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Skills needed to advance Engineering

66% Project management

54%

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Communication/presentation Computer

45%

Team-building

39% 33%

Marketing/sales Language

15%

Finance

13% 9%

Recruitment

24-30 COVER: Control Engineering Career and Salary Survey, 2020, asked respondents what skills they needed to succeed. See Career Update section, pages 24-30. The background image, courtesy of Emerson, is Solvay’s PVC polymerization plant at Tavaux, France, which has deployed Emerson’s DeltaV process control software and systems.

INSIGHTS 6 | Research: Poll results, week 2: Doubled adverse COVID-19 impacts 8 | Technology Update: Power conditioning to match power quality environment 12 | Integrator Update: 10 ways manufacturers can add COVID-19 preparedness Technology Updates 14 | How to operate manufacturing remotely 16 | Essentials of remote monitoring and control for operations 18 | How to quickly start a robotic pick-andplace application 19 | MESA smart manufacturing model to detail 8 areas 21 | Rugged smart wireless devices improve smart cities COVID-19 impacts 6, 12, 14, 16, 22, 23, 26, P1 www.controleng.com/manufacturer-health-wellness

NEWS

22 | COVID-19 developments and effects on engineers; ONLINE News 23 | Think Again: Impact on COVID-19

MAY 2020

ANSWERS 24 | Control Engineering Career and Salary Survey, 2020 26 | How COVID-19 is changing the engineering jobs, jobs market 28 | Education, attitude, communication are top tip topics in 2020 salary survey 29 | Career advice for engineers: Step out of the comfort zone 30 | Five engineering career tips: Set a vision and live it out 31 | Automation controllers, edge computing 32 | Open-source benefits for industrial controllers 34 | Edge controller, PLC, or PAC? 36 | Industrial controllers: past, present, future 38 | Combine Ethernet, fieldbus advantages, avoid limits 40 | Five ways industrial Ethernet can use TSN 42 | Industrial Ethernet is not office Ethernet 43 | Robot cybersecurity threats to watch 44 | Compliance for robotic companies 46 | Identify and mitigate robotic hazards INSIDE MACHINES

P1 | How to run virtual process hazard analysis meetings P2 | Advanced controls, linear programming, fuzzy logic

CONTROL ENGINEERING (ISSN 0010-8049, Vol. 67, No. 4, 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. Periodicals 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: ctle@omeda.com. Postmaster: send address changes to CONTROL ENGINEERING, PO Box 348, Lincolnshire, IL 60069. Publications Mail Agreement No. 40685520. Return undeliverable Canadian addresses to: PO Box 348, Lincolnshire, IL 60069. Email: ctle@omeda.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 348, Lincolnshire, IL 60069. 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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MAY 2020

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53 | Know the differences among a PLC, PAC and IPC

A programmable logic controller (PLC), process automation controller (PAC) and industrial PC (IPC) have features and benefits that are blurring as technology becomes more sophisticated.

NEWSLETTER: COVID-19 Engineering Alert • Signs of hope for manufacturing amid COVID-19 • Engine emission researchers retool to identify effective N95 mask alternatives • Laser treatment designed to kill bacteria on metal surfaces • Self-sanitizing face mask project for COVID-19 research receives NSF grant • Associations unite for COVID-19 recovery. Keep up with emerging trends: subscribe. www.controleng.com/newsletters.

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INSIGHTS

TECHNOLOGY UPDATE Mark T. Hoske, CFE Media and Technology

COVID-19 poll impact doubles ANALYSIS, ADVICE: Adverse effects of coronavirus more doubled during two survey periods.

CONSIDER THIS Catch up on engineering effects of COVID-19 at CFE Media and Technology websites; share your impacts in our ongoing poll.

ONLINE Click on the digital edition headline for more on survey method, analysis, comparisons and advice with this article online. The Coronavirus Engineering Alert newsletter from CFE Media and Technology is offered after taking the survey.

early 3 of 4 respondents to a coronavirus (COVID-19) impact survey said their businesses have been negatively affected, up from half the week before. Of the 74% negatively impacted, those feeling a “great deal” of impact increased 13% to 35% in a week; 39% of respondents felt negative impact was not much or difficult to measure, up from 35% the week before. Those experiencing severe supply chain impacts also nearly doubled in a week from 9% to 17%. Among respondents, 53% are having supply chain problems March 20-25, up a bit from 48% March 10 to 19. Minor problems decreased from 39% to 33%. No problems remained at 38%. Leading company actions focus on limiting travel (77% the first week increased to 80% the second); encouraging work from home (52 to 56%); working on contingency plans now with changes expected soon (52 to 57%); and eliminating travel (36 to 45%).

Survey method

From March 11 to 19 and from March 20 to 25 visitors to Control Engineering, Plant Engineering, Oil & Gas Engineering, and Consulting-Specifying Engineer websites gave coronavirus impact data. The survey continues to be available for future reporting.

Government strategies

What strategies should the U.S. government review to help address this type of situation in the

Figure: Three fourths of survey respondents said their companies were experiencing negative effects from Coronavirus (COVID-19), up from half in last week’s. Courtesy: CFE Media and Technology COVID-19 engineering impact survey, March 11-19 and 20-25

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control engineering

future? The three ranked responses gained support since the last period surveyed. 1. Incentivize re-shoring of key manufacturing segments back to the USA (pharmaceutical or feedstock products (ranking score of 192 for the full period March 11 to 25 up from 154 during the first period ending March 19.) 2. Invest in medical R&D to speed vaccine development and virus testing capabilities (ranking score 189 for the full period up from 153) 3. Do more to promote manufacturing automation where production can be completed with minimum operator involvement (ranking score 117 up from 89).

Advice from respondents

The survey also asked several open-ended questions. A sampling of lightly edited replies follows. • Create more separation of the work force, adding remote conferencing and online collaboration. • Have always had hand sanitizer available as well as registered nurse on-shift and on-call. • Replace air filters with HEPA type, deep clean. • Tested IT infrastructure and VPNs, making upgrades as needed before the bulk of people transitioned to remote work. • Daily updates, daily review of best practices, additional hand washing, sanitizers, etc., closer availability of gloves, mask, eye protection, etc. • Look at non-mechanical solutions (passive systems) for tempering buildings. • Encouraging sick to stay home, eliminating international travel, severely limiting domestic travel, encouraging limited personal travel: If person travels they work from home for 14 days, • Depend less on other countries for medication. • Improve worldwide disaster recovery plans. • Pull manufacture of chemical raw materials from China. • Something like healthcare-for-all and some sort of income for sick hourly/part-time workers. Sick folks need to be able to get care AND have enough funds to stay home to get well. • Stop processes that spread such a virus. ce

Mark T. Hoske is content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com, with help from the CFE Media and Technology research team. www.controleng.com

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INSIGHTS

TECHNOLOGY UPDATE: POWER QUALITY Mark Stephens and Alden Wright, EPRI

Power conditioning to match the power quality environment Voltage sags depend on the facility. An uninterruptible power supply (UPS) may be needed, but for large-scale issues, a UPS might not be the best option. See five UPS alternatives.

Figure 1: Sensitivity curves illustrate the vulnerabilities of a few control components still found in the field. All figures courtesy: EPRI

oltage sags have negative impacts on sensitive control circuit components and reliability. Understand the facility’s source of power to decide if the answer requires an uninterruptible power supply (UPS) or power quality mitigation technologies. Part 1 of this series “Why is my industrial process so sensitive to power blips?” described the power quality (PQ) event defined as a voltage sag, but known to many informally as a surge, blip or outage. Part 1 also presented a typical ac control circuit and components used in many industrial processes: 120-volt control power transformer (CPT) with ac “ice cube” relay(s), a programmable logic controller (PLC), adjustable speed drive (ASD), etc. The sources of process sensitivity were identified as control components vulnerable to voltage sags, or momentary reductions in supply voltage below 90% of nominal voltage. This article, part 2 identifies and examines possible solutions to the impact of voltage sags on sensitive control circuit components. These impacts may depend largely on the facility’s source of power. Is it supplied from a transmission circuit or a distribution circuit? Transmission systems tend to be more interconnected, and at much higher voltage levels, than distribution circuits.

What’s a voltage problem?

Figure 2: Mitigation curves for battery-less mitigation solutions (events above lines are mitigated). The coil hold-in device, for relays and contactors, can mitigate sags down to 25% of nominal. The constant voltage transformer can mitigate all sags above ~45% of nominal. The fast tap changer can mitigate all voltage sags above 50% of nominal as can the static series compensator. The latter also can mitigate very brief, deep sags and interruptions. DC modules can support dc controls through an interruption for 0.2 second up to 38 seconds.

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control engineering

The PQ data (5 years) for the system under Figures 1 and 2 reveals multiple interruptions at 0 volts, and many more, much deeper, and much longer voltage sags. This pattern is characteristic of distribution-fed electrical systems. Note that voltage sags above 90% of nominal, while recorded at right, should not be a problem as most equipment is designed to function normally at that level. Figure 1 illustrates the sensitivities of various control system components. The green, brown, red, blue, and dark green lines represent respectively a sensitive PLC, a sensitive dc power supply loaded at 100%, a sensitive ac “ice cube” relay, sensitive PLC input/output (I/O) connections, and the same sensitive dc power supply loaded at 50% of full load – a remarkable improvement merely by under loading the power supply. The process control circuit is most susceptible to voltage sag events largely because sophisticated power www.controleng.com

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INSIGHTS

TECHNOLOGY UPDATE: POWER QUALITY

4. A static series compensator contains power electronic- and capacitor-based energy storage. For voltage sags above 50% of nominal, the unit pulls additional current to rebuild the missing part of the waveform. For events lower in magnitude, the device uses energy from the internal storage capacitors – with proper sizing, short duration voltage interruptions can even be mitigated. 5. Finally, dc buffer modules based on electrolytic capacitors or ultracapacitors may support dc systems for complete interruptions ranging from 200 ms to more than 38 seconds. Figure 2 illustrates all of these capabilities. Unlike the UPS, these devices may operate for 10 to 15 years with little or no maintenance required.

Figure 3: Example locations in the Control Circuit for Voltage Sag Mitigation: CPT and AC “Ice Cube” Relay.

electronics – such as those found in adjustable speed drives – may require very stable voltage. Therefore, the first remedy perhaps coming to mind may be the UPS, a battery-based power supply. However, is this the best prescription for the actual problem? For relatively brief interruptions of service, when voltage falls to zero for several minutes or even longer, a UPS may be the best choice. See more on when to use a UPS with this article online.

Five battery-less alternatives

Technologies exist that do not require batteries, which may be installed and forgotten (if installed correctly). These technologies, developed over the last 25 years, correct voltage to help industrial controls ride through voltage sags of 45 to 50% magnitude for one to several seconds in KEYWORDS: power quality, duration. Some also are capable of supporting uninterruptible power momentary interruptions. supply, UPS Note that these are applied to the control Careful consideration of the circuit only and not the entire machine proPQ data will lead to the best cess; therefore, much smaller energies are selection for PQ mitigation. involved. In one instance on a particularFor relatively brief interruptions of service, ly problematic distribution line, one facility when voltage falls to zero for reduced its process shut down problem from several minutes or longer, a 20 per year to five after implementing EPRI’s UPS may be the best choice. recommendations. One of five technology Recommended technologies that could alternatives to UPS may be serve instead of a UPS can be as simple as: more effective. 1. Power electronic coil hold-in devices that ONLINE keep relays and contactors operating through Read part 1 of this article voltage sags down to 25% of nominal. www.controleng.com under 2. The venerable ferroresonant, or conthe energy, power section in the System Integration stant voltage transformer (CVT), if sized corchannel. rectly, can condition power to the controls With this article online see 5 through voltage sags down to 45% of nomitips to Increase uptime nal. Constant voltage transformers are among when PQ issues occur, more the heaviest and least energy efficient of batabout UPS use, and more graphics. tery-less voltage sag solution technologies. 3. A very fast tap-changer is capable of CONSIDER THIS quickly tapping up to correct the output voltHow often does your facility age during a sag, then tapping back down check a UPS and what role do they play? when the event is over.

M More INSIGHTS

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control engineering

The importance of PQ data

As figure 2 may illustrate, PQ data is essential for identifying the extent of PQ anomalies on the system as well as control sensitivities with some precision. The mitigation solution (or solutions) will depend on the PQ experienced at the specific site and the equipment controls under consideration. Relatively inexpensive (under $3,000 as of March 2020) and commercially available PQ meters may be obtained and installed to provide the facility managers with this important data. Mitigation devices may be installed approximately as indicated in figure 3. While individual control components having known sensitivities may be mitigated individually, other components with unknown sensitives may exist in the control circuit; therefore, mitigating at the CPT may be the most effective approach for making process controls more robust to voltage sags. As with most choices in the industrial environment, the true cost of the solution to a problem must be weighed with the true cost of the problem.

Power quality: UPS, alternatives

After factoring in the initial costs plus including maintenance, facility managers may decide the UPS may not necessarily be the best PQ option. Careful consideration of the PQ data, the cost of the PQ problem, and the total long-term cost of the alternatives for power conditioning will lead to the best selection for PQ mitigation. Of course, every potential mitigation must include considerations for proper application and sizing – something that one learns from experience. While effective, these retrofit solutions might be avoided with robust control designs. Part 3 will examine how PQ robustness can be embedded into industrial control designs. ce

Mark Stephens is principal project manager; Alden Wright is technical leader, Electric Power Research Institute (EPRI). Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com. www.controleng.com

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INSIGHTS

INTEGRATOR UPDATE Matt Ruth, Avanceon

10 ways manufacturers can add

COVID-19 support preparedness Ask these 10 questions to improve preparedness for manufacturers during the COVID-19 pandemic.

t’s a tense time for all of us as COVID-19 changes how we work, socialize, travel, exercise and shop. Communications with neighbors (at a distance), friends and colleagues by phone and video conferencing has revealed everyone’s willingness to help one another, as best we can, given the circumstances. Businesses need to do the same. Priority for a control systems integration company has been to support customers in any way possible. These are tough times as many balance employee health and safety. Some on the “essential” list must expand operations with a reduced staff.

M More INSIGHTS KEYWORDS: Emergency

preparedness, COVID-19, remote operations Remote support and backups Access credentials, permissions, and partners Emergency contacts and alternate suppliers.

CONSIDER THIS

ONLINE If reading from the digital edition, click on the headline for more resources. www. controleng.com/magazine www.controleng.com/ manufacturer-health-wellness Learn more about Avanceon in the Global System Integrator Database.

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Contact with customers resulted in a list of 10 questions to ask to help prepare for current and future disruptions. 1. Do you have a plan for restricted access/accessibility to your plant? 2. Who decides who can works remotely and who is essential to on-site operations? 3. Who has the authority to approve partners for engineering and remote support?

Working with a system integrator could improve the answers to these 10 questions.

10 tips for preparedness

4. What is the structure if partners, vendors or suppliers need remote access to your systems? 5. Do you have a virtual private network (VPN) for more secure remote access? 6. Have you set up credentials and confirmed access for those who’ll need it?

control engineering

The Avanceon listing in the Global System Integrator Database has primary industries as food and beverage, live sciences, biotechnology, and water/ wastewater. Courtesy: CFE Media and Technology, Global System Integrator Database, April 2020

7. Are there any devices or processes that you can’t access remotely? 8. Do you have the knowledge bandwidth to support these on-site and what is the back up? 9. Do you have quick access to contact info to all your original equipment manufacturers (OEMs), suppliers and partners in the event you need to request support? 10. Do you have a backup for the above in the event they don’t have a structure to support an emergency? These questions set structure and game plan to approach when in an emergency situation. Knowing how to handle these areas will help in addressing the “line down” crisis amplified for essential suppliers or during normal production as part of a just-in-time supply chain. Reaching out to partners is one component of preparedness that will help see us through this time of crisis. We will get through this if we work together. ce Matt Ruth is president of Avanceon, a CFE Media content partner. This was originally published on the Avanceon blog and edited for use here by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com. www.controleng.com

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INSIGHTS

TECHNOLOGY UPDATE - COVID-19 Jason Urso, Honeywell Process Solutions

Remote operations Address five areas to improve remote operations, of growing importance to keep manufacturing sites running.

ndustrial organizations are striving to keep workers and communities safe and healthy and contending with the COVID-19 effects to the economy, to supply chains and operations. As the pandemic spreads, plant owners/operators seek ways to change how they work. This includes refineries, chemical plants and manufacturing facilities. With the loss of human assets from the pandemic and retiring of experienced workforce, it has become clear the on-site operating model must change quickly.

