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Headless HMI With the C-more headless HMI, you can display your factory floor data how and where you choose. The EA9-RHMI has all the powerful functionality of the C-more Touch Panel HMIs, but without display size restrictions. This HDMI-enabled device works with televisions, monitors, projectors, and most any other HDMI display device of any size to display real-time operational data or messages. Use the C-more Remote HMI mobile app or the embedded Web Server if you prefer no local display at all.

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the #1 value in automation

Improves productivity

Eliminates unplanned stops

Increases employee safety

— Condition monitoring For mechanical components The ABB AbilityTM Smart Sensor for mechanical products is an easy-to-use, wireless sensor which monitors the health of mounted bearings and gear reducers. The sensor provides warnings when health status declines, reducing the risk of unplanned downtime. In addition, connectivity and trend data allow maintenance to be planned proactively instead of reactively, and remote monitoring capabilities keep employees away from areas that are difficult or dangerous to access. Operate safely. Reduce downtime. Improve reliability.

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COVER STORY: • Top, p. 18: ESM Australia helped YourCoffee connect customers with the plant floor. Courtesy: Inductive Automation • Middle, p. 13: Traditional machine HMIs were used only for visualization, but newer products like Adisra SmartView support data storage and analysis at the operational edge. Courtesy: Adisra • Bottom, p. 16: To help with precision machined aluminum die castings and subassemblies for transportation, lawn and garden and industrial markets, MKC chose Ignition from Inductive Automation, an industrial application platform for SCADA, HMI, MES, and IIoT. Courtesy: Inductive Automation

Vol. 67 Number 6

JUNE 2020

ANSWERS 13 | Create value from data: Using HMIs as intelligent edge devices

p.13

16 | SCADA platform tools save time and money 18 | Doing more with HMI/ SCADA software 19 | Integrated control system can reduce cybersecurity risk

p.18

20 | Uninterruptible power supplies reduce machine downtime

INSIGHTS 6 | Technology Update: Creating a safe path to digital with open standards NEWS

8 | Ten recommended steps employers must take before reopening due to COVID-19; Lowering risk in COVID19 new normal; Headlines online: Protect PLCs and PACs from cybersecurity threats; Faculty grants for COVID-19 research awarded 10 | Think Again: Research says cybersecurity requires asset updates

22 | Understanding power quality and improving manufacturing system reliability 24 | DCS migration and IT/OT integration oil and gas system integration projects Online extra | Top products since COVID-19 pandemic relate to air control, cleaning

INSIDE MACHINES

M1 | Cultivating robotics and AI for sustainable agriculture M3 | More answers about robotic applications

CONTROL ENGINEERING (ISSN 0010-8049, Vol. 67, No. 6, 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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June 2020

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JUNE 2020

INNOVATIONS NEW PRODUCTS FOR ENGINEERS

44 | Mobile app for maintenance, operations

management; Loop-powered temperature transducers; Wireless cloud display device; Power over Ethernet switch; Safety laser scanner for mobile apps. More New Products for Engineers: www.controleng.com/NPE

BACK TO BASICS

46 | Five ways digital transformation metrics give manufacturers more flexibility

ADDITIONAL STORIES ONLINE If reading from the digital edition, click on the headline to read more.

Employee reviews: The right way and the wrong way

Incorporate these six tips to improve the review process for engineering employees and those around them. – Jon Breen, Breen Machine Automation Services

Separating process control and safety systems

Know what to separate and integrate and why is critical. Learn about safety instrumented function (SIF) and layers of protection analysis (LOPA). – Scott Hayes, Maverick Technologies

Seven ways automation design software helps IIoT

Electrical and automation design software can help with Industrial Internet of Things (IIoT) automation implementations in seven ways. See product examples. – Mark T. Hoske, CFE Media and Technology

Market survey: COVID-19 impact on China’s manufacturing

COVID-19 is negatively affecting manufacturing in China says a Control Engineering China April survey. Results? More automation with faster digitalization. – Aileen Jin, Control Engineering China

How to tune servo systems (Part 1): Questions and answers

More answers regarding servo system tuning follow the March 11 webcast, which focused on how tuning a servo system can be among the most difficult PID tasks. – Joseph Profeta, Ph.D., Aerotech

