February 2020

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2020

ENGINEERS’ CHOICE AWARDS

Safety – Process Safety, Intrinsic Safety

Software – Asset Management, Reporting

Software – Control Design

Software – Data Analytics

Vanguard WirelessHART toxic, combustible gas detector V1.2

Dream Report V5.0 analytics software

Connected Components Workbench V12 machine development software

Seeq R21 advanced analytical software for process manufacturing

Ocean Data Systems

United Electric Controls

he Vanguard WirelessHART toxic and combustible gas detector V1.2 has a 5-year battery life and is intended to augment gas detection coverage for brownfield and greenfield sites with minimum financial outlay and maintenance. Vanguard can improve monitoring capability at 10% of the cost of a wired system. The Vanguard is easy to operate and calibrate. It is interoperable with existing WirelessHART networks and asset management systems and can be dropped anywhere in the mesh network to provide an instant gas monitoring point. This is all done without the hassle and cost of running power and signal wires. www.ueonline.com

ream Report V5.0 software is taming that ocean of data with industrial reports and dashboards for every market. This software is a programming-free, user-friendly, automated reporting and data analysis platform designed specifically for industrial automation applications. It is designed to be the simplest solution for extracting data from virtually any data source and Dream Report will provide automated reports to anybody, anywhere and anytime. Dream Report fits for all types of reporting, from compliance to performance, efficiency, and maintenance reporting in discrete, hybrid and process automation markets. http://dreamreport.net Input 224 at www.controleng.com/information

Input 223 at www.controleng.com/information

Rockwell Automation

achine designers can develop a wider range of standalone machines and save time in the process using Connected Components Workbench V12 machine development software. With added simulation and trending features, Rockwell Automation has expanded the number of devices that the designand-configuration software supports to speed up development. A Micro800 Simulator can help designers program and refine their machine applications more quickly. Instead of having to connect to a physical controller, designers can create, test and debug their application code in a simulated environment without the hardware. The simulator can also be used for machine training and demonstrations.

Seeq Corp.

eeq R21 is advanced analytical software for process manufacturing data. With Seeq, users can work together to analyze data and publish insights from OSIsoft PI, Honeywell PHD, GE Proficy, and other historians. By leveraging recent innovations in big data and machine learning technologies, Seeq makes any type of analytics faster. The result is shorter times between investigation, decision making, and impact, plus predictive analytics to address issues before they occur. With Seeq’s publishing features, employees across the organization get access to the insights they need to deliver continuous improvements in quality, yield, and asset availability metrics. www.seeq.com Input 226 at www.controleng.com/information

www.rockwellautomation.com Input 225 at www.controleng.com/information

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February 2020

control engineering

www.controleng.com

New Products for Engineers Get coverage in CFE Media websites, Software – HMI Software

Software – Industrial Internet of Things Connectivity

Software – Mobile Apps

newsletters and magazines through New Products for Engineers

InduSoft Web Studio V8.1 + SP4 Aveva

KEPServerEX V6.7 industrial connectivity software Kepware

CFSWorX connected field service mobile application Iconics

(NPE), a CFE Technology database for new products appropriate for subscribers of

nduSoft Web Studio V8.1 + SP4 is a platform agnostic SCADA/HMI development and runtime software that incorporates all the tools users need to create SCADA and HMI applications, business intelligence dashboards, and OEE solutions. With runtimes available for multiple operating systems, InduSoft Web Studio can create powerful IIoT applications that can be deployed on smallfootprint embedded devices and accessed remotely from mobile devices, such as tablets, smartphones, and wearable gadgets. Over 250 communication drivers, in addition to support to standards and patented solution for database connectivity, make it easy to integrate sensors, controllers, ERP systems, and cloud analytics into a smart solution that can be accessed anywhere. www.indusoft.com