1. Benefit from digitization

Digital effectiveness is key to staying ahead in today’s manufacturing environment. An emphasis on digital asset and process management will enable plant operating companies to achieve new levels of efficiency, productivity and safety. Tools include the latest technologies in sensors, connectivity, data capture, visualization and advanced analytics. Activities such as remote monitoring and operations, condition-based and predictive maintenance and real-time operator intelligence can help. Transition to remote plant operations is made easier with secure digital tools. Remote monitoring and operations software can be cybersecure without increasing plant risk.

M More INSIGHTS

KEYWORDS

COVID-19 safety, remote monitoring, manufacturing modernization Five areas can help remote manufacturing. Develop a strategy; look at services, cybersecurity.

CONSIDER THIS Updated systems help remote manufacturing connections, processes as part of the COVID-19 response.

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

See more COVID-19 impacts www.controleng.com/ manufacturer-health-wellness/

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2. Evaluate remote operations

To help industrial organizations meet their business objectives, leading automation suppliers have developed innovative remote operations solutions, which provide the expertise, skills and technology capabilities customers need to operate in a difficult business climate. Remote operations help with running complex manufacturing plants and relies on a modern automation infrastructure. Using data from process or assets, plant personnel can manage daily production, maintenance and safety and improve multiple sites. They can operate the plant, track production targets, monitor asset health, and create scenarios to determine the effect of operational changes prior to implementation. Remote capabilities supporting installed automation systems, networks and devices, and migrations.

3. Use safety, digital, monitoring

Remote operations and support strategy to lower worker risk and comply with social

control engineering

Wireless process transmitters can help remote operations, as shown at the Honeywell Users Group Americas, June 2019. Courtesy: Mark T. Hoske, CFE Media and Technology

distancing guidelines may require reducing the number of onsite employees. This will help protect workers who are onsite and keep operations running. It’s important to support them with advanced safety equipment and use tools such as digital video systems for the facility’s security as well as monitoring access control systems, so it’s clear who is on site. Physical equipment and devices can be remotely monitored with a secure app, giving plant operators visibility of critical processes on a mobile device.

4. Use services for remote operations

Technical service and support can be performed remotely, including remote consultation and maintenance and video collaboration and troubleshooting. With a wearable device, workers can help the remote team identify issues and troubleshoot in real time. During a production problem, team members can access systems and collaborate to solve the matter remotely. This helps plant personnel perform essential tasks with the knowledge and insights required to do the job correctly and maintain operational uptime.

5. Update controls, cybersecurity

Modernization can be achieved through plant automation and cybersecure software updates. Experience has shown remotely-operated migration methods for upgrading control systems offers lower risk, flawless execution and lower costs. A remote controls modernization can minimize risk, time and effort in field and improve a migration experience. This approach can reduce cycle time by up to 80%, lower operational cost by as much as 20% and improves migration productivity by at least 60%, with the latest cybersecurity and process control improvements. Virtual training using augmented reality (AR) technology can enhance skillsets with an “on-call” operator where needed. ce

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

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INSIGHTS

TECHNOLOGY UPDATE: REMOTE MONITORING Stephen Greene, Stratus Technologies

Essential remote monitoring and control for manufacturing The COVID-19 pandemic is forcing companies to adjust their business practices and settle to a new normal. See four tips on how edge computing and the Industrial Internet of Things (IIoT) can help companies adjust.

he COVID-19 pandemic demands companies and people think and act differently in challenging odds. For many, the call of the day is maintaining operational levels while our people, the most critical resource, have been constrained by needed social distancing practices and work-from-home requirements. For some, the situation requires scaling back operations with an eye toward how to quickly ramp up as demand returns. For others, this means flexing a production line to a new purpose or level of production under the same constraints. In any case, adjusting operations in real-time makes modern monitor and control capabilities essential. During the COVID-19 pandemic, engineering and operations leaders seek ways to optimize performance under these dynamic conditions. The current situation calls for leaders to lean in and adopt new approaches. This does not mean tolerating more risk. Safely maintaining or scaling operations requires capabilities that enable greater KEYWORDS: COVID-19, and more reliable remote and secure monitorremote monitoring ing and control of critical systems. The COVID-19 pandemic The current situation also points to Indusis forcing engineering and operations leaders to find trial Internet of Things (IIoT) and edge comways to optimize peak puting benefits, which are being realized in performance under these industrial automation projects worldwide. dynamic conditions. Edge computing platforms collect, organize The right edge computing and analyze data from sensors and process platform and bringing information technology (IT) data on site in real time without latency coninto the process will help. cerns, connecting critical applications with Manufacturers able to critical equipment or enabling advanced and adjust quickly to the new remote monitoring and control. normal will thrive under the Distributed computing automates core pronew business environment cesses and helps ensure availability. This allows COVID-19 has created. manufacturers, at a local facility or plant level, ONLINE to remotely drive operational efficiencies and Read this article at performance safely while freeing limited perwww.controleng.com for sonnel to focus on higher-value work. Without more on COVID-19. time for extensive planning and pilots, how CONSIDER THIS can engineering and operations leaders move What challenges is your quickly with confidence they are implementcompany facing when it ing the right approach? Four steps can help. comes to COVID-19?

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Safely and efficiently maintaining or scaling operations requires capabilities that enable greater and more reliable remote and secure monitoring and control of critical systems. Production environments and supply chains can more dynamically respond to demand changes with the help of edge computing. Courtesy: Stratus

1. Identify a key process to virtualize: Identifying high-touch repetitive processes that can be better addressed as an automated process is an underlying tenant of industrial automation. Virtualization enables multiple processes to simultaneously run on one platform. These virtualized machines deliver tremendous manageability benefits while establishing a future-ready solution to supports ongoing industrial automation and larger digital transformation efforts. 2. Select the best edge computing plat-

form: Total cost of ownership (TCO), service and

support are overall factors when selecting an edge computing platform. Nearly 300 respondents to a recent study conducted by Stratus and CFE Media also pointed to the following five attributes as essential when choosing an edge-computing platform. a. Ability to self-monitor and self-diagnose b. Possess built-in pre-integrated physical and cybersecurity c. Proven high availability with little or no downtime d. Easy to install and maintain e. Support for a wide range of applications.

3. Integrate IIoT with modern monitor and control software: IIoT-enabled devices, Continued on page 20

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input #10 at www.controleng.com/information

INSIGHTS

TECHNOLOGY UPDATE

Mark T. Hoske, Control Engineering

Robot pick-and-place See May 12 webcast archive and 7 tips below.

T SINCE YOU CAN’T SEE THE FUTURE, WE HELP YOU PREPARE FOR IT. In a market of ever-changing requirements and increasing rates of innovation, the need for equipment that can quickly adapt to meet these needs is important. Powered by our award-winning Crimson® software, the new FlexEdge™ platform

he complexity of automated bin picking requires huge efforts in integration and programming, said Universal Robots, a Boston-based robotic company in an April 9 press release and in a May 12 webcast, “Resolve robotic challenges using bin-picking intelligence.” When manufacturers with limited or no bin picking deployment expertise want to quickly achieve high machine uptime and accurate part placement with few operator interventions, Universal Robots recommended: 1. Combine real-time autonomous motion control, collaborative robotics, vision and sensor systems in an easy-to-use, fast to deploy and cost-effective kit that requires no vision or robotic programming expertise. 2. Set up the application with a “teach-by-demonstration” sixstep, wizard-guided setup process integrated into the collaborative robot teach pendant. 3. Use a system that can enable a collaborative robot to autonomously locate and pick parts out of deep bins and place them precisely into a machine, accurate pick and part-oriented placement. 4. Eliminate the duplication of engineering efforts when deploying widely-used applications with an available component or user-defined end effector, and application-specific frame or fixture as needed. 5. Use pre-integrated software for user interface and autonomous motion control to enable the robot to operate inside deep bins that hold more parts, difficult for some vision systems. 6. Select 3D sensors suitable for the application. 7. Avoid more complex approaches to automating machine tending stations, such as implementing trays, bowl feeders or conveyors to get the parts to the machine. ce

Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media, mhoske@cfemedia.com. See the webcast at www.controleng.com/webcasts/past

enables companies to connect new and existing equipment with ease, regardless of manufacturer, ultimately future prooﬁng IIoT and Digital Transformation initiatives.

REQUEST A DEMONSTRATION 877.432.9908 flexedge@redlion.net flexedge.net input #11 at www.controleng.com/information

ActiNav is a new UR+ application kit that simplifies the integration of autonomous bin picking of parts and accurate placement in machines. Courtesy: Universal Robots

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INSIGHTS

TECHNOLOGY UPDATE Brandy Richardson, MESA International

MESA smart manufacturing model to detail 8 areas The MESA International “Model for Smart Manufacturing” intends to cover business intelligence, product lifecycle management (PLM), value chain management, manufacturing operations, the Industrial Internet of Things (IIoT), asset management, workforce and cybersecurity.

mart manufacturing will get an operations management boost from MESA International. MESA’s knowledge committee chairman, Khris Kammer, told Control Engineering (CFE Media and Technology) how “The Model for Smart Manufacturing” intends to help, as it covers eight intersecting areas: Business intelligence (BI), product lifecycle management (PLM), value chain management, manufacturing operations, the Industrial Internet of Things (IIoT), asset management, workforce and cybersecurity.

Real-world benefits, integration

Kammer said the “intent is to describe in detail the functionality provided by each dimension, as well as the interaction between them that makes for a complete Smart Manufacturing environment. We will emphasize the real-world benefits offered by integration of these functions, with descriptions of supporting technology and actual examples of the functionality in action.”

Goal of smart manufacturing model

The model intends to be low-cost and high value and will focus on how modern technology makes them “smart,” Kammer said. It also will briefly explain the history of the eight functions for context. MESA’s goal is to help “industry understand and adopt the vision of Smart Manufacturing rapidly, with minimal cost and maximum benefit. The new model will build on existing and similar frameworks and standards, so that practitioners can advance their current state while taking advantage of the newest and most progressive techniques available,” Kammer said. “We are working with (and seeking) practitioners that have experience and expertise in one or more of the dimensions listed.” Those wishing to participate in creation and vetting of the Smart Manufacturing model should become MESA members and contact the executive director, Brandy Richardson.

MESA models, smart manufacturing

MESA has published various models on manu-

www.controleng.com

facturing execution and operations space, as well as enterprise-level strategic initiatives and business operations, including the honeycomb model (See figure). MESA’s various models have been referenced in many publications, textbooks, and requests for proposals. “MESA continues to evolve and, today, is at the heart of the industry’s drive toward Smart Manufacturing. The development of the Smart Manufacturing model is a valuable next step and MESA is well positioned to be the home of that model,” Kammer explained in the March 30 MESA announcement. Due to social distancing guidelines, working meetings will be held virtually throughout the year, according to the organization, based in Chandler, Ariz., near Phoenix.

MESA International is collaborating with an array of experts to create a smart manufacturing model. Will you be one of them? Contact MESA International for more information.

What is MESA?

MESA stands for Manufacturing Enterprise Solutions Association. The global, not-for-profit community of manufacturers, producers, industry leaders and solution providers focus on improving operations management capabilities through application of information technologies, IT-based solutions, and best practices. MESA: • Enables members to connect, contribute, cultivate understanding, and exchange strategies to drive operations excellence. • Collects, shares, and publishes best practices and guidance to drive greater productivity and the overall profitability of the manufacturing enterprise. • Educates the marketplace on manufacturing operations best practices through the MESA Global Education Program. ce

Brandy Richardson is executive director, MESA International, a CFE Media content partner. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media, mhoske@cfemedia.com. control engineering

M More INSIGHTS KEYWORDS: Smart manufacturing, MES MESA International is collaborating with experts to develop a smart manufacturing model. Smart manufacturing model intends to include BI, PLM, manufacturing operations, IIoT, cybersecurity and other areas. CONSIDER THIS How can manufacturing get smarter?

ONLINE If reading from the digital edition, click on the headline for more resources. www.controleng.com/ magazine www.controleng.com/ info-management/ manufacturing-it-mes

May 2020

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INSIGHTS

TECHNOLOGY UPDATE Essential remote monitoring, control... Continued from page 16

such as sensors and programmable logic controllers (PLCs) improve manufacturing processes when they are combined with modern monitor and control software powered by edge computing. This combination enables real-time data to be converted into actionable insights that drive specific actions with little human interaction. This also opens the possibility of bridging from the edge to the enterprise and, when needed, the cloud. The increased use of IIoT devices within edge computing architectures can introduce security vulnerabilities if they’re not addressed properly. The risks of software vulnerabilities and system manipulation reinforces the need to invest in systems that provide self-monitoring and diagnosis, as well as built-in physical and cybersecurity. Edge computing platforms are inherently designed and proven to be secure. They can protect data collection and analysis points and make security programs more effective.

Bring IT onto the team: Operations technology (OT) and information technology (IT) silos can hinder success. The complementary skillset and insights IT offers can help ensure a successful deploy-

ment and uncover additional areas of benefit. There is a lot to be said about OT/IT convergence and organizational changes and challenges. Thissituation warrants an “all hands-on deck” mindset focused on the immediate operational needs of the facility or plant.

Flexible, adaptable architecture

We should not expect a return to normal operations. Manufacturers traditionally fare better when they are flexible and adaptable to real time and, at times like these, volatile market shifts. This has been proven over time by companies that continue to invest in capabilities that allow them to respond to changing customer needs, better manage production changes and drive operational excellence in any condition. Such companies emerge stronger in difficult times. They emerge as leaders who can remotely monitor and control local operations with increased visibility into their supply chain in real-time and can adjust operations accordingly. Those adopting digital transformation capabilities can simplify, protect and automate business-critical operations. ce

Stephen Greene, vice president of global marketing, Stratus Technologies. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.

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INSIGHTS

TECHNOLOGY UPDATE Neil Carey, MultiTech Systems

Smart, wireless help for smart cities Smart cities leverage newest protocols, Internet of Things wireless gateways and sensors.

ugged wireless gateways help communications for smart city communications. Smart cities are urban areas that use electronic Internet of Things (IoT) sensors to collect data and manage assets, resources and services efficiently. Collecting real-time and actionable information on a city’s infrastructure has benefits. IoT devices must be protected from the environment. U.K.-based Lucy Zodion, part of the Lucy Group, member of the LoRa Alliance and leader sought to implement a lighting infrastructure. Lucy Zodion’s smart city platform is Ki. The platform communicates via an open, wireless ecosystem of enabling hardware and IoT software. It leverages LoRaWAN communications due to long signal range and minimal power requirements. A LoRaWAN gateway enables continuous connectivity and communications so nodes can transmit street lighting data to generate actionable insights that enhance asset management. Street lighting has

CFE

changed from illumination hardware into open ecosystems. Working with a client, Lucy Zodion “needed to validate if heat had an impact upon the technology specification and understand any performance issues upon data collection, against temperature,” said Richard Perry, smart cities lead at Lucy Zodion. After review, the chosen gateway was deemed scalable, certified, protected against power surges and against harsh environmental factors and high impact. Lucy Zodion plans to continue to develop smart city solutions that bring together a wide range of collaborators to create multi-vendor ecosystems. ce Neil Carey is regional director, MultiTech Systems, a LoRa Alliance member. Edited by Mark T. Hoske, content manager, Control Engineering, mhoske@cfemedia.com.