COVID-19 emergency support for safety, VFDs, PLCs, more

System integrators can provide emergency support for automation troubleshooting to shorten or prevent downtime, improve quality and save money. – Matt Ruth, Avanceon

Create history: Motion control, industrial communications

Integrated automation and motion controls help to suspend, move heavy garden museum “clouds” using a wireless pendant. Fiber-optic, water and power cables. – Dan Thompson, igus

Control Engineering eBook series: IIoT Cloud eBook Summer Edition Learn how the Industrial Internet of Things (IIoT) and the cloud are changing manufacturing in this helpful eBook. Featured articles in this eBook from Control Engineering and Beckhoff, InfluxData, Siemens and Wago include machine retrofit benefits for a network, skills for the edge computing revolution and cloudbased analytics for manufacturing. Learn more and register to download at www.controleng.com/ebooks/. Oil & Gas Engineering helps maximize uptime and increase productivity through the use of industry best practices and new innovations, increase efficiency from the wellhead to the refinery by implementing automation and monitoring strategies, and maintain and improve safety for workers and the work environment. Read the digital edition at www.oilandgaseng.com.

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

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June 2020

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INSIGHTS

TECHNOLOGY UPDATE Ed Harrington, The Open Group

Open standards, a digital path New open standards balance uptime requirements with digital technologies.

ompeting in this data-driven economy means organizations need to have a clear open-strategy for technology adoption and a clear vision for future systems. Companies are trying to digitally transform because of the clear benefit it provides. Accenture said companies that have implemented emerging technologies into core processes see revenue grow two times faster than those who are not. Yet 97% of information technology (IT) decision-makers say legacy infrastructures are holding them back; many companies struggle to quickly deploy new technologies. Within the context of process automation – industries that cannot turn off factories ever – organizations often can’t take advantage of advances in digital technologies due to the inability to insert these advances within a facility’s infrastructure. To keep pace with the digital age, the critical infrastructure and automation industries are looking beyond today’s control systems for new, common technologies that can deliver uptime and take advantage of digital technologies. Open standards can help.

Open standards, best in class

Process automation control systems are central to any industry required to maintain operations. These include, among others, oil and gas, petro- and specialty chemicals, utilities, mining and metal, pharmaceutical, food and beverage, and pulp and paper. For most, downtime is not an option. The power generation and distribution industries fuel our lives. The same type of equipment and processes often are deployed across sectors, yet only a few suppliers provide relevant services. These suppliers have a complete “stack,” running from a device to providing information to a separate planKEYWORDS: Open process ning system. These systems are proprietary standards, interoperability and cannot be easily replaced, creating venFinding common ground, best dor lock-in. Digital transformation can be in class process automation limited if innovations aren’t provided by the Process automation cost current supplier. savings and efficiency are goals. Organizations seek common technoloCONSIDER THIS gies that can help balance requirements for If today’s industrial standards uptime, security and safety with the need to efforts lead to interoperability, will take advantage of digital innovation. Digital you help? transformation does not require a “rip and ONLINE replace” approach. Organizations improve If reading from the digital the functional capabilities of the facility and edition, click on the headline for move to a new software environment that more resources. extends life of traditional legacy systems. www.opengroup.org/forum/ open-process-automation-forum Many commonalities exist in process

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ExxonMobil, at ARC Forum 2020, discussed its open process control pilot, using multiple vendors. Courtesy: Control Engineering

automation industries for efficiency, interoperability and the ability to integrate best-in-class technologies. Recognizing the need for collaboration, three years ago a group of companies discussed the possibility of developing an open standard for process automation; more flexible solutions was the driver. The Open Process Automation Forum (OPAF) was born under the guidance of The Open Group. The Forum been developing a standard for the security, interoperability and scalability of new control systems. A year ago, over 90 member organizations created OPAF’s O-PAS Standard, Version 1.0, now a full standard of The Open Group. While industry standards for process automation are available and fit for purpose, the O-PAS Standard focuses on interoperability, using existing industry standards and adopting and adapting them to create a “standard of standards.” Digital technologies are the future. This is why we’re already seeing end-user and supplier organizations work with peers to agree on technical standards that are open and based on common interfaces. This will make it easier and cheaper to replace and repair control systems and to reduce operational costs. It will be easier for digital transformation initiatives to be done at a low cost and with minimal disruption. Work continues. More companies are expected to follow the first, who are already looking to open standards to help improve operational efficiency and ease digital complexity. A safe path to digital unlocks significant cost savings and efficiency for the process automation industry. ce Ed Harrington is forum director, Open Process Automation Forum, The Open Group. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com. www.controleng.com