EPServerEX V6.7 industrial connectivity software makes it easier to connect to all industrial automation assets via a single, secure application. Enhanced connectivity for manufacturing and features for secure server deployment allows enterprises to standardize industrial communications on KEPServerEX. KEPServerEX’s breadth of connectivity, reliability, and security features empower engineers to focus on process efficiencies and product improvement. KEPServerEX includes advanced security enhancements to address the rising rate of cyber-attacks on operations networks. To combat the risk of IP theft, downtime, and comprised safety, among other threats, PTC has expanded and enhanced its secure remote configuration tools.

he CFSWorX connected field service mobile application is a solution designed to streamline the efficiency of field service organizations through intelligent scheduling and reliable notifications. It empowers field service workers and maintenance personnel to move past the legacy break/fix model towards more proactive facilities and equipment management. This enables organizations in any industry to reduce downtime and lower maintenance costs. It provides real-time monitoring of connected equipment, on-premises or via the Internet of Things. With an alarm or faulted state, CFSWorX uses intelligent algorithms and a customizable weighted scoring system to determine which field worker is best for the maintenance task and then notifies the field worker’s mobile device for action.

www.kepware.com

www.iconics.com

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Input 229 at www.controleng.com/information

Input 227 at www.controleng.com/information

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control engineeering

Control Engineering and other CFE Media supplements and publications: Applied Automation, IIoT for Engineers, Oil & Gas Engineering, Pure Power, Plant Engineering, and ConsultingSpecifying Engineer. The NPE database uses a detailed taxonomy to automatically feed new products to appropriate areas of our websites and newsletters, and it serves products for print and digital editions and awards programs.

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

February 2020

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2020

ENGINEERS’ CHOICE AWARDS

Honorable Mentions Hardware – HMI, Operator Interface, Thin-Client

Graphite 12.1-in. outdoor HMI Red Lion Controls

Machine & Embedded Control – PLCs

PLCnext programmable logic controller Phoenix Contact

The Graphite 12.1-in. outdoor HMI offers a UV-protected brilliant display with widescreen format 1280 x 800 resolution, making it easily viewable even in direct sunlight. www.redlion.net Input 230 at www.controleng.com/information

PLCnext technology is completely open, enabling users to directly access the core of the product via Linux, which provides virtually limitless creative freedom to leverage the open-source community or develop individual Linux-based applications from the ground up.

Hardware – Industrial PCs, CNCs

www.phoenixcontact.com/us Input 234 at www.controleng.com/information

MIC-770 compact, fanless industrial PC Advantech

Machine Vision, Code Readers

Geva 400 multiple camera vision system Teledyne DALSA

The MIC-770 compact, fanless industrial PC provides flexible expansion capability and excellent computing through the Intel 8th generation Core i socket type processor, dual channel DDR4 memory, optional I/O modules and unique Advantech i-module products.

Equipped with a low power, quad core processor and high-speed system resources, the GEVA 400 effectively manages multi-camera acquisition and processing. www.teledynedalsa.com Input 235 at www.controleng.com/information

www.advantech.com Input 231 at www.controleng.com/information

Industrial Internet of Things Connectivity – Edge Controller

Sinumerik Edge machine tool application Siemens Sinumerik Edge is a platform to run applications for data acquisition, pre-processing and analysis directly at the CNC machine; it contains dedicated pre-installed hardware and MindSphere cloud applications.

Motion Control

Kinetix VPH hygienic servo motor Rockwell Automation Designed to help tackle the growing standards for food safety, the Kinetix VPH hygienic servo motor provides a full wash-down and hygienic design that meets IP69K and NSF. www.rockwellautomation.com Input 236 at www.controleng.com/information

www.usa.siemens.com Input 232 at www.controleng.com/information

Industrial Internet of Things Connectivity – Gateway

Simatic PN/J1939 Link gateway Siemens

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February 2020

GA800 variable-speed drive Yaskawa America Designed to control traditional and emerging motor technologies through 600 HP, the GA800 variable-speed drive handles applications ranging from simple fans and pumps to high performance test dynamometers requiring precise regulation.