Edu

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5/5/2020 9:10:41 AM

INSIGHTS

NEWS

COVID-19 developments and effects on engineers from the industry

‘

The COVID-19 pandemic continues to affect engineers in profound ways. Social distancing, remote working and many other changes are forcing a new normal in our society. While engineers work to adjust to this and what this means for the future, many continue to find ways to help out and make work safer during the pandemic. Here are some notable highlights featured on the Control Engineering website and our e-newsletters during the month of April. If reading the digital edition, click on the headlines to read the full story.

sent in the past 14 days to a database. Others can then scan the database to see if any of those chirps match the ones picked up by their phones. If there’s a match, a notification will inform that person that they may have been exposed to the virus, and will include information from public health authorities on next steps to take. This process is done while maintaining the privacy of those who are COVID-19 positive and those wishing to check if they have been in contact with an infected person. - Kylie Foy, Massachusetts Institute of Technology (MIT)

Workarounds are being found for supply chains. Factories

’

are learning to keep people safe and producing. Robots and automation fight the COVID-19 pandemic

As the world continues to fight the spread of the COVID-19 pandemic, robots and automation are playing a critical role in helping to safeguard people and process the supplies that humans need as they shift to remote working and home learning. Robots are helping disinfect hospitals. Autonomous deliveries are bringing supplies to people as they adopt social distancing. Automated workstations are speeding up the work of pharmaceutical companies. Automation is on the front lines of this battle. - Keith Shaw, Robotic Industries Association (RIA) and Robotics Online

Bluetooth smartphone signals may automate contact tracing

A team led by MIT researchers with experts from many institutions is developing a system that augments “manual” contact tracing by public health officials, while preserving the privacy of individuals. The system relies on short-range Bluetooth signals emitted from smartphones. These signals represent random strings of numbers, likened to “chirps” that other nearby smartphones can remember hearing. If a person tests positive, they can upload the list of chirps their phone has

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Signs of hope for manufacturing amid COVID-19

The COVID-19 pandemic has delivered a gut punch to American manufacturing. The picture, while grim, is by no means the catastrophe of our worst fears. Factories have idled or slowed production to allow deep cleaning and to protect workers. Supply chains have been disrupted. Shortages of products from medical supplies to, yes, toilet paper are the stuff of headlines. However, U.S. manufacturers have been swift to respond. Some manufacturers are switching production from their usual product lines to turn out badly needed medical supplies. Workarounds are being found for disrupted supply chains. Factories are figuring out how to keep their people safe while still producing what the market needs. - John Gallagher, Robotic Industries Association, Robotics Online

COVID-19 effects on safety operations

Cybersecurity issues remain a top issue during the COVID-19 pandemic, but little has been said about the safety ramifications industrial operations are facing as they undergo production slowdowns and reduced operations.

With more companies operating with skeleton crews on site, manufacturers want to keep continuous processes running but at a reduced rate because they know the most dangerous times for any manufacturing facility is a start-up or a shut down. Like security professionals having to conduct more assessments remotely, safety experts are having to do the same as they are doing process hazard analyses (PHAs) and layer of protection analysis (LOPAs) remotely versus the usual in person. And while facilities have a great deal of automation going on, staff still needs to come in to ensure a safe environment. That is becoming difficult with workers wanting to stay home and out of harm’s way. ce - Gregory Hale, ISSSource.com

M More ONLINE

Register for the weekly COVID-19 engineering alert newsletter at www.controleng.com/covid19newsletter as well as other editorial newsletters from Control Engineering. Control Engineering has a COVID-19 and coronavirus sub-channel with the latest stories on the pandemic. www.controleng.com/ manufacturer-health-wellness/

Headlines online Top five Control Engineering articles Research for lab testing, COVID-19 engineering impacts, and others were among Control Engineering’s five most-clicked articles, April 27 to May 3. Tech giants unite in COVID-19 smartphone efforts Effective remote workforce strategies Portable pathogen detector developed to work in minutes Manufacturing index slides into contraction for first time in 11 years www.controleng.com

INSIGHTS ®

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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, senior project manager, Gannett Fleming Engineers and Architects, www.gannettfleming.com Frank Lamb, founder and owner Automation Consulting LLC, www.automationllc.com Joe Martin, president and founder Martin Control Systems, www.martincsi.com Rick Pierro, president and co-founder Superior Controls, www.superiorcontrols.com Mark Voigtmann, partner, automation practice lead Faegre Baker Daniels, www.FaegreBD.com

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

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THINK AGAIN

Engineering impact on COVID-19

How are engineers applying what they’ve learned to help during the COVID-19 pandemic? See six ways automation can help.

ngineers are responding to needs created by the COVID-19 (Coronavirus) pandemic. Control Engineering’s section on COVID-19 shows how engineers are applying their skills. Nine pages of coverage in this issue is augmented by 40 articles online March 27 through April 28. The annual Control Engineering Career and Salary Report and career update section also provides advice.

40 COVID-19 articles

During the four weeks ending April 26, four weeks of Top 5 Control Engineering articles, only two didn’t directly pertain to the COVID-19 engineering response. Control Engineering’s 40 articles of COVID-19 engineering coverage, from March 27 through April 28 include: • Control Engineering’s polls show deepening COVID-19 impacts • Electronics industry survey on COVID-19 impacts • Coronavirus will force manufacturers to enhance automation, digitalization • Bluetooth in smartphones could automate COVID-19 contact tracing • Robots and automation are fighting the COVID-19 pandemic • Articles about masks, germ control • Signs of hope for manufacturing amid COVID-19.

Six ways automation helps

Engineering support extends to automation, controls and instrumentation to help with COVID-19 responses. 1. Hands-off production: In general automation and controls enable production with fewer humans, maintaining, quality, consistency, safety and through-

M More INSIGHTS

www.controleng.com/ manufacturer-health-wellness/ www.controleng.com/newsletter www.coronavirus.gov

put at high levels to help sustain critical supply chains. Sensors measure, send signals to controllers, which make decisions, and tell an actuator what to do. Secure networks transmit information, and software optimizes processes. Lab automation increases testing throughput. 2. Automation upgrades to separate humans: System integrators and original equipment manufacturers (OEMs) are examining designs of machines and lines to add separation between humans where possible by integrating more robotics (stationary, mobile, and collaborative), wireless secure human-machine interfaces (HMIs) and smarter software to lower risk. 3. Smarter supply chain management: Automation can help with part management, kitting, delivery, looking at where materials and parts are manufactured and mitigating risk of future supply chain disruption. Some manufacturing locations may shift to mitigate risk with reshoring initiatives; doing so creates opportunities to redesign and improve processes and apply more automation and controls to augment efficiencies in the new location. 4. Sensors and instrumentation and analytics: A myriad of measurements and data analytics go into a pandemic response. Appropriate applications of sensors and instrumentation, secure networks and data analytics present new opportunities for smarter responses. 5. Automated 3D printing: From maker-space help with personal-protective equipment (PPE) to rapid part creation and replacement during supply chain interruptions, additive manufacturing is helping. 6. Artificial intelligence applied to logistics support: Analytics software can be applied to anticipate logistics requirements, similar to rerouting resources during large-scale weather emergencies. Engineers are thinking again about how to impact COVID-19 needs. ce Mark T. Hoske is Control Engineering content manager, mhoske@cfemedia.com control engineering

May 2020

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2020 CAREERUPDATE

Control Engineering

Career and Salary Survey Many subscribers work in critical industries; half of non-salary compensation relies on profits, some changed by COVID-19. Lack of skilled workers continues to be the top threat to manufacturing for the survey period ending March 16, before more recent COVID-19 impacts.

ngineers expected to get paid more in 2020 ($102,669 in 2020, $101,450 in 2019 compared to $100,339 in 2018 survey respondents), and 69% expected a 2020 salary increase, down from 74% in 2019, according to respondents to the Control Engineering Career and Salary Survey for 2020. Top threat to manufacturers remains lack of available skilled workers, 42%, followed by competition and the economy tied at 32%, similar to 2019. Note: Data was collected Feb. 26 through March 16, before more recent adverse effects of COVID-19 hit the economy. In separate CFE Media research on COVID-19’s impacts (p. 6), 74% of respondents said their businesses have seen negative effects, and 35% of respondents said a great deal of impact, for the five-day period ending March 25. Many Control Engineering subscribers work in industries deemed essential (Full report lists industries).

During times of economic challenge, financial compensation becomes more important among factors impacting job satisfaction, and, in 2020, compensation came out on top, followed by technical challenge, and feeling of accomplishment. In 2019, technical challenge and feeling of accomplishment both ranked higher than compensation for job satisfaction criteria. However, in both years the top three were within the margin of error for each survey, making the ranking difference anecdotal. As Figure 1 shows, 52% expect a salary increase of up to 3% in 2020 (63% in 2019; 56% in 2018); 18% expect an increase of 4% or more (11% in 2019; 19% in 2018); 30% 25% expect the same (25% in 2019; 23% in 2018); and 1% expect a salary decrease (same as 2019; 2% in 2018). The 2020 survey noted that of the increases above 4%, 12% of respondents expect a 4 to 6% increase, and 5% said more than 6%. COVID-19 created some economic

Expected change to 2020 base annual salary

Expected change to 2020 non-salary compensation

Increase more than 6%

Decrease

12%

Stay the same

Increase 4% to 6%

Increase e more more % 6% than 6%

6% 30%

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Survey methods

Survey respondents for the Control Engineering Career and Salary Report for 2020 were invited to anonymously provide their annual compensation informa-

Compensation summary 2020 SALARY

12%

Minimum

$24,000

Maximum

$800,000

NON-SALARY COMPENSATION

Increase 1% to 3%

Figure 1: 69% of respondents expect a salary increase. Courtesy: Control Engineering research, CFE Media and CFE Technology

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Increase 1% to 3%

$11,937

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60%

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52%

slowing in March to 49.1 on the purchasing manufacturers’ index (PMI) from the Institute of Supply Management (ISM), dipping to 41.5 in April (below 50 is contraction). Previously, upward salary pressures resulted from strong U.S. manufacturing results, coupled with demographic pressures of an aging workforce and too few going into science, technology, engineering, and math (STEM) related professions. Regarding the shortage of skilled workers, 35% strongly agree that grade schools and middle schools should be more encouraging of trade school attendance, up from 29% in 2019; 27% said immigration policy needs revising to get talent to remain competitive, up from 19% in 2019.

Stay the same

Figure 2: 28% of respondents expect an increase in 2020 non-salary compensation.

67% $17,811

Minimum

Maximum

$250,000

Figure 3: In 2020, the average salary of respondents topped $102,669. In 2020, average non-salary compensation was 11,937. www.controleng.com

M More ANSWERS

tion and opinions on the current state of their facilities and industries. The 2020 Control Engineering Career and Salary Report reflects data gathered from 379 automation professionals; margin of error is +/- 5.0% at a 95% confidence level.

Salary, bonus details

For base salary compensation, the minimum was $24,000 ($25,000 in 2019), and the maximum was ($800,000 in 2019), for 379 survey respondents providing this information. For non-salary compensation (Figure 2), 28% expect an increase (23% in 2019); 12% expect an increase of 4% or more (9% in 2019); 60% expect about the same (same as 2019); and 12% expect less (17% in 2019). Leading criteria for bonus compensation were company profits, 53% (down from 57% and 73% in the last two years), and personal performance, 43% (down from 47% and 62%) in Figure 4. Rounding out the top five were product productivity, plant or line productivity, and safety. In 2019, the top 5 included new business and sales, product profitability, and plant or line productivity. ce

Mark T. Hoske is content manager, Control Engineering, CFE Media, mhoske@cfemedia.com. Amanda Pelliccione, director of research and awards programs for CFE Media and Technology, conducted the research and assembled the related report.

Criteria for non-salary compensation Company profitability Personal performance Product profitability Plant or line productivity Safety metrics Reducing plant costs New business, sales increase Quality metrics Company stock performance Uptime/downtime Customer feedback Energy efficiencies Other Not applicable (no bonus received)

20%

30%

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50%

Areas of operations

Financial compensation Technical challenge Feeling of accomplishment Relationship with colleagues Job security Location Flexible work hours Benefits Relationship with boss Feeling of recognition Workload Ability to work from home Advancement opportunities Leading a team Company's financial health Relationship with subordinates Managing people Company size Travel Ergonomic environment Other

Automation and controls Budget, profits, financials Customers, sales Energy Equipment upgrades

Highest emphasis Should have highest emphasis

Human Resources Instrumentation Maintenance Manufacturing IT Operations Product development Safety Systems Training, education Other

10%

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Figure 5: Top factors for job satisfaction are feeling of accomplishment, technical challenge, and financial compensation. www.controleng.com

10%

Figure 4: Company profits and personal performance remain, by far, the leading criteria determining non-salary compensation.

Job satisfaction factors

For more information, read this article online for extra tables, graphics and analysis. Also download the Control Engineering 2020 Career and Salary Report for respondent regions, titles, functions, company size, staffing, views on energy, cybersecurity, and outsourcing, along with salary and non-salary compensation benchmarks by age, education, number of years with employer and industry, by job title, by job function, and by employees managed. www.controleng.com/research On the next pages, see articles on career advice, training from survey respondents and Engineering Leaders Under 40, and others.

10%

15%

20%

Figure 6: Red shows what should get the most emphasis: Automation and controls is the leading category.

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May 2020

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2020 CAREERUPDATE

Jeff Briggs, Miller Resource Group

How COVID-19 is changing engineering jobs, market Taking control in an uncontrolled time: Leaders share lessons from the industrial automation, controls, and manufacturing industries during the COVID-19 pandemic.

he COVID-19 impact continues to be felt around the world and has created unforeseen hurdles with regards to its people, economy, industry, and engineering. With varying messages and new information being uncovered daily, it can begin to feel as if we are losing control. Experts in controls, automation, and manufacturing from around the country offered some promising advice.

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Controls are the center of any automation system. Control engineers are the center of all engineering disciplines. System integration

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As CEO of Control System Integrators Association (CSIA) Jose Rivera explains, “It’s clear, every business will be impacted by this. We will also see areas of strength and growth emerge as well, but in time. The good thing about an industry packed full of engineers, you’ve got a lot of folks that were prepared as best they could be and had systems in place to battle through this. Whether that is remote work setup, company e-meetings, applying virtual control engineering principles, etc. Of course, there will be lots of adapting on the fly, but engineers are good at that too.” Rivera shared several stories of how CSIA members are changing their remote strategies. “We have some companies that are not just doing remote engineering work like testing and

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May 2020

control engineering

virtual factory acceptance tests (FATs), they’re also continuing to focus on that office culture and team bonding piece that is so important, as well. One company even went as far as sending delivery birthday cake to an employee while all colleagues call in via Zoom to sing ‘Happy Birthday.’ Don’t get me wrong, we are in a tough time, and it will not be easy, but we will get there if we continue to work together.”

3D printing

There are other positive stories popping up throughout the country. Robert Fell is president at Iris Custom Solutions, a company focused on providing custom automation and system integration. He and his team immediately sprang into action amid the crisis. They had 3D printing technology available and decided the best use for it would be to create shields for the overwhelmed medical supply industry. “Our goal is to get 1,500 new shields to New York as quickly as possible. We’re sending them in smaller batch sizes of around 400 per week. We will continue to try and help where we can. We’ve even ordered more 3D printers.” Fell and his engineering team are doing this while running day-to-day business. Engineering skill sets are being applied in new ways, especially now.

Data sciences, robotics

There are even groups applying control theory principles to healthcare system capacity problems and sharing their findings on LinkedIn. Greg Stewart, a data science expert at Ecoation, a company that offers an automated greenhouse management platform turned expertise to coronavirus by looking at policy design for stable population recovery. The work applies control principles to www.controleng.com

hospital capacity problems the pandemic has created. Ecoation and others are using engineering skillsets to help encourage collaboration among control communities to address pandemic-related global challenges. Companies are addressing internal situations as well. Charles Lowrey, controls engineering manager at Calvary Robotics, noticed areas challenging and surprising control engineering managers. “Anytime your primary market is impacted by external forces beyond your control, it is a test of an organizations preparedness and adaptability. Webcams and teleconferencing are becoming essential to keeping teams focused on the same goals. Managers and team leads are being challenged to find new ways to provide direction and mentor without face-to-face meetings. I think people also are surprised at the volume of work they’re able to accomplish at home relative to the office,” Lowrey said. He believes the control engineering skillset will continue to hold major value, in person or digitally. There are many ways skillsets can transfer to new industries and situations, Lowrey noted.

Automation benefits

Gary Miller, president of the Miller Resource Group, agreed with Lowrey. “I’ve always viewed the control center as just that, the center of any automation system. Control engineers can view themselves the same way, at the center of all engineering disciplines. Because they are part of a larger engineering community, the value of digital networking via sources like LinkedIn can become a major resource in times like this. It’s a place for them to increase their learning, allow them to contribute, and hence, increase their value.” Value creation and business development opportunities continue to develop. EN Automation’s director of business development, Garett Williams, discussed preparedness and outlook for engineering, consulting, and environmental services. “We were as ready as you can be for something like this. Fortunately, we had remote strategies in place already which helped us keep things moving. We are even seeing an uptick in business development activities at this time, especially when you factor in various things like travel time being eliminated. We’re keeping virtual messaging high, but doing it in a highly targeted manner using video campaigns and other various apps to create a

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more custom, unique message. I guess you could say while we’re still adhering to the new norms of society and keeping distant physically, we’re also maintaining the important social aspect of our job,” Williams said. The EN Automation team has been working with current and new partners to ensure automation systems are performing optimally now and into the future, with new needs emerging frequently.