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INSIGHTS

NEWS

10 recommended steps employers must take before reopening due to COVID-19 Prioritizing safety during and after the COVID-19 pandemic is crucial. The National Safety Council – based on recommendations from the SAFER task force – identified the 10 universal actions every employer must consider before reopening, and released a series of playbooks with indepth recommendations to lower risk. SAFER – a group of experts from companies of all sizes, leading safety organizations, nonprofits, government agencies and public health organizations – identified 10 universal actions employers must take. 1. Phasing – Create a phased transition to return to work aligned with risk and exposure levels. 2. Sanitize – Before employees return, disinfect the workplace and make any physical alterations needed for physical distancing. 3. Screenings – Develop a health status screening process for all employees.

4. Hygiene – Create a plan to handle sick employees, and encourage safe behaviors for good hygiene and infection control. 5. Tracing – Follow proper contact tracing steps if workers get sick to curb the spread of COVID-19. 6. Mental health – Commit to supporting the mental and emotional health of your workers by sharing support resources and policies. 7. Training – Train leaders and supervisors not only on the fundamentals of safety such as risk assessment and hazard recognition, but also on the impacts of COVID-19 on mental health and wellbeing, as employees will feel the effects of the pandemic long after it is over. 8. Engagement plan – Notify employees in advance of the return to work, and consider categorizing workers into different groups based on job roles – bringing

Lowering risk in COVID-19 ‘new normal’

ountries are looking to get back to work and that means manufacturers are contemplating starting up processes they slowed down to a snail’s pace or returning idled plants to operation, but in the wake of tragic incidents that occurred in India recently, this a time to make all the right decisions. Whether it is restarting production or ensuring workers remain safe and virus free at the office, safety issues will remain top of mind in the coming months. “For many people this is a ‘first’ in many ways,” said Steve Elliott, senior director – marketing and a safety expert at Schneider Electric. “Not just coming to terms with the new ways of working together, but a ‘first’ having to restart operations after an enforced shutdown. And some things just can’t be done ‘remotely.’ Make sure that everybody fully understands the inherent risks of the facilities and their operations before starting,” Elliott said. For manufacturing, “if you have three shifts, there are employees using the same workstations, now employers are having to contemplate how to clean and sanitize workstations at turnover,” said Eric Glass, senior risk and safety advisor for building life and safety technologies at UL. “We need to look at what needs to be done. That is what is going on right now. They are trying to figure out how to operate in this new normal.” That new normal may include a staggered approach. “There is a methodical approach many industries are using,” Glass said. “Overall, most industries are doing a very good job of regulating themselves. They understand the dangers of COVID-19. I think you will see staged approaches throughout the country. The speed of that will vary. I have not seen a company yet that said we are going back 100% (right away).” However it’s done, Glass said safety has to be top of mind all the time. “The absolute first and most important step you can take as an employer is to ensure your employees returning to work understand the hazards related to COVID-19 and what their responsibilities are when they return to the workplace.” - Gregory Hale, ISSSource

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control engineering

groups back one at a time. 9. Communication – Develop a communications plan to be open and transparent with workers on your return to work process. 10. Assessment – Outline the main factors the organization uese as guidance to provide a simple structure to the extremely complex return to work decision. The NSC and the SAFER task force also released a framework from which employers should develop reopening action plans. The framework breaks down considerations within six key areas: physical environments, medical issues, mental health, communication needs, external considerations, and employment and human resources. From the framework, NSC researchers created playbooks with detailed recommendations for each of the six key areas, as well as guidance for four specific environments: Office spaces, closed industrial settings, open industrial settings and public spaces. ce - Edited from a National Safety Council (NSC) press release by CFE Media.