The Simatic PN/J1939 Link gateway integrates seamlessly in a PROFINET network and enables data exchange between this network and the fieldbus SAE J1939, enabling communication with up to 253 logical nodes.

Motion Control – Drives

www.usa.siemens.com

https://yaskawa.com

Input 233 at www.controleng.com/information

Input 237 at www.controleng.com/information

control engineering

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Motion Control – Drives, Servo

Network Integration – Data Acquisition

Kinetix 5100 servo drive Rockwell Automation

ELM314x Economy EtherCAT measurement module Beckhoff Automation

The Kinetix 5100 servo drive offers a comprehensive power range solution (50 to 2,000 W at 100 to 200 V) to support stand-alone applications and can easily be used with Micro 800 or CompactLogix controllers.

The ELM314x Economy EtherCAT measurement module allows high-precision measurements with 100 ppm accuracy over a wide temperature range at low channel costs.

www.rockwellautomation.com

www.beckhoffautomation.com

Input 238 at www.controleng.com/information

Input 242 at www.controleng.com/information

Motion Control – Linear Transport

Network Integration – Ethernet Hardware, Switches

MagneMover Lite transport system Rockwell Automation The MagneMover Lite system rapidly moves products in carts along a motorized track, making a flexible system that reduces downtime by allowing changeovers with the push of a button—no mechanical intervention. www.rockwellautomation.com

P2M industrial Ethernet node Parker Hannifin – Motion Systems Group The P2M industrial Ethernet node provides the opportunity for customers with traditionally hardwired networks to migrate to an Ethernet solution that is intuitive, easy to use, install and maintain. www.parker.com

Input 239 at www.controleng.com/information

Motion Control – Pneumatics

Input 243 at www.controleng.com/information

Network Integration – I/O Systems

BPGS pneumatic gripper system Bimba

Flex 5000 discrete safety I/O module Rockwell Automation

The BPGS pneumatic gripper system features a high gripping force that allows for picking up large heavy objects in the most demanding environments. www.bimba.com Input 240 at www.controleng.com/information

The Flex 5000 I/O is a rugged and flexible distributed I/O solution that introduces discrete safety I/O modules to meet unique fail-safe application requirements in process and heavy industries. www.rockwellautomation.com Input 244 at www.controleng.com/information

Motion Control – Robots, Robotics Network Integration – Wireless

Robotiq Sanding Kit Universal Robots

Tosibox Lock 150 industrial router Tosibox Oy

The Robotiq Sanding Kit reduces programming time from hours to minutes, automating sanding tasks the easy way, and covers a wide range of product finishes. www.universal-robots.com Input 241 at www.controleng.com/information

The Tosibox Lock 150 provides a nearly 70% increase in encrypted throughput while continuing to provide ethernet and WiFi connectivity. www.tosibox.com Input 245 at www.controleng.com/information

www.controleng.com

control engineeering

February 2020

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2020

ENGINEERS’ CHOICE AWARDS

Honorable Mentions Power – Energy, Power Protection

Safety – Machine Safety

Varitector PU II UL surge protection device Weidmuller

outdoorScan3 outdoor safety laser scanner Sick The outdoorScan3 outdoor safety laser scanner uses the patented outdoor-safe HDDM technology to implement high-precision measurement data for reliable use, even under challenging weather conditions.

The Varitector PU II UL surge protection device enables the Varitector PU product concept to be transferred to systems for the North American market.

www.sick.com Input 250 at www.controleng.com/information

www.weidmuller.com Input 246 at www.controleng.com/information

Power Supply, UPS

Safety – Process Safety, Intrinsic Safety

SCS 24Vdc P1SIL3 I safety relay Weidmuller

5P lithium-ion uninterruptible power system Eaton The 5P lithium-ion uninterruptible power system provides a dependable, integrated solution with enhanced network security, extended battery life and remote management. www.eaton.com Input 247 at www.controleng.com/information

Process control – Process Sensors, Transmitters

Rosemount 5300 level transmitter Emerson

The SCS 24Vdc P1SIL3 I safety relay is suitable for switching safety-related circuits up to SIL3 level according to IEC 61508, for highrisk installations. www.weidmuller.com Input 251 at www.controleng.com/information

Software – Asset Management, Reporting

XLReporter V14.0 reporting software SyTech

The Rosemount 5300 level transmitter is ideal for challenging measurements on liquids, slurries, and solids, offering state-ofthe-art reliability and safety features in level and interface applications.