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Future partnerships are being formed now; companies are seeing areas of need

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or systems that need to be updated.

“Through some of the conversations we are having, it’s clear that future partnerships are being formed right now with this pandemic shining a light on certain areas that companies are seeing areas of need or systems that need to be updated,” said Williams. Ryan Prickette, an industry sales leader at Rockwell Automation, is noticing some positive trends as well. “There is more flexibility and understanding of ways we can serve customers virtually or alternatively. There will be several new KEYWORDS opportunities created in terms of helpEngineering skills, COVID-19 ing customers to be better prepared COVID-19 is affecting people, to handle future situations like this,” economy, industry, and engineering. Prickette said. Remote capabilities and From various perspectives, “wins” productivity are increasing. are happening within the automation Engineering talents are being industry’s talented network. People are applied and appreciated in new attempting to apply tighter controls ways. over what they can influence, applying CONSIDER THIS engineering and business development What engineering skills are principles, and adapting on the fly, lesyou applying to the COVID-19 sons that many can consider and benresponses? efit from. ce

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ONLINE

Jeff Briggs is industrial automation recruiting specialist, Miller Resource Group. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media, mhoske@cfemedia.com.

See graphic with online version; click into the headline in the digital edition. www.controleng.com/magazine www.controleng.com/research www.controleng.com/ manufacturer-health-wellness

control engineering

May 2020

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2020 CAREERUPDATE

Mark T. Hoske, Control Engineering, CFE Media

Top engineering career tips Education, attitude, communication are top tips from respondents to the 2020 career and salary survey from Control Engineering, CFE Media and Technology.

lways keep learning, positivity and inclusivity, and strong communications are among the top areas of advice offer by respondents to the 2020 career and salary survey from Control Engineering, CFE Media and CFE Technology. Seven categories were offered to respondents to pre-sort their advice. A total of 580 pieces of advice were offered from 379 respondents from Feb. 26 to March 16. Survey respondents were asked: What engineering career-related advice do you offer to others? Some replies were edited for clarity and duplicates removed. (See full list with the article online: Click through the headline on the digital edition to see much more, sorted by category.) The most advice was offered in education, attitude and communication, with more in each category in the online version of this article. Advice includes: • Get as much education as you can; find an employer who will encourage further education. • Get a mentor, ask questions and listen. • Ask who, what, where, why and how. Define

Skills needed to advance

research and execute. • Accurate work done slow is superior to shoddy work done fast. • See what is. Engineers never learn how equipment works until they operate it alone. • Difficulty does not obviate simple. • Don’t look back at failures. Move forward. • Read anything that you think might be helpful. • Science, technology, engineering, and mathematics (STEM) majors are currently the best and likely only guaranteed return on investment. • Your attitude will have the most impact on your success. • Work to improve communications skills; they are critical for your success. • Always consider the operators’ viewpoint when making changes. • Be on good terms with everybody, especially support staff. • Maintain a good work/life balance. • Good, fast, cheap. Pick two. • Get involved with things that are “firsts.” There is usually a lot of support, and they are great learning experiences. What are your favorites? ce Mark T. Hoske, content manager, Control Engineering, CFE Media, mhoske@cfemedia.com. Amanda Pelliccione, director of research and awards programs for CFE Media and Technology, conducted the research and assembled the related report.

Engineering Project management Communication/presentation Computer Team-building

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Marketing/sales Language Finance/accounting skills

KEYWORDS: Engineering career advice, education

Recruitment

Education was the most advice in the 2020 Control Engineering Career and Salary Survey report. A total of 580 pieces of advice is in seven categories.

Other Don't know 0%

10% 20% 30% 40% 50% 60% 70%

Figure: Leading skills needed to get ahead are engineering, project management, communication and presentation skills, followed by computer, and team building. Courtesy: Control Engineering research, CFE Media and CFE Technology

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CONSIDER THIS Measure and adjust your career goals and progress at least quarterly.

ONLINE From the digital edition, click on the headline for more advice. Also see www.controleng.com/research. www.controleng.com

2020 CAREERUPDATE Dileepa Prabhakar, Fluke

Career advice: Step out of the comfort zone Looking wider, at engineering career development requires looking at other perspectives, understanding customers, finding a mentor and having fun.

s a software engineer, I wasn’t always big on the big picture. But hearing diverse views in feature prioritization discussions and bug triages made me question my interpretation of why something was important. Later in my career, taking on a leadership role pivoted my view, introduced discomfort (the good kind), made me question my assumptions and helped with bigger and broader thinking. Specific things to do at any point in an engineering career: • Talk to group managers and participate in staff meetings or stand-ups of other groups. Understand their perspectives. Wear someone else’s shoes, as they say. • Look for opportunities for direct customer interaction. Customers can be internal or external. Think from the customer’s perspective — not just the functional job, but the social and emotional aspects of it, as well. (Book recommendation is “The Innovator’s Method: Bringing the Lean Start-up into Your Organization” by Nathan Furr and Jeff Dyer, Harvard Business Review Press.)

Find a mentor

In 2014, I was looking for a new challenge and I communicated that to my engineering manager. That information got to the-then vice president of engineering. He gave me several challenges, including hiring me into the technology incubation group, where, in my current role as the group manager, I got to work with some of the brightest minds inside the company and with external innovation partners. Finding good mentors gives a career a big boost. Mentors can remove roadblocks, big and small. For those who are growth oriented, mentors can help with career-path decisions and accelerate a career. Decisions are not set in stone. If you change

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your mind after giving a new role a good try, work with your manager and leadership team to find another role that may work better for you.

Be proactive; have fun

According to some estimates, one-third of life is spent working and another third sleeping. Work experience should, on balance be enriching and enjoyable and engineers should be active in their

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Perform the role you want to grow into and demonstrate that you can do the job

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before you have the job.

pursuits. If you see an opportunity, go after it. A big part of this is performing the role you want to grow into and demonstrating behaviors you can do the job even before you have the job. Being proactive also can be about how you execute ce

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KEYWORDS

Engineering, career development Step out of your comfort zone. Find a mentor to provide perspective and guidance. Be proactive and have fun.

CONSIDER THIS When did you last spend time working on your career, beyond just doing your job?

ONLINE If reading from the digital edition, click on the headline for more resources. See other engineering career advancement articles in this issue. www.controleng.com/magazine Fluke ii900 Sonic Industrial Imager was among projects Prabhakar worked on. Learn more at www.controleng.com/NPE. control engineering

May 2020

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2020 CAREERUPDATE

David P. Hostetter PE, LEED AP, CEM, SCS Engineers

Five mindful career tips

Engineering career decisions should consider opportunities, balance, the long view, flexibility and how to develop well-rounded expertise.

never could have predicted the path that I took to get where I am now, as I look back on the first quarter of my engineering career. That said, I am where I planned to be at this point in my life. I had a vision for today, 10 years from today, and after another decade. An engineering career vision is not a pathway engraved in stone, but instead should be approached as a series of goals to achieve, with a set of principles to stay on track. Five tips to help an engineering career follow.

1. Engineering opportunities in life

One way to look at our lives is as a series of choices or opportunities. We are all living an adventure. Little things add up. We are presented with a multitude of mini-opportunities each day: • Do I catch up on email, or do I spend time mentoring a younger engineer? • Do I read the article about best practices, or get my fourth cup of coffee? • Do I leave work on time to spend time with my family, or stay late to work on my presentation? • Do I work out, or watch TV?

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KEYWORDS: Engineering career tips Plan ahead to see the engineering opportunities in life. Be flexible in working on an engineering career. Engineering experiences should include diversity and expertise.

CONSIDER THIS Invest time and resources into developing skills in your areas of passion.

ONLINE If reading from the digital edition, click on the headline for more resources on career development from May 2020 Control Engineering. www.controleng.com/magazine www.scsengineers.com

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May 2020

Some choices may not have an enormous impact on life, but every choice adds up in time, which collectively does impact life. Be consistent with principles and choose the small opportunities that align with the chosen vision. Stephen R. Covey’s “The 7 Habits of Highly Effective People,” Franklin Covey Co., offers more details on how to apply these ideas, in the second habit, which discusses starting with the end in mind.

2. Balance engineering life

Live a life of balance in engineering and elsewhere. Life is not all about work. Work hard and play hard. Know when to say yes or no. Sometimes in life, clear-cut life altering decisions present themselves. In these times, it is easy to know whether to say yes or no to the opportunity. Other times, the “right decision” may not be as clear. Cling to your principles, get guidance from trust-

control engineering

ed advisors and be firm in your choices. Your “yes” and “no” each should be final. Decide and move forward with your life. It is neither helpful nor tenable to live a life of constant doubt and “what-ifs.”

3. Engineering: Take the long view

Engineers often can see the longer view with many projects. They should apply that practice to their careers. Charles R. Swindoll is quoted as first saying, “Life is 10% what happens to you and 90% how you react to it.” What did I learn from my 90%?

4. Be flexible in engineering, career, life

We can use our goals and our principles to help guide us through sometimes tough decisions. Use opportunities and hardships to mold yourself into the person that you want to be. Setbacks are normal and to be expected. Our path towards our vision is not a straight line. Instead, it is a flexible path that routes around and sometimes through unexpected obstacles in life. It isn’t easy.

5. Engineer a well-rounded expert

Be well-rounded overall and an expert in specific fields. We are passionate about particular areas in our companies or fields; it might be technology, building relationships, design, art, teaching, mentoring, etc. For me, it’s making a difference in the world through my work, helping my clients and coworkers, mentoring and technology. Listen to yourself and invest time and resources into developing skills in your areas of passion. Do as much work in these areas as you can. Become the person other people call when there’s a problem. This expertise will help advance your career. On the flipside, push yourself to understand all aspects of your company and field from a high level. You never know what you might be doing next or who your next boss may be. Having a good general understanding of everything will help during the inevitable changes in life. ce

David P. Hostetter PE, LEED AP, CEM, is regional RMC manager at SCS Engineers and a Control Engineering and Plant Engineering 2019 Engineering Leader Under 40; Edited by Mark T. Hoske, content manager, Control Engineering, mhoske@cfemedia.com. www.controleng.com

ANSWERS

CONTROLLERS: PLCS, PACS Jim Wilmot, Bernd Raithel, Siemens Industry Inc.

Automation controllers, edge Which to use? A multi-tasking controller combines functions of a PC-based software controller with visualization, PC applications, and I/O device.

oes an application need a modern programmable logic controller (PLC) or an edge device? Attributes of each can help in selecting the appropriate architecture for an application.

Car charging stations integrate a modern controller architecture with compact size, a PC-based controller independent of Microsoft Windows, high-level modular programming structures, and easy integration of Microsoft Windows applications, with a multi-tasking PLC and touch panel. Courtesy: Siemens Industry Inc.

Integrated PC/PLC

tasking controller architecture, which can include safety, security, diagnostics, and high-level motion control.

A PLC brings about a vision of simple, proprietary device running a dedicated ladder logic program performing basic automation tasks, previously left to hard wired relays. Controllers are expected to be high performing, robust and modular, and have onboard high-level communications, standard/open connectivity, and simple integration with PC applications and model-based simulation. Some controllers have these features and can “multi-task,” acting as a PLC, human-machine interface (HMI) and a standard PC in one compact device. A modern multi-tasking controller combines the functions of a PC-based software controller with visualization (an HMI), PC applications (Microsoft Windows or Linux), and central input/output (I/O) connections in one compact device. Such controllers, with pre-installed and preconfigured PLC software controller for the control program, operates independently of Windows for high system availability. This enables the controller’s rapid start-up and supports Windows updates and reboot during ongoing operations. Windows failure does not stop the controller. Applications for optimized controllers include series machine manufacturing and for machines with distributed architectures. Such modular controllers minimize space in compact control boxes on machines, improving the cost-performance ratio. An industrial flat panel connected through the graphics interface can provide visualization, optionally with multitouch functionality. Since the PC is built in, no separate PCs are required. For commissioning, mouse and keyboard can be connected via standard onboard USB interfaces. The gigabit Ethernet interfaces support high-performance connection to higher-level networks. Many applications can benefit from a multi-

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Edge controller

Edge devices provide a platform to run analytics, predictive maintenance and other tools that help optimize production without interfering with production. An edge computing device could be an industrial PC (IPC) or the edge functionality can be integrated in the automation device like an HMI panel. This way the HMI panel ensures stable production and allow for a high degree KEYWORDS: Programmable logic controller, PC, HMI, edge of flexibility in running new programs computing or tools that help increase productivity. Integrated PLC-PC-HMIs help New production concepts for Indusdigitalization. try 4.0 don’t rely on the International Edge computing can run Society of Automation (ISA) automation analytics, predictive maintenance pyramid. Instead, they split production in and other tools. smaller and flexible units that exchange Rugged applications data on many levels. This requires flexbenefit from updated control architectures. ible and scalable HMI systems where the same project and screens can be used on CONSIDER THIS a 7-inch HMI panel, a supervisory control How will more advanced and data acquisition (SCADA) system or controller architectures help optimize applications? a smartphone. The data is available in real time on any device when needed without ONLINE more programming. ce If reading from the digital edition

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Jim Wilmot is factory automation marketing manager; Bernd Raithel is director product management and marketing, Siemens Factory Automation, both with Siemens Industry Inc. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media, mhoske@cfemedia.com.

(www.controleng.com/magazine), click on the headline for more resources, including links to related articles -Compact, multi-tasking controllers yield big digitalization benefits -Automation meets edge computing

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May 2020

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ANSWERS

PLCS AND PACS Bill Dehner, AutomationDirect

Open-source benefits for industrial controllers New controller options make it possible to add open-source features to industrial-grade automation. Think of industrial versions of Raspberry Pi or Arduino controllers.

Figure 1: Arduinos and similar microcontrollers are a staple of the maker community, enabling many hobby-focused computing and automation projects. All images courtesy: AutomationDirect

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May 2020

ndustrial microcontrollers are bringing opensource benefits to industrial applications even though many industrial automation technologies seem to be a frumpy distant relative of the glitzy consumer-grade hardware and software so common in our everyday lives. Industrial controller technologies are closing the gap with consumer cousins, which is creating some significant and unexpected benefits for end users. Industrial automation technologies, including controllers, are often portrayed as developing at a slower pace when compared with consumer technologies, and rightfully so. The lag is explained because consumer technologies only will be adopted into more conservative and rugged industrial applications after proven and accepted in the mass market. Because industrial applications need to reliably operate potentially dangerous equipment for years, it is more important for automation products to be carefully crafted and packaged. This means other controller features, such as ease of use and good connectivity, are often secondary considerations. Over the past 15 years or so, a “maker” culture has gained momentum in the consumer world. This community brings a passion and creativity to using PCs and microcontrollers to operate all sorts of do-it-yourself projects. Most of these developers make these homebrew projects “open source” for anyone to use, but the technologies usually aren’t ready for the factory floor. Industrialized microcontrollers now combine open source benefits with proven industrial platforms to give end users more automation options. CONTROL ENGINEERING

Open-source processing Open-source projects are relevant for industrial applications in many ways. For example, the common Linux open-source operating system has played an increasing role in the past few years as it is embedded within Industrial Internet of Things (IIoT) implementations and as a platform for running control and visualization software. Open-source programmers make code snippets and programs available to all users, generally at no cost. Many would consider this open nature as increasing risk to those implementing it. However, greater openness makes code available for anyone to inspect, and the large community of developers can provide a quick response when issues are identified. From an open hardware standpoint, the two leading microcontrollers are Raspberry Pi and Arduino. The former is more like a miniaturized single-board PC, while the latter is more barebones. For Arduinos, stackable accessory boards called shields add Ethernet, Wi-Fi, GPS, and other extended functionality, making these systems well suited for prototyping and hobbies (Figure 1). Microcontrollers like the Arduino were created for students learning to program in C++ and are designed to be usable by those with any level of programming experience. An effectively free and extensive software library, many low-cost hardware options, and an end-user design focus have made this open-source concept a favorite of the maker community. Microcontrollers’ popularity has made the industrial automation industry take notice because many of the features desired by hobbyists also are needed for industrial projects. Some end users have even incorporated consumergrade microcontrollers into industrial applications, but there is some risk involved related to the differences between commercial and industrial specifications. www.controleng.com

Figure 2: New products, such as AutomationDirect’s ProductivityOpen, offer a way to combine opensource microcontroller functionality within an industrial-grade form factor with I/O designs.