Headlines 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 also has a COVID-19 and coronavirus sub-channel with the latest stories on the pandemic. www.controleng. com/manufacturer-health-wellness/ Protect PLCs and PACs from cybersecurity threats Protecting programmable logic controllers and programmable automation controllers from security threats begins before an attack. Faculty grants for COVID-19 research awarded Rice University researchers received grants to research COVID-19 effects and develop mitigation technologies and protocols. University helps manufacture PPE, medical devices for COVID-19 pandemic Texas A&M University and the Texas A&M Engineering Experiment Station are helping. www.controleng.com

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INSIGHTS NSIGHTS

THINK AGAIN: CYBERSECURITY

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

Cybersecurity requires asset updates Age of existing assets are the greatest cybersecurity risk factor, 67% in 2020 Control Engineering research, up from 46% in 2016. This is of particular concern with remote operations increasing due to the COVID-19 pandemic and manufacturing starting up again.

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and link to the full report online. www.controleng.com/research

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Mark T. Hoske, Content Manager 630-571-4070, x2227, MHoske@CFEMedia.com Jack Smith, Content Manager 630-571-4070, x2230, JSmith@CFEMedia.com Kevin Parker, Senior Contributing Editor, IIoT, OGE 630-571-4070, x2228, KParker@CFEMedia.com Emily Guenther, Director of Interactive Media 630-571-4070, x2229, eguenther@CFEMedia.com Amanda Pelliccione, Director of Research 978-302-3463, APelliccione@CFEMedia.com Chris Vavra, Associate Editor CVavra@CFEMedia.com

Contributing Content Specialists

hose answering the 2020 Control security within the organization for 65% Engineering cybersecurity survey of respondents. The next greatest consaid, in a significant shift, the cerns were network devices and wireless age of existing assets is the high- communication devices. est risk factor at 67%. In a similar 2016 Vulnerable components: Of the cybersecurity survey, age of existing assets respondents, 39% said they are aware was 46% (third) in 2016. In 2016, the lack of zero malicious cyber incidents in the of appropriate technologies and lack of past 24 months while only 9% said they training or enforcement relatare aware of more than five ed to technologies were tied for malicious cyber incidents in first at 53%. the past 24 months. With more remote operaMalicious incidents: The tions related to the COVID-19 largest share of respondents, pandemic, and as manufac40%, said cyber incidents they turing retools to lower human were aware of were accidental risk while ramping up again, infections; while only 22% said cybersecurity remains a conwere targeted in nature. Mark T. Hoske, cern. Data was collected Feb. 7 Content Manager Accidental incidents: More through March 5. than half of the respondents said they were allowed to report Cybersecurity research: cyber-related incidents, and they did. threats, vulnerabilities, training Of the respondents, 20% said they were Threat levels: Perceived cybersecurity allowed and did not report the incident. threats within respondents’ organizations Incident response team: An operatwere 3% severe and 73% high or moderate. ing operational incident response team Perceived severity remains the same within was present in the organization for 50% margins of error for each study: 25% high, of the respondents; however, about a 48% moderate, 22% low, 3% severe. third (34%) said their organization does Most concerning threat: The most not have such a response team. concerning threat to control systems is Training to identify things that may malware from a random source with no indicate a cyber incident or attack was specific connection to our company or received by 64% of respondents. Trainindustry. The least concerning threat was ing about who to contact during a cyber an inside, intentional threat. incident or attack was received by 50% of Greatest concern: Computer assets respondents, and 49% said they receive running commercial operating systems training on identifying social engineering are the greatest concern regarding cyber- attacks. Training on any of these topics was not received by 14% of respondents. Think again about opportunities for upgrades and how to decrease risk from remote workers even as more manufacturers and engineering businesses restart. ce See graphics on cybersecurity risk factors

Content Specialists/Editorial

June 2020

Mark T. Hoske, mhoske@cfemedia.com

control engineering

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

ANSWERS

COVER: MORE THAN HUMAN-MACHINE INTERFACES Marcia Gadbois and Chuck Kelley, Adisra

Create data value: Using HMIs as intelligent edge devices Human-machine interfaces (HMIs) can be edge-located, data handling, analytical powerhouses: 5 HMI attributes.

uman-machine interface (HMI) software can be used to create value from the rapidly increasing amount of industrial data. Devices of all types continue to add sensors. More sensors, naturally, leads to more data collection. The exponential growth for industrial systems is outpacing available network bandwidth. Much of this data remains an untapped source from machines and processes, but gaining access to this data is crucial for obtaining valuable business insights. An emerging possibility is to mine this data using human-machine interface (HMI) software deployed near the source. This calls for the HMI’s role to evolve from being only a basic visualization tool to an enhanced role as an intelligent edge-located data collector and machine-learning processor.