XLReporter V14.0 propels users to “Go Beyond Excel” by taking the best of spreadsheet functionality and delivering to an industrial environment securely, efficiently and with around-the-clock robustness.

www.emerson.com

www.sytech.com

Input 248 at www.controleng.com/information

Input 252 at www.controleng.com/information

Software – Control Design Process Control Systems

ControlEdge PLC R151 Honeywell Process Solutions The ControlEdge PLC R151 controller reduces configuration, integration and support costs while decreasing risk with advanced cybersecurity. www.honeywellprocess.com/en-US Input 249 at www.controleng.com/information

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February 2020

control engineering

Smart Commissioning Emerson Automation Positively impacting the overall certainty of project execution, Smart Commissioning helps automation projects meet strict and shifting deadlines. www.emerson.com Input 253 at www.controleng.com/information

www.controleng.com

Software – Data Analytics

Software – Industrial Internet of Things Connectivity

TwinCAT 3 Scope software with OPC UA integration Beckhoff Automation TwinCAT 3 Scope software with OPC UA integration provides optimum support for integrated data acquisition across heterogeneous system environments. www.beckhoffautomation.com Input 254 at www.controleng.com/information

Honeywell Forge for Industrial enterprise performance management software Honeywell Process Solutions Honeywell Forge for Industrial enables enterprise performance management that delivers actionable recommendations for intelligent operations and profitability using real time intelligent models and visual analytics. www.honeywellprocess.com/en-US Input 256 at www.controleng.com/information

Software – HMI Software Software – Mobile Apps

ThinManager V11.0 thin client management software Rockwell Automation ThinManager V11.0 thin client management software allows control and security in a sustainable and scalable platform regardless of the size of an industrial environment or number of facilities.

WIN-911 V4.19.17 alarm notification mobile application WIN-911 Software The WIN-911 V4.19.17 alarm notification mobile application that lets users receive and respond to industrial alarm conditions in real-time on their Apple or Android smartphone or tablet. http://win911.com

www.rockwellautomation.com

Input 257 at www.controleng.com/information

Input 255 at www.controleng.com/information

How to enter the competition

et a head start on the 2021 Engineers’ Choice Awards program by listing your products in the New Products for Engineers database (www.controleng.com/NPE) and completing the entry

form on the Awards Programs tab of your company’s vendor/manufacturer profile. All product nominations, including supporting materials and payment, are conveniently submitted through the database. Submit a new or significantly modified hardware, software or combination of the two introduced and available in North America from November 2019 through October 2020 for the 2021 awards. The product details provided should be factually convincing and clearly differentiate benefits in the voting criteria: technological advancement, service to the industry, and market impact. (Hint: We observe that engineers often appreciate quantified benefits more than adjectives.) Typically, 85 to 120 products are nominated, with 3 to 10 products in each category. One winner from each subcategory is selected based on subscriber votes. For the 2020 awards, 119 products from 57 companies (or major divisions) were nominated in 29 categories, resulting in one Grand Award to one company (with the highest number of votes among all categories), 29 Engineers’ Choice Awards to 20 companies (highest number of votes in that category) and 28 Honorable Mentions to 20 companies (second highest number of votes in that category).

www.controleng.com

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February 2020

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2020

ENGINEERS’ CHOICE AWARDS

Automation design advice: Create smarter products Automation product design, system integration, and application advice follows from some of the 2020 Engineers’ Choice winners.

hose recognized in the 2020 Control Engineering Engineers’ Choice Awards were asked to offer automation, control, or instrumentation design advice. Expert tips from Emerson, InduSol, Opto 22, Siemens, and Tosibox follow on advanced level sensing, connecting information technology (IT) and operational technology (OT), open-source automation, energy saving meters, and user interface design.