Open-source programming benefits

End users choosing open source for their automation project will certainly benefit from the mashup of contemporary programming options with proven industrial practicalities. Users can mix-andmatch many ways to get just what they need. Sometimes, it makes sense to continue using a programmable logic controller (PLC)-based system, while adding an industrialized open controller networked nearby to perform specialized tasks or calculations. In some cases, users can develop all the control logic and general-purpose calculations in the open controller, and then automate associated equipment with input/output (I/O) devices. Another consideration involves design and maintenance personnel skill sets. While existing industrial users have been trained on PLCs through their careers, the next generation of users are more likely to be comfortable with contemporary technologies and programming languages used in maker hardware. This platform can bridge open controllers with PLCs and I/O, industrial manufacturers can apply their current skillsets while growing their technical staff with new employees who would prefer to work on modern open-source platforms.

Open-source controller applications

As industrial open source gains momentum, users will continue to find new applications. A basic way to use an open controller, even for those who are new to C++, is to configure it as an inexpensive data logger. Original equipment manufacturers (OEMs) can use open controllers as an all-in-one solution for operating machinery, while incorporating more advanced algorithms and data handling than they would with a PLC. Open source also can be a great fit for various semi-industrial applications like environmental controls or laboratory equipment monitoring. More consumer-oriented applications such as automated smoker grills, home automation and agricultural projects also become viable with industrialized open-source platforms. A gardening hobbyist might configure a microcontroller to operate a backyard vegetable hothouse and irrigation. At work, they could use these same concepts to automate much larger-scale agricultural systems and equipment. Someone using a microcontroller at home to remotely control lights and other devices also could extend the same concepts

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Figure 3: Unlike consumer-grade controllers, industrialized controllers like the AutomationDirect ProductivityOpen shown here, are tested in extreme conditions to ensure reliability in the field.

Figure 4: The addition of AutomationDirect ProductivityBlocks graphical programming software gives end users another accessible way to incorporate opensource Arduino microcontroller functionality into their industrial projects.

to automate lighting and environmental controls at a commercial or industrial facility.

Industrial environments

The proliferation of consumer-grade microcontrollers might be a tempting automation choice, especially for machine manufacturers, due to the low hardware cost. However, any controller unable to withstand an industrial environment will KEYWORDS: PLC, PAC, opensource controllers drain support budgets because up to Industrial automation 20% of operating expenses are typicalcontrollers are catching up with ly maintenance-related. Now that PLC consumer-grade models. and programmable automation controlOpen-source controllers offer lers (PACs) technologies have evolved to many previously impossible include industrialized open-source hardoptions to industrial automation. ware options, end users can incorporate ONLINE modern automation systems they want Read this article online at using the robust platforms they need. ce www.controleng.com for “From

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Bill Dehner, technical marketing engineer, AutomationDirect. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.

PLC to PAC and beyond” and “Reducing open-source controller risk” links to related articles.

CONSIDER THIS What open-source hardware options are the most wanted?

control engineering

May 2020

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ANSWERS

EDGE CONTROLLERS Darrell Halterman, Emerson

Edge controller, PLC, or PAC?

Edge control technologies excel at familiar PLC and PAC applications while delivering future-proof computing and communication options.

dge controllers can provide advantages in many applications where traditional industrial controllers have been used. For commercial and industrial computing products, software and hardware development progress proceeds in tandem, with the lead alternating. Sometimes the software complexity and features increase in a way that bumps into processing limitations; then there are times when hardware advances unleash newfound capacity for more sophisticated software. It is easy to look at today’s traditional operations technology (OT) industrial controller options, represented most often by traditional programmable logic controllers (PLCs) and process automation controllers (PACs), and see them as mature technologies with capable software and fast hardware. The challenge is identifying what comes next. A few industry trends are pointing the way. Modern consumer and commercial computing experiences are ripe for merging into industrial products. Internet of Things (IoT) devices are becoming commonplace and many are looking at incorporating Industrial IoT (IIoT) devices into automation systems. Digital transformation requires connecting with many data sources, collecting and storing the data, visualizing and analyzing it, enabling optimized operations.

Figure 1: Edge controllers, such as those offered by Emerson, combine deterministic control like a PLC or PAC, and independent general-purpose processing like a PC. All figures courtesy: Emerson

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CONTROL ENGINEERING

The journey to realize value in these trends calls for something new; an edge controller that is more than a PLC or a PAC. Edge controllers are making it possible for implementation of robust automation systems to continue as they always have and seamlessly add the latest communication and application development options. Edge controllers can upgrade existing systems, create new designs, improve productivity, address skill gaps and enhance security.

Edge controller hardware, software Casual observers and implementers of industrial technology can be excused for believing the industrial controller world has plateaued in processing power and physical footprint, looking at simple processor clock speed. Cutting-edge commercial and industrial processors, however, have realized substantial processing performance gains due to multi-core designs and increasing numbers of processor cores in a device. At the same time, hardware-level virtualization provides a convenient way to manage multiple cores and assign them to virtual machines (VMs). PCs and servers used in conjunction with industrial controllers already benefit from this improved computing performance coming from the fast-paced commercial world. Deterministic industrial control systems, on the other hand, require high speed, repeatable and timebased processor execution. Unlike many commercial applications, any industrial application of VMs and multi-core management must be free from jitter or any other deviations from reliable timely operation. Realizing equivalent performance gains for industrial applications requires a new class of controller, and the edge controller was born. (Figure 1). These controllers feature multiple cores managed through carefully crafted VMs. A real-time operating system (RTOS) supports reliable, deterministic runtime control, similar to a PLC or PAC. The real upgrade is a second on-board general-purpose operating system (OS) running a variant of Linux. The two OSs are independent at the hardware level and can communicate with each other via OPC UA. The “open” general-purpose OS can be rebooted independently without affecting the deterministic runtime. Combining a deterministic runtime with a generalpurpose OS builds on traditional control methods by enabling closely-integrated deterministic computing www.controleng.com

Figure 2: A bare metal virtualization hypervisor design as used with Emerson edge controllers delivers rock-solid deterministic control in parallel with an independent general-purpose OS.

and secure real-time data-access technologies.

What makes edge controllers different?

Conventional PLCs and PACs will continue to be available for many years, although today, many users find significant overlap in these product descriptions. The term PAC has been used to describe controllers with more advanced control strategies and communication capabilities than a PLC, but in fact, many PLCs have been creeping into PAC capability territory. PLCs and PACs are good technologies developed in different eras. Edge controllers can update or replace PLCs and PACs and offer advantages by implementing carefully-designed OSs for addressing OT and IT needs for control, communications, and application development. As dedicated control devices with a specific functional scope, basic PLCs are often “bare metal” designs or use an extremely limited and proprietary OS. PACs gained more advanced communication and functional services, while preserving a deterministic runtime, through the use of an RTOS. For creating an edge controller, which adds at least one general-purpose OS in addition to the deterministic runtime, designers must address new considerations. Hosting all these functions in one OS puts deterministic performance at risk. Incorporating a bare-metal virtualization hypervisor, enables deploying a rock-solid deterministic runtime securely and independently in parallel with a general-purpose OS on the same platform (Figure 2). This foundation is crucial. PLCs used to be isolated or communicated with slow and cumbersome serial links. PACs included better industrial protocol implementation and Ethernet for improved connectivity and interoperability. Edge controllers deliver these advantages, and can perform in an increasingly IT-connected environment. They should incorporate a management umbrella adding security and defenses suitable for prevalent IT-like issues like network storms and denial

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Figure 3: Edge controllers implemented into automation systems provide a good platform for those entering the workforce to apply coding skills and mobile computing experiences.

of service (DoS) attacks. IT-oriented protocols with built-in security such as OPC UA, MQTT and secure sockets (HTTPS, SSL, FTPS) can provide appropriately secure communications performance. For application development, PLCs used mostly proprietary ladder logic and relatively rudimentary tools. Adopting concepts from the greater software industry, PACs may offer a level of support for standard IEC-61131-3 programming languages, custom user code blocks, and some basic capabilities for code reuse and KEYWORDS: Edge controllers, object-oriented design. A well-designed operations technology edge controller preserves the deterministic Edge controllers can provide runtime, and adds a computing environplant operators and end users ment for performing analytics, data aggrewith better performance on the gation, and other advanced tasks. plant floor. The general-purpose OS allows appliEdge controller suppliers should ensure their product can validate cation development in IT-oriented lanthe supply chain and incorporate guages like C and C++, Python, and Java. security technologies. The most flexible architectures can allow End users are focused on OT personnel to focus on the determinfinding controllers that deliver istic system, IT personnel can work on strong performance and security for their applications. the general-purpose system, and the two groups can coordinate and crossover as ONLINE needed or desired in a clearly defined Click on the headline to read manner. more on: Edge controllers can help in many • How to move to edge control areas by delivering a combination of the • Controller usability latest technology coupled with ease of • Controllers fill the skills gap use. ce • Edge controller cybersecurity

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Darrell Halterman, senior product manager, Emerson. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.

• Edge controller performance criteria

CONSIDER THIS What is your biggest consideration when choosing an edge controller?

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ANSWERS

PLCS, PACS

Josh Eastburn, Opto 22

Industrial controllers: past, present, future Increasing technology integration, cross-pollination and connectivity have shaped the industrial controller development and future: PLCs, PACs, edge.

ince the advent of the programmable logic controller (PLC), automation controllers of all kinds have migrated into industrial applications, including programmable automation controllers (PACs) and today’s edge programmable industrial controllers (EPICs). Users have many options in terms of cost, footprint, input/output (I/O) density, fieldbus compatibility, communication, programming options, and processing speed with competition among vendors seeking supremacy. While it’s generally true diversity is healthy for the market, it also can be a source of frustration for engineers and end users. Selecting a control platform is often a long-term investment and carries related overhead like training and support contracts. Decision-makers want the reassurance they are putting their money to work in the right way. Rather than taking sides on the issue, however, it’s better to look at how the industry arrived at this point. What were the trends that drove the evolution of these different control solutions? How are these trends at work now? And how should users invest their automation dollars in the future to be sure they make winning bets?

Figure 1: Today’s edge controllers benefit from decades of technology integration, offering diverse I/O options, multiple communication interfaces, and embedded HMI and programming options. Images courtesy: Opto 22

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Controller, I/O integration cycle An obvious pattern that emerges from studying past decades of progress in automation control is how successive generations of a particular technology fed the development of new I/O and control options. For example, when the first I/O systems were developed, the standard for control and sensing from the field relied on electromagnetic and pneumatic components, which were subject to physical degradation that limited their lifespan. Compact, low-voltage components, like solid-state relays, drove users to demand more options for integrating I/O directly CONTROL ENGINEERING

into their systems. This led to the first modular I/O around the same time electronics companies were bringing high-tech computing into the mainstream. The sensitive electronics in those systems meant they needed to interface with external I/O in order to interact with the real world. This led to the first serially addressable I/O racks, which were an alternative to the chassis-based I/O used in PLCs. Going from specialized, individual I/O devices to modular I/O to bussed I/O exemplifies a pattern repeated in industrial control. Later generations of control platforms combined and embedded I/O processing circuitry. Modules expanded from one I/O channel to 32 channels, and now I/O comes built into PLCs and other standalone devices. In some cases, I/O channels can be configured to accept a variety of different signal types on a channel-bychannel basis. This pattern demonstrates how innovation diffuses through the industry: Over time, an individual innovation becomes modularized, partnered with other technologies, and then embedded into those technologies to become part of a new cycle of innovation. For PLCs and PACs, this pattern has given us smaller controller and I/O module footprints. It has yielded greater computing power “per square inch” as math and programming co-processor functions have been incorporated directly into control boards, as well as other devices, like I/O, transmitters, and network gateways. The same pattern manifests in the propagation of new embedded communication interfaces and protocol standards into controllers over time.

Controller cross-pollination Interwoven with the integration cycle is the parallel trend of cross-pollination: technology innovations from outside the industrial control market making their way into controllers. Continuing with the history of bussed I/O, we can see how this trend also led to the development of new controller options. Serially-bussed I/O led to parallel I/O busses and other solutions that let mini- and microcomputers www.controleng.com

Figure 2: Early Progammable automation controllers (PACs) drew on PC technology to provide a wider feature set, including discrete, analog, and serial communication as well as high-level programming languages.

Figure 3: Modern industrial control continues to move toward higher degrees of connectivity between systems, like direct-to-cloud I/O.

interact with I/O. This also spurred the idea of an independent I/O communications processor, which decoupled the I/O from the computer, allowing anything with a communications port to interact with it. As I/O modules and I/O processors improved, these early hybrid controllers were able to offer analog signal processing options, which was something found only in distributed control systems (DCSs) at that time. Since ladder logic — used by PLCs as a programming language — wasn’t designed to handle analog data formats, this led to new programming languages for hybrid controllers. Then low-cost IBM-PC alternatives began to flood the market. Since PCs were the primary control option for hybrid systems, this created concerns about reliability. It made sense for vendors to develop an industrially-hardened alternative, which crystallized the I/O, networking and programming components of early hybrid solutions into a system, which would later be called a PAC. PACs used the same processors that powered PCs and could offer a feature set that filled a niche between low-cost, PLC-based discrete control and high-dollar, DCS-based process automation. Innovations from the high-tech business and consumer PC market led to opportunities for industrial control evolution. This trend has accelerated as the operations technology (OT) domain has merged more with the information technology domain. It appears, for example, in the wave of mobility solutions entering the market in recent years. It’s also manifesting in the push for Big Data, cloud analytics, and machine learning (ML) support, which are technologies that originated outside of industrial automation.

tems continues into the future, where will it take us? How should engineers invest budgets to ensure they can ride that wave? Based on the patterns explored here, we can derive guidelines that can help companies select the right control technologies to do that.

Three tips for future controller use

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

As the trend toward deeper technology integration, greater cross-pollination between industries, and greater connectivity between devices and sys-

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1. Focus on design over features Understanding that technology will continue to improve over time, becoming more tightly integrated and embedded, it makes sense to prioritize investment in the aspects of a control system that cannot be changed easily or quickly. Engineers need to emphasize the control system architecture over the whiz-bang features of the moment. 2. Look for outside innovation If engineers seek to design systems that will evolve over time to keep up with the pace of digital transformation, reduce maintenance and rework, and impress end-users, they can remember the technologies that define the future have often come from outside the industry. 3. Keep an “open” mind Squabbling over market share for proprietary technologies stymies innovation while supporting open standards raises the ceiling on what is possible for everyone. With increasing connectivity as a goal of Industry 4.0, engineers need to invest in technologies that create the opportunity for disparate systems to work together. ce

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KEYWORDS: PLCs, PACs, Edge

controllers Programmable logic controllers (PLCs) and programmable automation controllers (PACs) are converging as technology advances. Industrial controllers are becoming more connected and useful on the edge of applications thanks to the Industrial Internet of Things (IIoT). While they’re converging, companies need to know the difference to make the right choice for their applications.

ONLINE Click on headline or see this article at www.controleng.com for more about controller connnectivity and fieldbus wars and on each tip.

CONSIDER THIS What is the next step in the industrial controller’s evolution and what impact will it have on engineers and manufacturers?

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ANSWERS

INDUSTRIAL ETHERNET Sree Swarna Gutta, Beckhoff Automation

Combine Ethernet, fieldbus advantages, avoid limits EtherCAT provides reliable, deterministic communication through industrialhardened hardware and unique functional principles. How does EtherCAT work?

etworking technologies for industrial applications have grown in capabilities and number. Fieldbuses were introduced in the late 1980s as digital replacements for analog 4-20 mA relay systems for programmable logic controllers (PLCs), but few could keep up with the faster cycle times of emerging PC-based machine control. During the ensuing fieldbus wars, engineers and plant management began gravitating towards realtime-capable fieldbus systems based on Ethernet that could deliver high speed and help drive the information technology/operations technology (IT/OT) convergence. Ethernet-based systems are commonly used as the many flavors still in use today prove. However, the question now is not which flavor should plants choose, but whether they need to choose one at all. Ethernet conforming with IEEE 802.3 Ethernet communications standards has also come a long way since that time, and many new components support communication without being tied to a traditional fieldbus. Would this move help plants ditch expensive managed switches and other shortcomings of popular fieldbuses? Would it get rid of vendor-specific protocols? While some industrial Ethernet systems have limitations, using standard Ethernet for missioncritical manufacturing, packaging and material

The EtherCAT industrial Ethernet system offers significant benefits over standard Ethernet for deterministic, real-time manufacturing applications. Images courtesy: Beckhoff Automation

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handling applications would be a mistake. The real-time capabilities, time synchronization and independence sought by engineers considering this option are already available in open technologies such as the EtherCAT industrial Ethernet system. EtherCAT offers determinism, robust hardware for industrial environments, flexibility in system architectures and built-in security to protect machine- and enterprise-level networks without IT departments intervening.