New roles for HMI software

HMI software hosted on edge devices need to keep pace with the ever-growing requirements for how data need to be acquired, parsed, mined and refined. The sheer volume of data being collected means advanced analytics and machine learning at the operational edge needs to play an important role in the overall digital transformation plan for smarter operations. HMIs have often worked with data sources such as programmable logic controllers (PLCs) and sensors. Traditionally, HMIs were used as a visualization tool and sometimes as a data collector viewed on a dedicated control panel, mobile device or web browser. Modern HMIs still need to perform these roles, but they must collect data in real time, store it locally for further analysis and use the data to find patterns and inferences to make predictions (Figure 1). HMIs are evolving as a source of data for real-time machine-learning execution. Time-series process data must be correlated with alarm and event record data to train machine-learning models. This allows these models to detect the quality of a product in manufac-

www.controleng.com

COVER figure 1: Traditional machine HMIs were used only for visualization, but newer products like Adisra SmartView support data storage and analysis at the operational edge. Images courtesy: Adisra

turing or predict the health of a critical piece of equipment. Machine-learning models perform best when supplied with large quantities of high-fidelity data. Predictive maintenance is possible when these models detect deviation from a common behavior and indicate a possible impending failure, which could result in downtime.

HMI analytics, anomaly detection

Advanced analytics are possible with modern HMIs. Much of the world’s data is streaming and time-series data where anomalies provide significant information indicating critical situations. There are numerous use cases for anomaly detection, including preventative and predictive maintenance, fault detection and monitoring. Anomalies are defined as a point in time where the behavior of the system is unusual and quite different from past behavior. Anomalies can be spatial, meaning the value is outside the typical range, or temporal where the value isn’t outside the typical range but the sequence in which it occurs is unusual. State labels can be associated with anomalies and can classify them as temporal or spatial. The alarm system also can assign weighted values to predict control engineering

Figure 2: Edge-located HMIs are well positioned to perform analytics and quickly deliver indications and alarms to users.

June 2020

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ANSWERS

HUMAN-MACHINE INTERFACES failure based on priority, importance and frequency. Any modern HMI also must natively support mechanisms for sending and receiving messages in a stateful way and ensure remote device data is current and valid. Stateful communications can be ensured by using protocols such as MQTT and Kafka, while the Sparkplug B

specification handles state management. Once in the cloud, the data can be aggregated and joined with data from multiple data sources. The value here is users can consider multiple operations or an entire fleet of equipment together, regardless of their physical location. Cloud-based filtering and analytic models can be used to refine the data for deep analysis to pre-

Rugged Precision The MAQ®20 Industrial Data Acquisition & Control System

Figure 3: Adisra’s SmartView HMI moves beyond simple visualization to help OEMs and end users manage data transmission and perform machinelearning analytics.

dict behavior and trends, such as the mean time between failure (MTBF) or end of life for machines. This information can then be deployed back to edge-located machinelearning models running in HMIs to improve their operation.

5 modern HMI requirements HMI’s role will need to evolve to accommodate massive quantities of data. Modern HMIs have the ability to connect to a wealth of machine data to 1) Monitor and analyze this data in real time; 2) Visualize it in a coherent and userfriendly manner; 3) Help users make intelligent decisions; 4) Store data in a useful way so it can be mined at will; and 5) Overcome compromises and constraints. This is the HMI’s new role as more sensors are being deployed and reliance on machines continues to increase. Machine functions will expand, and the HMI will be the brain of the intelligent edge. ce

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KEYWORDS: human-machine interface, HMI, edge analytics HMIs can send and retrieve high volumes of information from edge devices and act more as machine-learning tool.

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Read this article online for more on: -4 ways to verify industrial data quality -How to build a machine- learning model -Modern HMI architecture, edge analytics -The need to filter industrial data.