Advanced level technology

Christoffer Widahl is manager of solutions management, Emerson. The ability to accurately measure an interface level, when a vessel contains two immiscible liquids such as oil and water, is vital in separation process applications, as it helps prevent costly cross-contamination when the liquids flow into independent channels. One of the most widelyapplied solutions in interface level measurement applications, such as separators, is guided wave radar (GWR), which provides a number of advantages over other technologies. GWR provides accurate and reliable measurements in vessels of all sizes. No compensation is required when there are changes in the density, dielectric constant or conductivity of the fluid, while changes in pressure, temperature and most vapor space conditions have no impact on its measurement accuracy. In addition, GWR devices also are easy to install and need minimal maintenance because they have no moving parts. GWR transmitters are based on microwave technology. The probe of the transmitter extends to the full depth of the vessel, and a low-energy pulse of microwaves is guided down the probe. At the surface of the upper liquid level, a significant proportion of the microwave energy is reflected up the probe to the transmitter, which measures the time delay between the transmitted and received echo signal. An onboard microprocessor then calculates the distance to the liquid surface. As a proportion of the pulse continues down the probe, a second echo can then be detect-

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ed from the interface between the two liquids. This enables the device to accurately measure the interface level.

Design advice for connecting IT and OT

Christian Wiesel is with marketing and public relations, Indu-Sol GmbH. The more IT systems and the machine/plant level OT systems are connected, the more data traffic is expected to occur in the network. It also becomes more difficult to identify the routes data takes through the network and recognizing critical changes in the network status. In Ethernet-based networks, like Profinet where Profinet traffic and non-Profinet traffic are mixed, sporadic and unpredictable events are likely to occur. Availability, security and performance of Ethernet-based industrial networks are influenced by the kind of network switches used. On a capital cost basis, unmanaged Ethernet switches are selected for many machines and systems. These

Opto 22’s groov EPIC is built on open technologies like Linux and MQTT to support a future that can share more and do more. The groov EPIC controller won a 2020 Engineers’ Choice Award in the Industrial Internet of Things Connectivity – Edge Controller category. Courtesy: Opto 22 control engineering

February 2020

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2020

ENGINEERS’ CHOICE AWARDS The more information technology (IT) and operational technology (OT) are connected, the more attention network infrastructure requires, especially to the switches. Indu-Sol’s PROmesh P20 functions as a distribution layer switch in the Industrial information technology (IIT) level. That product won a 2020 Engineers’ Choice Award in the Network Integration – Ethernet Hardware, Switches category. Courtesy: Indu-Sol GmbH

switches are cheap to buy, but only provide a limited range of functions and can increase risk, adding lifecycle costs. For example, the port statistics unmanaged switches determine cannot be retrieved and are worthless. Unmanaged switches are not detected during a topology scan and are therefore may be overlooked in network or cybersecurity documentation. They can sometimes even negatively affect network communication by not supporting certain protocol-typical functions (such as for Profinet). Unmanaged switches cannot be integrated in the hardware configuration either: If an unmanage switch fails, the programmable logic controller (PLC) does not receive a diagnostic message. Using managed switches makes network management much easier. They offer many possibilities for device and port configuration, as well as activating additional functions, such as port mirroring, bandwidth control or redundancy support. They also supply important information for diagnostics, such as errors, discards and network load. In interface level measurement applications, the Rosemount 5300 Guided Wave Radar Level Transmitter from Emerson enables the minimum detectable thickness of the upper liquid layer to be reduced to 25 mm to optimize separation process efficiency. It received 2020 Engineers’ Choice recognition in the Process control – process sensors, transmitters category. Courtesy: Emerson