EtherCAT determinism, reliability

When using Ethernet at home, very few activities can go critically awry. It usually isn’t mission critical if a webpage doesn’t load properly, an email fails to send, or Netflix freezes. Maybe this adds another 2 seconds or even a minute, but it doesn’t qualify as mission critical. Most consumers don’t fret much about the shortcomings of standard Ethernet, such as poor bandwidth utilization, stack delays, switch latencies and star topology. In industrial settings, however, reliable data transmission is crucial. If commands do not make it from the machine controller to individual components quickly, and if the controller does not receive adequate feedback, serious consequences could result. Compared to standard Ethernet and other industrial Ethernet protocols, EtherCAT provides the reliable determinism required in applications across industries. Even at the industrial Ethernet system’s 100 Mbit/s communication speeds, users are assured with reliable, synchronized sending and receipt of frames across machines and factories of all sizes. EtherCAT G and G10 – at 1 Gbit/s and 10 Gbit/s, respectively – also will provide the necessary bandwidth for applications with high degrees of machine vision, high-end measurement, advanced motion control, robotics and mechatronic systems. A unique branch controller model will allow 100 Mbit/s EtherCAT networks to integrate EtherCAT G branches, and vice-versa, with the simple addition of a coupler. This ensures system scalability and the ability to upgrade brownfield applications without a complete rip and replace. www.controleng.com

Industrial applications call for industrial-hardened devices, and EtherCAT offers IP67-rated I/O modules for mounting in the field.

The EtherCAT Technology Group (ETG) adopted EtherCAT G in 2019. The vendor-neutral organization, with more than 5,600 members, is devoted to EtherCAT technology use. EtherCAT was released in 2003 by Beckhoff Automation. ETG ensures interoperability among more than 200 listed EtherCAT masters and even more slaves from numerous vendors. Developers can design devices based on the open EtherCAT standards.

Industrial Ethernet, hardened hardware

Production environments require technologies that can withstand extreme conditions. Industrialhardened I/O terminals offer more form factors and functionality than the consumer grade routers and switches IT departments might use inside an office. These can include classic IP20 cards, IP67 and IP69K field-mounted I/O boxes and PCB board-mounted plug-in modules for series production machinery. Even standard Ethernet cables should possess proper shielding and connectors designed for industrial use or communication issues could arise. As an open solution, EtherCAT interfaces with “regular Ethernet” and more than 25 other fieldbuses and industrial Ethernet systems with the simple addition of a coupler or gateway without causing transmission delays. There are multiple couplers, and Ethernet over EtherCAT (EoE) with TCP/IP communication ensures interoperability in EtherCAT networks.

EtherCAT provides synchronization

Individual networks can support 65,535 EtherCAT devices, automatically configuring hardware without requiring MAC or IP addresses. Free topology selection, whether star, line, tree or another, is built in with no resulting performance losses. Improving already robust diagnostics, troubleshooting is easier through a diagnosis interface that culls existing diagnostic information from across the network. With processing on the fly, EtherCAT possesses the ability to cyclically communicate with many nodes in one Ethernet frame at 100 Mbit/s. With EtherCAT, 1,000 distributed digital I/O could be polled every 30 μs and 100 servo axes every 100 μs. Integration of EtherCAT ASIC or FPGA hardware in slaves and the direct memory access to the master’s network card enables this. The communication protocol processes information independent of CPU performance, protocol stacks or software implementation. EtherCAT network devices synchronize through the principle of distributed clocks. A local clock is built into all EtherCAT devices to continuously maintain a standard time base with deviation of less than 100 nanoseconds between clocks, which accounts for varied communication runtimes. This ensures precise

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PCB board-mounted EtherCAT plug-in modules enable optimal series production of machinery.

synchronization among all devices. It also enables deterministic actual value acquisition and deterministic set value output to achieve absolute precise response times.

Functional safety, security

EtherCAT also offers Safety over EtherCAT (FSoE), a TÜVcertified protocol for functional safety. FSoE is used in all TwinSAFE devices, among others, and it uses a “black channel” approach to provide the necessary safety communication redundancy over the same Ethernet cable used for machine control. FSoE enables digital and analog safety for wide-ranging discrete and process industry applications. The functional principles of EtherCAT also help secure plants from cyber threats. The EtherCAT master controls all slave devices, which nullifies human-in-the-middle attacks. Malware cannot travel over EtherCAT since the system is not based on internet protocol. A network forwards only KEYWORDS: Ethernet, EtherCAT EtherCAT frames, so slave controller Industrial Ethernet offers plants chips filter out any other Ethernet frame, greater levels of connectivity on the plant floor and better access to including those with corrupted or infectreal-time information. ed data. These features and the absence EtherCAT offers determinism, of managed switches also dissuade IT robust hardware for industrial departments from getting involved in environments and built-in security production systems. to protect machine- and enterpriseWhile standard Ethernet works well for level networks. consumer and ancillary industrial compoONLINE nents, it is not ready to run machines. ce Click the headline to see a section

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Sree Swarna Gutta, I/O product manager – USA, Beckhoff Automation. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.

on “EtherCAT basic functional principles.”

CONSIDER THIS What benefits does your plant receive from industrial Ethernet and in what ways can it be improved?

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ANSWERS

ETHERNET Steve Fales, ODVA

Five key ways an industrial Ethernet protocol can use TSN Time-sensitive networking (TSN) helps industrial Ethernet in five key ways.

ime-sensitive networking (TSN) in the industrial space will be made up of a subset of IEEE 802.1 standards, known as the IEC/IEEE 60802 TSN Profile for Industrial Automation, which are in the later stages of being selected and approved. The significant amounts of diagnostic and prognostic data, on top of existing control traffic, that will be added by information technology/operations technology (IT/OT) convergence, is a key driver of the set of the standards for transmission of time-sensitive data over industrial Ethernet networks. TSN will be a practical option to meet the needs of time critical applications, create flexibility in network design and plan for the future brought about by Industry 4.0 and IIoT. Furthermore, TSN will enable greater industrial communication interoperability and can work with existing IEEE 1588 time-synchronization methods such as ODVA’s CIP Motion and CIP Sync. ODVA recognizes the importance of TSN and is engaged in work through its member companies to adapt EtherNet/IP for TSN.

Figure 1: TSN time standard relationship diagrams show how TSN can meet the needs of time critical applications. Diagrams courtesy: ODVA

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1. Help time-critical applications

TSN prioritization of data, to ensure motion data isn’t slowed down by routine diagnostics as an example, can take place within Ethernet bridges in different ways based on user commissioning. The IEEE 802.1Qbv Queuing Structure graphic below shows an example of TSN prioritization using some of the following key prioritization mechanisms:

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• Shapers – Such as strict priority quality of service (QoS) and the credit-based shaper. These algorithms give precedence to high priority traffic and ensure fairness on the wire. While these mechanisms are not new, the shared language to configure them is. • Preemption – Pauses an existing packet transmission to allow higher priority data through. • Scheduled traffic – Control transmission of traffic based on enabling and disabling switch queues on a configured time-based schedule. These key TSN prioritization mechanisms also have companion techniques to help provide a solution set, including: • Ingress policing – Knowledge and policing of expected ingress traffic on a port to decrease the probability of a malicious or misbehaving device from affecting overall network determinism. • Frame replication and elimination for reliability – Layer 2 redundancy that uses multiple virtual paths on physically separate infrastructure in a meshed network with active topology control.

2. Create flexible network designs

TSN opens up the possibility for industrial networks to have new technologies on the factory floor, such as cameras that feed image recognition algorithms for quality control, alongside traditional motors, valves, and sensors, and even existing motion control applications using variable frequency drives and ODVA’s CIP Motion. Keep in mind fundamental principles of segmented network design and architecture for reliability and security are still a recommended best practice for optimal performance. The clock is a key time consideration to enable flexibility in network design with TSN as master time needs to be kept by specially-designated devices known as grandmaster clocks while other devices will need to be capable of synchronizing with the master time clock, in much the same way time is kept with IEEE 1588 Precision Time Protocol. Devices that do not support TSN can be used on the same network, but may only be end station or engineering tool devices. TSN uses IEEE 802.1AS www.controleng.com

which implements a peer-to-peer time delay mechanism and is a profile of the IEEE 1588 Precision Time Protocol. CIP Sync uses an end-to-end time delay mechanism and is the default profile in the IEEE 1588 Precision Time Protocol. CIP Sync has the advantage of not requiring all devices in the path from grandmaster to the ordinary clock consuming time needing to be time aware as shown in in the clock systems graphic below. CIP Sync and TSN time profiles are sufficiently precise to meet the needs of industrial automation now and in the future and can be converted to each-other via a dedicated device.

3. Enable Industry 4.0, IIoT

Networks are now facing the impending addition of large amounts of data from the factory floor to edge devices and/or the cloud and back for system analysis and prognostic purposes due to Industry 4.0 and Industrial Internet of Things (IIoT). Increased bandwidth as a result of technologies such as Wi-Fi 6 and Gigabit Ethernet will help to mitigate potential data packet delays, deviation in data transmittal relative to the time clock, or packet loss. Keep in mind it is hard to foresee all of the new ways that will be created to produce and consume industrial data in the future. Who could have foreseen the creation of programmable logic controllers (PLCs) that can handle safety and standard control when all that existed were safety relays? Physical and digital roads are no sooner built than they are clogged with traffic, which can benefit from prioritization.

4. Enable greater interoperability

The goal is creating one overarching set of TSN standards at the data link layer that allows for increased network interoperability across the application layer. This means EtherNet/IP (ODVA), Profinet (PI North America), and OPC-UA (OPC Foundation) traffic can all co-exist on one network and respect the same quality of service (QoS) considerations, with the addition of common time and common prioritization. Data packets with common headers and standardized priority levels will make this possible. Once finalized, TSN will enable prioritization of time critical data on industrial networks based on specific rules and methodologies that will be applied by TSNcapable network switches and bridging devices.

5. Work with other time synchronization

Ever increasing demands on manufacturing efficiency and output led to the development of industrial Ethernet networks like EtherNet/IP, which offers greater speed and bandwidth, higher node counts, as well as improved diagnostics and easier vertical integration compared to traditional fieldbus. Network extensions like ODVA’s CIP Motion and CIP Sync were then created to address specific applications such as the use of proportional motion

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Figure 2: Illustrating the fifth point, EtherNet/IP network architectures for CIP Motion and CIP Sync will work with TSN Capabilities.

control in positioning conveyors that required a higher level of determinism. CIP Motion and CIP Sync will continue to be supported even with the advent of TSN. A time gateway function also is anticipated to allow CIP Motion and CIP Sync devices to interoperate across TSN networks. Along with existing network extensions such as CIP Motion and CIP Sync, the TSN standards for sending time critical data via industrial Ethernet are an option to meet the needs of high determinism applications, add network design options and plan for the significant future increases in data traffic brought about by IT and OT convergence. A new level of interoperability will also be possible as other communication network implementations can coexist on Ethernet with TSN. EtherNet/IP’s advantages of being a well-adopted, object-oriented, KEYWORDS and multi-vendor interoperable network Industrial Ethernet, TSN will remain with the additional support Time-critical, flexible network design of TSN. Industry 4.0 and IIoT The high level of standardization, Allow greater interoperability. leveraging of TCP/IP, and usage of commercial off the shelf hardware will also CONSIDER THIS stay consistent. EtherNet/IP will continue How can more deterministic meeting critical industrial communication industrial networking offered TSN help your time-critical and control needs today and tomorrow, applications? including interoperability and a perforONLINE mance guarantee for highly-engineered If reading from the digital applications with TSN. ce

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Steve Fales is director of marketing, ODVA. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com.

edition, click on the headline for more resources. www.controleng.com/magazine www.controleng.com/ networking-and-security/ethernet www.odva.org

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ANSWERS

ETHERNET

Jon Breen, Breen Machine Automation Services

Industrial vs. office Ethernet Learn four differences between Ethernet reliability, failures.

ffice Ethernet and industrial Ethernet implementations differ in four critical ways that determine reliable or unreliable operations: Determinism, noise immunity, environmental ratings, and protocols. Ethernet, an evolving set of standards under IEEE 802.3-2018, has overtaken other networking standards, accounting for 52% of new installations, according to HMS Industrial Networks’ annual study in 2018. There’s no sign this trend will slow any time soon. Home and office familiarity can support Ethernet use in industrial automation, but know four important differences.

1. Network determinism

Network speed is often defined in megabits per second (MB/s). In industrial applications, network hardware is most often rated for 100 MB/s, with 1,000 MB/s starting to gain popularity. In the office, this is usually the important speed metric, but in an industrial control network, determinism is more important. When controlling or monitoring real events at high speed, device communication must occur in a consistent time frame. If an office printer has a 2-second delay while receiving a file, that’s no problem, but if a servo motor has to wait that long, it could be catastrophic. Separate automation and office networks.

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KEYWORDS: Industrial Ethernet Determinism determines scheduled communications. Environment and noise can interrupt Ethernet signals. Protocols are the software that provide communications.

CONSIDER THIS Reliable communications can improve throughput.

ONLINE If reading from the digital edition, click on the headline for more. www.controleng.com/magazine Breen Machine Industrial Ethernet Design Guide www.breen-machine.com/ebook https://standards.ieee.org/ standard/802_3-2018.html

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2. Noise immunity

The industrial environment is electromagnetically noisy. Large currents, often driven by switching power devices like variable frequency drives (VFDs) are notorious for creating high frequency harmonics and electromagnetic interference (EMI) that can affect other devices. A few options can reduce EMI’s effect on an industrial network: Segregation, twisting signal pairs, bonding and shielding. Include all four if practical. Follow manufacturer’s recommendations. VFD manuals cover grounding and bonding. Don’t skip that.

3. Environmental ratings

Industrial environments can be very harsh on components. Extreme temperatures, moving parts, reactive

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The balance of knowledge helps with reliable Ethernet communications. Courtesy: Breen Machine

chemicals, and high voltages are all common. Each cable and device needs to be rated for the environment, or enclosed to protect it. Network cables can be purchased to resist harsh environments. Cables must have insulation rated for the highest voltage in the enclosure or wireway. Even though Ethernet is low-voltage, it often needs a 600-V-rated jacket. If the cable will be flexed in normal operation, get a flex-rated cable. If it goes through an exposed tray, National Electric Code (NEC) requires a tougher jacket to protect against mechanical damage. (Buy a tray-rated cable.) For other challenging environments, find crush-rated and abrasionresistant cables and ratings for extreme temperatures, flame resistance, and oil/chemical resistance.

4. Industrial vs. office protocols

When plugging in an Ethernet cable at the office, we don’t need to know what’s going on inside the cable. In industry, not all Ethernet is compatible, so we have to know a little more. A protocol is a language devices use to communicate over an Ethernet cable. Protocols are often used in layers, with a low-level protocol providing the foundation for a high-level protocol. Since industrial applications have different needs than building/office/home networks, protocols exist to fit these needs and each has its own tradeoffs. When an industrial protocol is defined “on top of ” a widely used protocol (often TCP/IP), standard architectures and hardware can be used. When a protocol is defined at a low level (stacked on few other protocols), architecture and hardware options may be more limited. The other tradeoff between these two broad categories is performance. A low-level protocol will usually be more deterministic than a high-level protocol. In practice, Ethernet protocol is usually dictated by programmable logic controller (PLC) choice. Each PLC manufacturer has a preference, and while some offer a few options, best results (easiest implementation, best support) usually follow by staying with that manufacturer’s standard. ce

Jon Breen is founder/owner, Breen Machine Automation Services, a Control Engineering content partner. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com. www.controleng.com

ANSWERS

ROBOT SAFETY, CYBERSECURITY Robotic Industries Association (RIA)

Robot cybersecurity threats: What to watch for Minimizing robot risk means protecting against cyberattacks, security breaches.

ndustrial robots are helping to change the way we manufacture products for decades. We use them to deal with risk on automotive assembly lines, operate them in mines, and use them in other hazardous environments, but advances in connectivity systems for industrial robots are adding a new cause for concern. Although the benefits of such connectivity are numerous, the risk of cyberattacks must be addressed to ensure safety.