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June 2020

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ANSWERS

COVER CASE STUDY: SCADA PLATFORM INSTALLATION Jim Meyers, Inductive Automation

SCADA platform tool savings Installing a supervisory control and data acquisition (SCADA) system improved efficiency throughout plant for a Wisconsin-based automotive supplier.

sers who want to make data-driven decisions need a lot of data. Madison-Kipp Corp. (MKC) implemented a new system for supervisory control and data acquisition (SCADA) and has had access to more data than previously to accelerate problem solving. With new insights into processes, the company raised productivity, lowered costs, and shared more information with customers. Based in Madison, Wis., MKC makes precision machined aluminum die castings and subassemblies for the transportation, lawn and garden and industrial markets. After looking at several possible SCADA software packages, MKC chose a web-based platform that provides unlimited licensing and interoperability, which helps MKC with numerous projects. The company uses it for central SCADA, human-machine interface (HMI), control of edge clients, part tracking, part history, reporting, alarms, alarm history, transaction management, API access, predictive control for HVAC, text notifications and other applications. The software platform can connect to almost anything, which eliminates numerous proprietary roadblocks. “The platform has filled a void for us between multiple manufacturers and platforms,” said Jay Sandvick, senior automation controls engineer at MKC. “It’s given us interoperability that we didn’t believe we could have. We now have accessibility to data streams we didn’t have before. And we have the KEYWORDS: SCADA, system integration ability to generate seamless reports from Madison-Kipp Corp. machines that were previously thought implemented a new SCADA unconnectable.” platform for more data access. Equally important is the ability to have Benefits included providing numerous systems on one platform — a customers with more information, big improvement over what MKC had in more programming languages and improved interoperability. the past. “I can’t train over 150 maintenance personnel in 30 software platforms ONLINE and keep everyone relevant and current,” Read this article online for: Sandvick said. “Now we have a single plat-Platform interoperability form that everyone can learn, including provides opportunity online and at their own pace. It’s been an -Customers see data too exceptional increase in our productivity.” -Real-time graphic display.

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CONSIDER THIS What is the one feature you’d like most if your company installed a new SCADA system and why?

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SCADA migration; think bigger The transition is aligned with the company’s larger objectives. “Technology is very important to us,” said Bill Johnson,

control engineering

COVER: To help with precision machined aluminum die castings and subassemblies for transportation, lawn and garden and industrial markets, MKC chose Ignition from Inductive Automation, an industrial application platform for SCADA, HMI, MES, and IIoT. Courtesy: Inductive Automation

vice president of operations for MKC. “We have to keep ahead of our competitors in many different areas. Using this software and taking real-time data from our processes helps us understand our data — which helps us make better decisions.” With real-time data from the SCADA system tied into MKC’s continuous improvement process, problem-solving goes much faster, Johnson said. “We did this with a customer. We were able to double our throughput in less than a month. It was very quick, and our customer was very happy with the results.” The new SCADA system has made a big difference throughout MKC. “Some of the results we have are in the cost savings realm, and we’ve also seen improved efficiency,” Johnson said. “Before, engineers had to collect data on their own. This would take a long time. Now we’re able to pull that data in and look at it and solve problems very quickly.” Based on the positive results, MKC plans to expand its use of the SCADA platform. “Strategic initiatives are vitally important for any organization,” Johnson said. “When we set our initiatives for 2020 on the technology side, this software is one of those strategic initiatives that’s going to help move us forward this year.” ce Jim Meyers is communications manager at Inductive Automation. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com. www.controleng.com

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ANSWERS

COVER: HMI/SCADA SOFTWARE Travis Cox, Inductive Automation

More: HMI/SCADA software

HMI and SCADA software help with OT and IT convergence. See six SCADA software advantages, applications.

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ANSWERS KEYWORDS: HMI,

SCADA HMI/SCADA software increases efficiency.