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February 2020

control engineering

Five automation design tips for the future

Josh Eastburn is director of technical marketing, Opto 22. The following five design tips can help in selecting and integrating automation devices and systems. 1. Open source: Many human-years have been expended in developing features for closed operating systems where mature open-source solutions already exist. Open-source fosters innovation by lowering barriers to entry and increasing the size of the talent pool. With lower licensing restrictions, designers can try out new technologies with very low risk. They also become part of a community of developers working on other interesting projects. Projects can be tapped to create new customer opportunities. 2. Lower capital costs: Lower up-front investment also provides the flexibility to pick up and put down feature development as priorities change. As a vendor, you never know for sure which features are going to hit, so the flexibility to try things out and deliver new features increases the chances of success. With an open environment and off-the-shelf components, product development can focus on outcomes for customers rather than reinventing a proprietary wheel. 3. Easy evolution: As the industry evolves, customers will look to solutions that can evolve. 4. Multiple vendors: The need for openness should also impact the designer’s choice about the standards they support in the products being www.controleng.com

designed or retrofit. In a connected future, it doesn’t make sense to play in a sandbox built for only one vendor. 5. Cybersecurity: Connection also demands security. Future-ready products have to operate in a larger arena than ever before. It is a world where every actor is not a known entity, and where the threat of a cyberattack is increasing. Enterprise-grade opensource security standards are available. Why not take advantage of them?

Three energy meter selection tips

Drew Knobloch is senior product manager, Siemens. For many customers, the only measure of energy usage is a utility bill, which is an aggregate of all energy consumed within a building. The first step to learn more about energy usage in a building or facility may be an energy audit. This gives the customer a view into the overall energy usage of the facility, a breakdown of which circuits are using the most energy, and when the usage is heaviest. Once the existing usage is understood, the customer can use this data to create targeted programs that reduce usage in specific areas such as lighting, HVAC, or upgrades to building efficiency. When selecting an energy meter, ask: 1. How long will data collection occur? If the need is temporary, selecting a simple data logging device may be enough. However, there’s need to collect data over a period of months, a permanent installation may be the answer. 2. How many phases need to be measured, and what accuracy is needed? Select a meter with enough capacity to monitor all the loads and phases that are needed. If data will be used for billing purposes, a meter and current transformers with higher accuracy may be needed. 3. How should data be collected? The two primary methods are individual collection and integration into a building automation system. For one meter, it may be adequate to download the data on a periodic basis over a USB, wi-fi or Ethernet connection. For larger installations, a direct interface with the building automation system via BACnet or Modbus can continuously retrieve energy data for analysis.

Building the perfect user interface

Petteri Hämäläinen is product manager, Tosibox Oy. Quite often, product design fails when the development team: 1. Does not understand the differences between novice and expert users well enough. Especially in corporate products, expert users are often the pri-

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MD Series High Density Networked Power Metering System with BACnet or Modbus Protocols from Siemens Smart Infrastructure is optimized for use in equipment rooms, multi-family housing, data centers and other high metering load measurement areas. It won a 2020 Engineers’ Choice Award in the Power – Energy, Power Protection category. Courtesy: Siemens

mary user group and user interfaces allow use cases that results in misbehavior of the product, or in worst case in error. This causes frustration among beginners and lower satisfaction level. With user interface design, presume all users are novices when logging in to the user interface for the first time. Modern user interfaces have views Tosibox Lock 150 that combine related objects and data in one brings a simple soluplace. These views provide a logical way to manage tion to the industrial and group data for users. If the product has tasks automation and buildthat must be completed in sequence, a wizard-like ing automation sectors approach is often worth considering. to better manage and 2. Ignores cultural differences among various build remote IoT conuser groups. Using colors should be considered trol operations. The very carefully as colors and symbols can be interLock 150 industrial preted differently depending on the user’s cultural router from Tosibox background. received recognition 3. Ignores physical differences among users. in the 2020 Engineers’ Physical disabilities also limit users’ capabilities to Choice Network Inteinterpret user interfaces. For example, some form gration – Wireless of color blindness is surprisingly common, about category. Courtesy: 1 to 10% of population depending on cultural Tosibox Oy background. Therefore, using only colors to indicate information is strictly a bad design decision. Colors should always be combined with form or size to make the difference clear. KEYWORDS: Industrial automation, 4. Overlooks language as an obvidesigning controls ous reason for difficulties. Not everyInterface liquid level measurement one studies other languages. Supporting has challenges. the native language of users is a crucial Connections between IT and OT are requirement. At minimum, versions in increasing. some of the most common languages Interoperability means integrating multiple vendors should be considered. InternationalizaEnergy measurement needs are tion and localization support are built-in application dependent. in most software libraries these days. User interface designs should The biggest mistake is making consider differences in skill levels. assumptions not based on knowledge. CONSIDER THIS Presuming too much is the mother of all Are you thinking about how failures. ce