Security threats for industrial robots

Many service robots and automated systems are now connected to company networks and the internet, leaving the system sensors vulnerable to hacker attacks. Today’s Industrial Internet of Things (IIoT) devices communicate directly with whatever or whoever needs the data they collect. Thanks to this connectivity, hackers no longer have to attack sensors at the bottom of the hierarchy as laid out on the Purdue model, a commonly used architectural reference model containing five levels from zero to four. For example, a drive for a welding robot may be transmitting usage data to its builder via the internet. It may report information like, “based on my duty cycle, I will need a certain part replaced in 12 days and 2 hours.” The robot is exchanging this data to maximize performance and uptime, but this communication could be at risk of being intercepted. The Purdue model and other security standards are in place to protect the robot’s systems, but if there’s a flaw in the robot’s operating system, a hacker may be able to take control of the robot or disable it with a buffer overflow or some other type of communications attack. To prevent cyberattacks and maintain robotic safety, manufacturers need to be aware of the possible security threats to industrial robots. If a hacker gets control of an industrial robot, the intruder could cause defects in part production. This would compromise the final use of whatever it is producing, causing significant losses for the company.

System blockage

A connected, industrial robot is vulnerable to ransomware attacks. A hacker could use such an attack to block access to data and the entire production system.

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Physical damage, process disruption

An attacker may take control of a robot that can harm operators. The hacker may use the robot to interfere with security mechanisms, damage a work cell, or attempt to cause injury. Production can be compromised in the long term. A hacker may alter or suspend a process, which could jeopardize company operations.

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With an operating system flaw, a hacker

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may be able to take control of the robot.

Exfiltration of sensitive data

Like with all industrial objects connected to the company’s internal network, a security flaw in an industrial robot represents an access point for attackers. Hackers could use this vulnerability to gain access to and steal confidential information. With the increasing popularity of automation in industrial processes, security threats are heightened. “If hackers were launching an attack against a plant, looking at the supply chain and at smaller manufacturers that provide equipment, such as robots, would be an easier target. This is something that big and small manufacturers need to consider,” said Nigel KEYWORDS: robotics, operations Stanley, chief technology officer for globtechnology (OT) al OT and industrial cybersecurity at TÜV A robot needs to be protected Rheinland. against potential cyberattacks and security breaches. Multilayered complexities of cybersePotential breaches include curity should be addressed when workexfiltrating sensitive data, physical ing alongside industrial robots. For a damage and system blockages. robot to be safe, it should be protected Increased automation on the plant against cyberattacks and possible secufloor will only make cybersecurity for rity breaches. ce robots more important.

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This article originally appeared on the Robotics Online Blog. Robotic Industries Association (RIA) is a part of the Association for Advancing Automation (A3), a CFE Media content partner. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.

ONLINE Go to the robotics sub-channel under discrete manufacturing at www.controleng.com for additional stories about the latest developments.

CONSIDER THIS What is the biggest cybersecurity you have when it comes to robots?

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ANSWERS

ROBOT SAFETY

Roberta Nelson Shea, Universal Robots

Compliance for robotic companies Making robots compliant regardless of the environment is a challenge. See three questions companies should ask.

ompared to traditional industrial sectors, robotics is a relatively young field with only about 40 years of deployment history in workplace environments. Technology within this field however is advancing incredibly fast, and thus, compliance needs to be adaptable to keep pace with these rapid changes. Another challenge is conveying the many facets of compliance comprehensibly to end customers and integrators to clear up issues such as: When is a robot system really compliant? And what are the requirements to which the robot and robot system have to comply? Companies should keep in mind three aspects of robotic compliance.

1. What is compliance in a robotic context?

The first thing to be clarified for compliance is what industry and for which purpose will this robot system be used. Compliance requirements differ from application to application, for example, EMC thresholds, temperature, indoors/outdoors, performance or accuracy, work environment and whether employees can come into contact with the robot application.

Figure 1: At Etalex in Quebec, Canada, a safety scanner alerts Universal Robots‘ UR10 robot tending the press brake to slow down to 20% of regular speed as soon as employees cross the yellow line. Images courtesy: Universal Robots

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CONTROL ENGINEERING

For other work environments, such as electronics, pharma-production or foods, there could be additional requirements, such as cleanroom use or washdown. The robot is the arm or manipulator with its controller while the robot system is the robot plus the end-effector for the intended application or use. Depending on the application and industry, there are very different expectations. This is also true for compliance in a safety context, especially when it comes to human-robot-collaboration without guards (“cage-free”). Keep in mind that there are excellent collaborative application using safety laser scanners and these applications are also “cage-free” (no perimeter guard). The fundamental point is that the robots permitted to contact a person are those with power and force limiting (PFL) capabilities.

2. What are the challenges for compliance in robotics?

Robot arms are often mountable in many different ways, such as to a wall, upside-down or on top of a table or mobile platform,and can be equipped with various end-effectors. Robot integrators face further challenges: Will the robot system be compliant for collaborative and “cage-free” use after the addition of end-effector and parts? First, some questions need to be answered. The parameters needed – payload, reach, performance, etc. – have to be clarified for the robot and the additions that be used in a robotic system. From a compliance point of view, many different additional factors exist when a “cage-free” collaborative application is desired. These need to be taken into account. We tackle this challenge in two ways: First, we only guarantee compliance of our “partial machine” – that is, the robot (arm or manipulator, controller and teach pendant) – to enable its use in collaborative applications. It is a power and force limited robot where the capabilities are provided by safety functions. Second, it should be emphasized to distributors and end customers that a risk assessment is required to make the robot application (robot system plus additional parts and equipment) compliant, e.g. to safety standards including the technical specification ISO/TS 15066. www.controleng.com

Figure 2: The free training modules offered in Universal Robots‘ UR Academy features interactive tutorials on how to set up safety zones.

Manufacturers need to be precise in communications with customers and partners. Robot manufacturers can only guarantee the compliance of their product to their specifications and approvals. They can state the robot is accurate to the tenth of a millimeter or that the robot is power and force limited allowing it to be used in accordance with ISO/TS 15066 including Annex A. Annex A covers a range of force and pain threshold values in which a collaborative robot system can be used without guards and protective devices. Manufacturers need to provide safety function information because this is critical to the safe integration and application of robots. Yet it is common to see claims of a “safe collaborative robot” with nothing to back it up and nothing to explain what “safe and collaborative” means. The premise of most collaborative robots to limiting harm is by use of the robot’s safety functions. This means compliance with either ISO 13849 or IEC 62061. But it is often difficult to determine what safety functions are provided with a robot. As a manufacturer, we do our utmost to inform our distributors and end-customers about our robot as comprehensively as possible. We lead the industry in disclosure of our safety certifications and our safety function details. Robots are being used in many different sectors, which means we aren’t able to cover all the applications that partners and end customers might conceive. Applications developed by customers continue to be surprising.

3. Who tests for compliance?

Manufacturers do their utmost to ensure compliance of their products to their stated intended uses and to as many use cases as they can envision, if reasonable. However, just as robotic technology is ever advancing, so is the ingenuity of integrators and end users. As integrators uncover new ways to use and develop robot applications, they have to ensure the complete application complies with applicable requirements. For collaborative applications, these requirements depend on the robot application’s work environment, force values, shape and weight of the end-effector and workpiece and the maximum permissive speed of the robot for the application to

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Figure 3: Aerospace manufacturer Tool Gauge in Seattle, Wash., has deployed a UR5 in a plastics assembly and dispensing application. The UR5 works in tandem with the employee, the force limiting safety system causes the UR robots to automatically stop operating if they encounter obstacles in their route.

remain within selected pressure and force values.

4. We need common ground

There is no unified test apparatus and procedure to test whether an application meets the free-space (transient) contact thresholds, so many have come up with their own testing methods. This results in different forces being measured due to the differing techniques. Thus, differences can arise in determining the limits which each robot should be configured so the PFL collaborative application is compliant. KEYWORDS: collaborative robots, robot standards Compliance managers need a comCollaborative robots are useful for mon and comprehensively accepted tool many manufacturing applications and to measure or simulate the quasi-static and are being used in innovative ways. transient contact values for a given appliWith these innovations, though, cation. There is a need for more sophisticome potential hazards because the cated protective devices that have greater robots weren’t specifically designed for the applications they are being interaction with the robot control, to used for. enable variable speeds as people are closThere is no common standard for er. And end-effectors will undergo many collaborative robots for compliance changes as attention turns towards reducmanagers for different applications. ing their risks. These are some of the next ONLINE challenges for standardization to aid in Read this article at the compliance collaborative and robotics www.controleng.com for links to technology. ce additional stories about collaborative

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Roberta Nelson Shea is chief technical compliance officer, Universal Robots. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.

robots and standards.

CONSIDER THIS Which of the three highlighted questions is the one your company struggles with most and what has been done to address the problems?

control engineering

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ANSWERS

ROBOT SAFETY

Prasanna Shukla, L&T Technology Services

Identify, mitigate robot hazards

Enforce safety rules. Heed appropriate standards. Do risk assessments.

n July 1984, an automated die-cast system operator died of cardiorespiratory arrest in a robotic accident. The operator got stuck between a steel safety pole and an industrial robot. The worker was an experienced employee trained on robotics for a week prior to this fatal encounter. It was later found he had entered the operating zone of the robot in an unsafe manner despite training, instructions, and warnings. A presence sensor in such an application could have potentially averted the incident. This incident established the need to identify and enforce safeguards and practices to mitigate workplace incidents, especially in robotic process automation (RPA)-enabled environments.

Identifying robotic risks

The U.S. Occupational Safety and Health Administration (OSHA) identifies four categories of workplace accidents associated with robotic work cells, all potentially detrimental to production and compliance. 1. Impact or collision accidents: Contact accidents from unpredicted arm or equipment movements, malfunctions, or program alterations 2. Crushing and trapping accidents: The trapping of a worker’s limb or other body parts between a robotic arm and peripheral equipment (includKEYWORDS: Industrial robots, ing individuals being driven into such robotic risk assessments a position and subsequently getting OSHA categorizes four types of accidents in robotic work cells. crushed by peripheral equipment) Robot accident sources, 3. Mechanical part accidents: The according to OSHA, include breakdown of a robot or peripheral equiphuman error, control error, ment can potentially result in an accident. unauthorized access and four 4. Other accidents: From electriothers. cal hazards to pressurized fluid hazards, RIA and NIOSH provide other from environmental accidents due to standards and guidance. the presence of equipment and cables on CONSIDER THIS the floor, among others. Robotic efficiency depends on

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robotic safety.

OSHA: 7 robot accident sources

ONLINE In the digital edition, click on the headline for more on “Robotic system design” and “Robotic worker training, supervision.” www.controleng.com/magazine www.controleng.com/robotics www.robotics.org www.ansi.org www.cdc.gov/niosh www.ltts.com

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OSHA gives seven sources or causes of the accidents mentioned above.

1. Human error: Dangerous, unpredicted movement by the robots resulting from human errors in programming and peripheral equipment setup, or insufficient caution due to familiarity with the robotic movements 2. Control error: Software malfunction, electromagnetic and radio fre-

control engineering

quency interference, and faults in control systems and hydraulic, electrical, or pneumatic sub-control systems 3. Unauthorized access: The presence of any person within a robot’s operating zone without adequate familiarity with the machine and the caution to be observed around it 4. Mechanical failure: Cumulative failure of mechanical parts or unpredictable operations may not be accounted for by the operating programs 5. Environmental interference: The external influence on a robotic operation 6. Power system fluctuations: Disruptions in power systems that directly communicate with the robotic work cell 7. Improper installation: Non-compliance in the installation of a robotic system and its functional testing measures to safeguard against incidents.

Risk assessment, safety, productivity

A comprehensive risk assessment matrix is imperative to contain potential hazards from robots. There are several stages for implementing the safeguard protocol in accordance with the robotic safety standard, ANSI/RIA R15.06-1999 (R2009) Industrial Robots and Robot Systems – Safety Requirements, from the Robotic Industries Association and American National Standard Institute. The National Institute for Occupational Safety and Health (NIOSH) has laid down a set of recommendations and guidance to mitigate risks of incidents on robotics-enabled work floors. These include, but are not limited to, system design and worker training and supervision. Adequate illumination for clear visibility of the operating area and the equipment may sound obvious but is ignored more often than not. Visible signs and floor markings invoke caution in workers. A safe workplace is a productive workplace. Building a holistic culture of safety and accountability includes accounts for all prescribed safety measures. Technology alone is not enough to achieve a zero-hazard (or near-zero-hazard) factory floor. Compliance with industry standards and educating the workforce also can save human lives and enable modern workplaces to harness the advanced optimal functionality of robots. ce

Prasanna Shukla global head of plant engineering practice at L&T Technology Services. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com. www.controleng.com

ANSWERS

INSIDE PROCESS

Kathy Shell, Laura Ankrom, PE; Craig Shell, PE; Jacob Morella; Jacob Lindler; Judith Lesslie, CFSE, CSP; and Paul Gruhn, PE, CFSE

How to run virtual process hazard analysis (PHA) meetings Critical infrastructure needs to keep operating even in the face of the COVID-19 pandemic. People are using ingenuity to remove those hurdles and take advantage of hours at home to focus on management of change issues, process hazard analyses (PHAs), cybersecurity assessments, engineering

and design reviews, standards development, action item closure and training. Industry is learning how to work differently, doing it successfully, increasing efficiency daily and contributing to the safe operation of high hazard processes. ce

Kathy Shell is executive vice president of strategic client partnerships at aeSolutions. Laura Ankrom is senior manager of process safety at aeSolutions in Ohio. Craig Shell is vice president of engineering at aeSolutions in Ohio. Jacob Morella is technical project team manager at aeSolutions. Jacob Lindler is process risk management principal specialist at aeSolutions. Judith Lesslie is senior principal specialist at aeSolutions. Paul Gruhn is global functional safety consultant for aeSolutions. Edited by Jack Smith, content manager, Control Engineering, CFE Media and Technology, jsmith@cfemedia.com.

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See more guidance with this article online. Click the headline. www.controleng.com

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May 2020

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ANSWERS

INSIDE PROCESS

Juan David Medina Gonzalez, Silvia Marina Araujo Daza MSc, Hernan Ivan Cadena Celis, Proctek S.A.S.

Advanced controls, linear programming, fuzzy logic Linear programming techniques and advanced control based on fuzzy logic were applied to improve water injection in oil production. Better control increased field production and allows more effective responses to deviations.

n advanced control strategy was developed for a water injection system composed of two storage pools, and two interconnected independent injection pads. A dynamic simulation model was created using chemical process simulation software, which allows the study of different situations in transient state and proves the feasibility of the control strategy, without developing a real test in the field. The simulated model represents the complete injection system including the pumping units, flow lines and the interaction between facilities. Linear programming techniques (simplex method), and fuzzy logic were used to establish independent unconventional control strategies for the pools and injection pads, and general strategies to unify the system (pools-injection pads) to keep the produced - injected water mass balance stable. The model with the control system was analyzed for different operation cases and unwanted situations showing the process behavior and functionality of the strategy when compared with the historical data of the field.

Oil production, automatic controls

Water injection is considered worldwide as the most common method used and one that most contributes to the oil production as a secondary recovery technique. In Colombia, many of the oil fields use this method to expand oil production. The automation and control of the pumping systems is fundamental to regulate the water injection and efficiently increase oil production. One facility available to perform the water injection in one of the production plants in Meta (Colombia), did not have an automatic control system that allows the stability of the facilities to avoid reaching operational alarm levels and generate an effective response in a preventive and corrective way. This system has a facility to treat the production water, which is then pumped to the injection patterns PAD-3 and PAD-1. Common problems include loss of the pumping units that produce water for industrial uses, loss of the injection units in the two interconnected facilities (injection pads) and variations in the injected flow rate or amount of produced water. To resolve the problem, an advanced engineering system was developed, including process engineering and advanced control strategies. Those involved built a dynamic model using the process simulator software that allowed observation of system behavior in a dynamic way and integrate it with the designed control strategy. The control scheme developed included an unconventional strategy based on fuzzy logic for each injection facility, where the suction and discharge Figure 1: Phase 1 – Global control strategy for the integration of the injection system: pressures of the pump units interThe advanced control area rebuilt the control system on programmable logic server act simultaneously with the flow emulators and developed a two-way communication interface (ProctekHysys2OPC) that passes through each. for real-time communication between the process simulator and the emulated control An unconventional control system. All graphics courtesy: Proctek SAS strategy also was implemented to

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CONTROL ENGINEERING

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Figure 2: General scheme of the diffuse control: The only control element that could be used was the Woodward governor that modifies the combustion motor velocity.

unify the injection system (production water treatment and injection facilities), which is focused on maintaining and achieving the mass balance that exists between the amount produced and injected, assigning the injection flow rate set point automatically in each facility. This strategy allowed to provide greater autonomy, stability and operational continuity to the entire water injection system.