ONLINE See more examples: -SCADA for recipes, barcodes, historian, MES -More SCADA data, more power, remote control -SCADA enables virtual reality, visualization, controls -Stronger connections -SCADA links servers, plant, management data.

uman-machine interface (HMI) and supervisory control and data acquisition (SCADA) systems are crucial for industrial organizations. SCADA, in particular, allows industrial organizations to control industrial processes locally or at remote locations; monitor, gather, and process realtime data; directly interact with sensors, valves, pumps, motors and more through HMI software; and record events into a log file. SCADA systems have undergone substantial evolutionary changes over the years, allowing industrial organizations to do more. With the introduction of smart machines, Big Data, and the industrial internet, operations technology (OT) and information technology (IT) departments are finding they need to solve the same problems: accessing industrial data, integrating more systems and solving business challenges. Modern SCADA systems aim to solve these problems by leveraging the best of controls and IT technology.

calculations; 4) Getting data to more people; 5) Leveraging mobile devices; and 6) Linking plants and people. SCADA is excellent at communicating with programmable logic controllers (PLCs) and field devices. Traditional SCADA systems often have limitations on the brands of PLCs they can communicate with. It’s incredibly important to be able to pull data from multiple disparate PLCs into one platform for a “single pane of glass” for operators. Thanks to modern standards such as OPC UA, users can connect SCADA to these devices. Along with PLCs, several other data sources and integrations are important to SCADA, such as computerized maintenance management systems (CMMS), enterprise resource planning (ERP), manufacturing execution systems (MES) and others. There’s enormous benefit in connecting these systems and adding more context to the operator’s screen.

Six SCADA software advantages

The team at ESM Australia helped YourCoffee connect its Shopify e-commerce platform to the factory floor. Using SCADA with RESTful web service APIs and a programmable automation controller (PAC)-based factory automation platform, ESM Australia delivered YourCoffee the Industry 4.0 tools to connect, evaluate, structure and control information and physical processes. This enabled the company to achieve their production goals. YourCoffee’s customers order their desired custom-made blends as well as selecting the bag size, type and label type. Using web service calls, SCADA harnesses the JSON data returned from Shopify. Orders are then divided into product-based objects where the users can collate several products from separate orders and produce a production run optimized to reduce changeover times. To get the most from SCADA software, identify challenges, build solutions to meet those challenges and achieve business value. Embrace new technology to allow operations to get more value from applications and allow more access across an organization. ce

Companies are embracing modern industrial application platforms and technology, creating new and innovative industrial systems in all industries. SCADA is in the middle and offering capabilities including: 1) Combining data and integrating with CONSIDER THIS disparate systems; 2) Eliminating paper and clipWhat applications need help in your plant? boards; 3) Running advanced logic engines and

COVER: ESM Australia helped YourCoffee connect customers with the plant floor. Courtesy: Inductive Automation

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control engineering

SCADA connects customer, supplier

Travis Cox is co-director of sales engineering at Inductive Automation. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com. www.controleng.com

ANSWERS

SAFETY/CONTROL SYSTEM INTEGRATION Sergio Diaz, Emerson

Integrated control system can reduce cybersecurity risk Integrated control and safety systems can simplify cybersecurity.

s more organizations embrace digital transformation, they have come to see how integration is critical for security, efficiency and scaling. That same line of thinking applies to the most critical systems in the plant—the basic process control system (BPCS) and safety instrumented system (SIS). Many organizations think it’s more secure to “separate” control and safety systems with an interfaced architecture to avoid “putting all their eggs in one basket.” Having more “baskets” means increasing the potential exposure to risk. The key is not the number of baskets, but how well each basket is protected. It is easier and more secure to integrate the safety and control systems, and then properly defend the overall architecture. Integration does not eliminate the separation between the distributed control system (DCS) and SIS. The SIS and DCS are still separate, but security is simplified.

Figure 1: An interfaced architecture requires defending both the DCS and SIS and can leave vulnerabilities in the engineered interface. Graphics courtesy: Emerson

SIS/DCS integration can add security

Integration does not mean less separation. Safety-critical components are still separated from the rest of the system. The interface to the DCS components is via a built-in interface based on proprietary protocols. With a well-designed integrated system, the number of entry points to safety-critical components is lower than on most interfaced systems. There are often more interfaces to the SIS than users realize. In addition to the DCS interface, the SIS might have connectivity to asset management systems, process information management systems and safety lifecycle management systems. While it is possible to secure all interfaces, significant effort is involved. On an integrated system, there is one interface to the SIS; all other systems communicate through the BPCS. One SIS interface means organizations employing an integrated architecture manage a unified defense-in-depth system to protect the control and safety systems. This simplified architecture leads to shorter install times and easier management.