M More INNOVATIONS

customers when designing products?

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

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

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Publication Services

Oriental Motor . . . . . . . . . . . . . . . . .18 . . . . . . . . .11 . . . . . . .www .orientalmotor .com

Jim Langhenry, Co-Founder/Publisher, CFE Media JLanghenry@CFEMedia.com

Phoenix Contact . . . . . . . . . . . . . . .49 . . . . . . . . 17 . . . . . . .www .phoenixcontact .com/PTV

Steve Rourke, Co-Founder, CFE Media SRourke@CFEMedia.com

SEW-EURODRIVE, Inc . . . . . . . . . . .13, C4 . . . . 8, 20 . . . . . .www .seweurodrive .com

Laura Prochaska, Marketing Services Manager (773) 818-7771, LProchaska@CFEservices.com

Stratus . . . . . . . . . . . . . . . . . . . . . .15 . . . . . . . . . 9 . . . . . . . .www .stratus .com Weidmuller . . . . . . . . . . . . . . . . . . .51 . . . . . . . . 18 . . . . . . .www .weidmuller .com Yaskawa America, Inc . . . . . . . . . . .C3 . . . . . . . . 19 . . . . . . .www .yaskawa .com

Aerotech Inc . . . . . . . . . . . . . . . . . .M7 . . . . . . . 15 . . . . . . .www .aerotech .com Control Engineering eBook Series 2020 . . . . . . . . . . . . .M12 . . . . . . . . . . . . . . . .www .controleng .com/ebooks Control Engineering Webcasts . . . . . . . . . . . . . . . . . . . . .M14, M17 . . . . . . . . . . . .www .controleng .com/webcasts WAGO Corp . . . . . . . . . . . . . . . . . . .M3 . . . . . . . 14 . . . . . . .www .wago .us

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

•

February 2020

Courtney Murphy, Marketing and Events Manager cmurphy@cfemedia.com Brian Gross, Marketing Consultant, Global SI Database 630-571-4070, x2217, BGross@CFEMedia.com Michael Smith, Creative Director 630-779-8910, MSmith@CFEMedia.com Paul Brouch, Director of Operations PBrouch@CFEMedia.com

Inside Machines

McKenzie Burns, Marketing and Events Manager mburns@cfemedia.com

control engineering

Michael Rotz, Print Production Manager 717-766-0211 x4207, Fax: 717-506-7238 mike.rotz@frycomm.com Maria Bartell, Account Director, Infogroup Targeting Solutions 847-378-2275, maria.bartell@infogroup.com Rick Ellis, Audience Management Director 303-246-1250, REllis@CFEMedia.com Letters to the editor: Please e-mail us your opinions to MHoske@CFEMedia.com or fax 630-214-4504. Letters should include name, company, and address, and may be edited. Information: For a Media Kit or Editorial Calendar, go to www.controleng.com/mediainfo. Marketing consultants: See ad index. Custom reprints, electronic: Shelby Pelton, Wright’s Media, 281-419-5725 x138, cfemedia@wrightsmedia.com

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input #19 at www.controleng.com/information

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seweurodrive.com | 864-439-7537 input #20 at www.controleng.com/information