Methodology, process description

The production water treatment facility consists of two interconnected polish pools each with eight pumping units that transfer the water to the injection pads by means of three branches of 30 inches diameter. for each. In the pads there are multistage centrifugal pumps and internal combustion pumps that inject water into the wells. Due to the multiple interactions between the operative variables, this system is considered non-linear, and requires unconventional tools for modeling and defining the control strategies to be implemented.

Dynamic simulation, control strategy

The dynamic simulation model of the water injection system was built in the chemical process simulator software. At an initial stage, the model was built in a steady state to ensure system stability. It was then moved to a dynamic state to represent the behavior of the real process and evaluate it against any perturbation. At this stage the fluid properties, initial operational conditions, the number of pumping units, the pipe diameters and lengths, and other accessories present in the system were established. The boundary conditions included such as pressure specifications in the inlet and outlet streams of the system, and the pumps were characterized with their respective curve. A loss of approximately 15% in efficiency was considered for the pool units. Subsequently, the model was validated by simulating the specific field conditions and comparing with historical data, an average deviation of 5% was found. In general, the model behaves similar to the historical data, which indicates it can be used to analyze the behavior of the system. Finally, the evaluation of different case studies was carried out. The behavior of the facilities was analyzed as if they were working on plant equipment. These studies led to the optimization of the control system

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Figure 3: Fuzzy controller model 3 shows the general scheme of the fuzzy logic controller. An RSLogix Emulator (Rockwell Automation) reproduced control logic for the injection system operation.

with an appropriate control strategy for the process. The advanced control area rebuilt the control system installed in the facilities on programmable logic server emulators and developed a two-way communication interface that allowed real-time communication between the process simulator and the emulated control system. An emulation tool helped KEYWORDS: process control, reproduce control logic developed for process simulation injection system operation. A dynamic simulation model was Through the simulation was possicreated using chemical process simulation software without ble to determine the variables of interest developing a real test in the field. behave in a nonlinear way, so a controlled This was done using linear based on fuzzy logic adapts better to the programming techniques and behavior of the system, since it provides an advanced control based on fuzzy inference mechanism that allows to simulogic. late the procedures of the human reasonUsing process simulators shows ing in knowledge-based systems, it means several benefits by allowing optimization of several systems and that imitates the behavior of the operator process plants. in known situations accelerating or deaccelerating the pumps. CONSIDER THIS For the unification of the injection How could linear programming and fuzzing logic help your advanced system (pools and pads), the mass balcontrol applications? ance was interpreted as a cost function and resolved through linear programONLINE ming techniques, such as simplex, If reading from the digital edition, click on the headline for 3 tables, 1 focused on maximizing the flow. The figure, and more text. optimal flow set point that each facility www.controleng.com/magazine must handle to maximize the injection Learn more about Proctek SAS was subject to these restrictions. in the Global System Integrator The simplex method is an iterative Database. procedure that allows improvement of www.controleng.com/ Global-SI-Database the objective function in each step. The http://proctek.co/en/home-5/ process finishes when it is not possi-

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ANSWERS

INSIDE PROCESS

ble to continue improving the value, meaning the optimal solution has been reached satisfying all restrictions. Implementing advanced control strategies in the injection system is divided in two phases.

units in the pads or in the injection pools, to determine the loss injection capacity and recalculate the new mass balance. The control system for the integration of the injection system is presented in Figure 1.

Phase 1: Injection system integration This strategy sought to increase field production. For this, a variable that directly affects the production was selected, in this case, the injection flow rate. ConsecThe simplex method is utively, a mathematical function was found to describe the an iterative procedure behavior of this variable subject to the constraints and elements of its system. Solving this functhat allows improvement tion with a maximization as the target, the results finally show of the objective function the optimal operating points to maximize flow-rate injection in each step. and improve oil production. The cost function was focused in finding a mass balance between the produced water pumped from the pools and the injected water in each one of the pads. To determine this balance, the operational availability of the vertical pumps located in each pool is taken as a starting point. The total flow data must be distributed efficiently to each injection pads. The distribution criteria depends on several factors:

‘

’

• Number of available units turned on in each pad • Injection capacity of each units. • Position of the valves that interconnect the branches to each pad. The function of the distribution algorithm is to find the optimal flow rate set point and automatically assign it to each of the diffuse control panels for injection flow, and create balance. To achieve this goal, it is necessary to account for the following conditions:

Phase 2: Pad 3 control strategy design This strategy sought to provide more stability and autonomy to the system to resolve disturbances that arise in the process, and are not possible to mitigate effectively and on time through manual operation. The proposed control strategy brings a dynamic equilibrium among the three variables that interact in the injection system (flow, suction pressure and discharge pressure). Tuning the only conventional control loop was not possible due to the strong non-linearity of the model (proved through the dynamic process model), and in turn, it did not consider changes in the suction and discharge pressure. Therefore, a controller based on fuzzy logic better adapts to the behavior of the system. However, the conceptual development of one fuzzy logic controller becomes too complex and with high computational demand. For these reasons, it was decided to design a diffuse controller for each variable that interacts with the pumps. The only control element that could be used was the governor that modifies the combustion motor velocity. It was necessary to choose a unique control output to the speed governor. Following the same scheme of the fuzzy controller, the final output is determined according to the dynamic behavior of the change of the output of each one of the fuzzy controllers in time. The fuzzy logic controller is composed of a block responsible for receiving the percentage error of the process variable with respect to the set point (the percentage is obtained from the range of the process variable). From this percentage error, a variation of the error is estimated an identified as “DeltaError.” The general scheme of the fuzzy logic controller is shown in the Figure 3.

The fuzzy control block • The mass balance must be constantly verified through the flowmeters installed at the exit of the pools and the flowmeter installed at the interconnection point and at inlet of each pad. • If it is impossible to achieve the mass balance planned with the instantaneous conditions of the injection system, the control system will notify the operator to start or stop the pumping units in the pads. • The control system should recalculate the flow set point, in case of the loss of pumping

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CONTROL ENGINEERING

The basic scheme for all loops of all “fuzzy control” blocks was taken from Figure 3. In this case it is proposed to have as error variables of entrance e(k)=PV(k)SP(k) and the delta error Δe(k)=e(k)-e(k-1) of the process variable. This scheme is taken to the fuzzy designer tool, where there are two fuzzy input sets, the first for the error, and the second for the delta of the error. The idea is to imitate the behavior of an expert www.controleng.com

through the interaction of fuzzy inlet sets. In this case, the goal is to imitate the operator´s expertise by reproducing the action taken when deviations in the variable of interest are detected. To reproduce this knowledge, some rules are created to evaluate the interactions of the linguistic values of each of the fuzzy sets and associated them with the output. A series of operations are carried out on this diffuse set of outputs that will allow obtaining a unique value of controlled variable by each control panel. These in turn will be evaluated to determine which of the three will be applied to the speed governor. The decision made for the controller is based on the experience of the operator, and some set of rules are established where this heuristic is established. In the event of a shutdown of a PAD1 unit, the flow rate set point is recalculated and assigns the lost flow to the set point of PAD2. In this way, the same injection rate is maintained despite the loss of the pumping unit. Maintaining the active distribution strategy, an increased in injected flow was seen, which leads to an increase in the barrels of oil recovered.

Process simulator benefits

An advanced engineering system was developed integrating process engineering and advanced con-

trol strategies to optimize the water injection flow in oil production facility. Linear programming techniques such as simplex and a control based in fuzzy logic were used since the system presents non-linearity. The control strategies developed were initially tested on a dynamic simulation performed in the chemical process simulation software, to evaluate dynamic system behavior and the common disturbances that can affect normal operation. Using process simulators shows several benefits by allowing optimization of several systems and process plants. This is due to changes in the model, which allows different scenarios to be evaluated without field tests that may require long periods of time and extensive resources. The proposed strategies allowed control of the total injection flow, increasing field production. In addition, an effective response was generated on time when deviations are detected in the process that can cause damage to people, loss of goods or reduction in production. ce Juan David Medina Gonzalez, Silvia Marina Araujo Daza MSc, and Hernan Ivan Cadena Celis are with Proctek S.A.S. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com.

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INNOVATIONS

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NEW PRODUCTS FOR ENGINEERS

Disconnect terminal blocks Dinkle International’s DPT DIN rail disconnect terminal blocks are designed to provide efficient, safe disconnect and testing of current transformer (CT) and voltage transformer (VT) circuits. CTs and VTs isolate a primary power feed from a secondary circuit, permit grounding of the secondary circuit, and step-down the current or voltage to an appropriate level for measurement. Terminal blocks are then used as the termination points for instrument loops on the secondary circuit. To perform direct-test for a single or three-phase circuit, the user switches a lever on the terminal block to disconnect a de-energized circuit. The user then places a current-measuring device across the block at its test points using either 4mm test probes or securely fastened 2.3mm test plugs. Dinkle International, www.dinkle.com

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Cybersecurity risk management platform for SMEs

ResiliAnt’s ResiliEYE is a cybersecurity risk management platform designed for small and medium size enterprises (SME). It provides risk and compliance management and makes it easy for information technology (IT) and operations technology (OT) departments to communicate with one another. The platform enables discovery of connected devices, identification of all vulnerabilities, risk management, incident planning and governance in compliance with the NIST framework. The ongoing threat of cyber-attacks leaves 60% of SME leaders more concerned about operational disruptions, intellectual property protection and compliance to regulatory requirements than ever. ResiliAnt, www.resiliant.co

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Industrial Ethernet switch series

Moxa’s EDS-2000 series of unmanaged Ethernet switches feature up to 16 Ethernet ports and two Gigabit combo ports to meet increasing needs for additional nodes and bandwidth. Slim enough to fit into crowded control cabinets and machines, these plug-and-play switches allow for easier deployment and upgrading of existing devices without configuration hassles. The switches connect a wide variety of data devices, such as meters, sensors and cameras, so that organizations can gain greater visibility into core processes. The EDS-2000 Series available in five designs within two families: the EDS-2000-EL and the EDS-2000-ML. The EDS-2000-EL Series is an entry-level model ideal for general automation; the EDS-200-ML is a mainstream switch for mission-critical automation. Both are designed to withstand harsh environments, extreme temperatures (-40 to 75°C), vibrations, and shocks.

Composite tubing for pneumatic, hydraulic cylinders

PolySlide Composite Tubing is designed for pneumatic and hydraulic cylinders. The tubing replaces metallic material in a variety of cylinder applications. Supplied as a cylinder tube ready for customer assembly, or as fully engineered cylinder assemblies for equipment manufacturer applications, the tubing is made of continuous filament-wound glass fiber and polymer resins. The fiberglass filament and resin materials combine to form a high strength component that exhibits dimensional stability, is non-corroding, impingement resistant and is non-conductive. It is ideal for harsh environments including high and low temperatures, grease, grit, salt, chemicals and other extreme conditions. The inside diameter of the tubing has a smooth finish. Polygon Composites Technology, www.polygoncomposites.com

Universal marshalling solution for process applications

Moxa Americas Inc., www.moxa.com

Eaton’s MTL SUM5 smart universal marshalling solution for process applications capable of reducing distributed control system (DCS) marshalling cabinet requirements by up to 50%. With six patents pending, it combines five functions in one modular design enabling one standard cabinet to deliver the lowest lifetime costs and lowest installed cost while saving valuable space in a control room. The marshalling solutions allows process and plant managers to benefit from a one-cabinet design, with plug-and-play configurable modules for the five key marshalling functions. This eliminates the need for intricate wiring to interconnect the components, improving uptime and reducing the cost of wiring, installation and maintenance.

Input #202 at www.controleng.com/information

Eaton Corp., www.eaton.com

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May 2020

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INNOVATIONS

BACK TO BASICS: INDUSTRIAL CONTROLLERS Jon Breen, Breen Machine Automation Services

Terms: PLCs, PACs and IPCs A programmable logic controller (PLC), process automation controller (PAC) and industrial PC (IPC) have unique features and benefits, but traits are blurring.

s a programmable logic controller (PLC) always a PLC, or is it a process automation controller (PAC) or an industrial PC (IPC)? What’s the difference? Which one is needed for my process or machine? Let’s start by filling in some historical context and defining each term. PLCs: Programmable logic controllers (PLCs) are industrial computers used for automation and control. A PLC system monitors inputs, makes decisions based on its program, and controls outputs to run a process or automated machine. This description also fits PACs and IPCs. So what’s the difference? The truth is, there are only very general guidelines that describe the differences, and there’s a lot of overlap. PACs: By traditional definition, PACs are considered to be more decentralized, able to connect to remote input/output (I/O) and other PACs. They’re also touted as having more advanced programming capabilities compared to a PLC’s ladder logic language. This definition may have worked 20 years ago, but virtually all PLCs today have these features. A more modern definition for PAC is elusive. The cRIO platform from National Instruments (NI) is a good example of a modern controller with the PAC label. It has features like a built-in field programmable gate array (FPGA) that aren’t seen on PLCs, but what exactly constitutes a PAC? A basic way of viewing it is a PAC is a PLC with a couple extra bells and whistles. Some of these extra bits will be adopted by the PLCs of tomorrow, which confuses the issue further. IPCs: IPCs, like their non-industrial counterparts run operating systems (OSs) like Microsoft Windows or Linux, giving them access to nearly endless software tools and connectivity options. Early IPCs were different from PLCs, bu like PACs, the technology is converging. Devices that run Windows, but still look and feel like PLCs, have been around for years. For example, Beckhoff Automation sells IPCs that mount in a rack with I/O cards and can be programmed with ladder logic. It’s possible Microsoft Windows will be the norm in 20 years and the term “PLC” will swallow up IPC just like it did with PACs.

reliable, safe, boring, limited. PACs may feel futuristic, exciting, scary, unknown or powerful. IPCs may feel unstable, unreliable, powerful, stable or reliable. Emotional responses vary depending on the individual, and may be extreme or dogmatic. For example, a person whose primary goal is to keep a production facility running may view everything in an extremely conservative way. This person may strongly prefer the term PLC because of its feeling of known, stable, reliable. Someone might things called PAC or IPC at all costs with thoughts like, “PCs get viruses, break down, require updates, etc.” and “Nobody knows how to troubleshoot a PAC if something breaks.” None of these thoughts is subjectively true across all devices with those names. In fact, many devices could easily be classified under two or all of those names. This is emotional rather than rational thinking; manufacturers know their audience and play to that. For example, a manufacturer targeting a user base in production will use the term “PLC” to describe even its most advanced offering that fits the definition of PAC. A manufacturer focusing on R&D, test and measurement, and datalogging will choose the term “PAC” even for its simplest offerings. These labels are chosen as much for an emotional branding effect as they are to describe a technical difference.

PLC, PAC, IPC use vs. emotion

Jon Breen, founder/owner, Breen Machine Automation Services, a Control Engineering content partner. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media, cvavra@cfemedia.com.

The terms PLC, PAC, and IPC are as much about branding as about capabilities. Each one has all the power to incite emotion that any logo ever did. PLCs may feel comfortable, predictable, known,

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Controller to fit the application

So are PLC, PAC, and IPC differences? Lack of clarity doesn’t have to get in the way of controller selection. Consider goals and find a controller to suits the application. What is locally supported? What do others use in similar situations? Know that each term is generally marketed towards certain industries and certain types of people. Understanding the target audience of a term and your position might help narrow down the options, despite vague definitions. Beware of emotional responses that affect decisions. Focus on specific benefits and capabilities. ce

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KEYWORDS: PLC, PAC, IPC

The terms PLC, PAC and IPC imply different things and there is overlap. When it comes to general capabilities, a PLC, PAC and IPC can do many of the same things. Some situations and applications suit one over others.

ONLINE Read this article online at www.controleng.com for more from Breen Machine Automation Services. www.controleng.com/control-systems/ plcs-pacs

CONSIDER THIS What criteria do you use when choosing among a PLC, PAC or iPC?

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Articles inside

Technology Update: Power conditioning to match power quality environment

Research: Poll results, week 2: Doubled adverse COVID-19 impacts

How to operate manufacturing remotely

Essentials of remote monitoring and control for operations

How to quickly start a robotic pick-andplace application

Advanced controls, linear programming, fuzzy logic