BPCS/SIS: Separate vs. integrated

An organization’s safety system and control system must be properly secured, but the architecture

www.controleng.com

Figure 2: Integrated systems can share layers of protection while still maintaining the connectivity and independent security between control and safety.

used is only one part of overall security. Opting for separated architecture is no more secure than choosing a properly designed integrated system. The primary difference between the two systems is the ease of connecting, configuring and securing the BPCS and SIS. An integrated system provides the logical separation plants need, while providing a smaller security footprint to maintain and more flexible and intuitive options for defense-in-depth. ce Sergio Diaz is DeltaV SIS product manager, Emerson. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com. control engineering

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KEYWORDS: SIS, DCS Control system integration is crucial for the basic process control system and safety instrumented system (SIS). ONLINE

This article online has -Separate DCS, SIS does not necessarily mean secure -Proper integration helps bridge the IT/OT gap

CONSIDER THIS What is the biggest cybersecurity integration application challenge?

June 2020

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ANSWERS

POWER QUALITY Eric Reiner, Beckhoff Automation

Uninterruptible power supplies

While UPS technologies are no longer optional in critical machine designs, engineers should still have options to select the best device for applications.

ithout unknowns in the design, commissioning and operation of machines, there would be little use for automation and controls engineers, who want to build reliable, dependable systems, despite environmental conditions. However, unplanned downtime due to improper controller shutdown should not be one. Today’s uninterruptible power supply (UPS) technologies, which enable proper machine shutdowns and allow controllers to save projects and recipes when power failures or other issues occur, allow machine builders to plan for the unknown.

How UPS help machine applications In the past, industrial UPS technologies were viewed as luxuries reserved for the most critical applications. Today, that view has changed as the

number of machines that reliable, uninterrupted power has grown. Most contemporary machines collect and transmit data to measure performance, send alerts and complete track and trace for industries such as pharmaceuticals, food processing, packaging and intralogistics. In an e-commerce or distribution center application, for example, abrupt shutdown could cause a conveying, sortation or automatic storage and retrieval (ASRS) system to lose track of packages and products, leading to incorrect shipments and costly returns. It also could lead to corrupted files and programs on the machine controller, which would delay restart once power is restored. Machine builder original equipment manufacturers (OEMs) know their facilities and the reliability of their electric utilities. Machines may be shipped to where the power reliability is unknown. Some areas

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regularly experience blackouts or rolling brownouts. Even if end user facilities have backup generators, the lag time between line voltage disappearing and the generator starting could be enough for disaster. With advances in capabilities, form factor and competitive costs, implementing UPS technologies for industrial PCs (IPCs), panel PCs and other machine controllers is no longer optional. However, there should still be flexible options to fit any machine requirements.

UPS form factor advantages For maximum benefit, UPS technologies should offer compact, easy-to-integrate form factors. Simple installation via DIN rail or a mounting bracket enables integration of devices into new electrical cabinets in greenfield applications or flexible retrofits in existing brownfield applications. With compact sizes of 100 x 100 x 90 mm or less, the capacitive or battery versions meet tight footprint requirements. For NiMH battery-backed versions, the battery cover should be accessible. All batteries eventually need replacement, and while UPS batteries are designed to last and provide maximum reliability, they are no exception. Selecting a device with a removable front cover will increase uptime, especially if it features only two screws. Through this design, the entire UPS will not need to be removed or taken apart for necessary maintenance, which means

machine availability can remain as high as possible. By selecting the correct UPS options for each application, machine builders and OEMs can be assured systems will shut down and start up again without issue. All systems, in general, should have a UPS because of the potential risks to system integrity, data acquisition and other tasks. Even if the price of reject product or improper shipments is minimal, the potential downtime resulting from improper shutdown could be quite expensive. Whether its safeguarding a PLC running basic machine control logic or a panel PC providing a human-machine interface (HMI), cloud communication and more, UPS technologies allow today’s engineers to reduce risk. ce Eric Reiner, IPC product manager, Beckhoff Automation LLC. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.

UPS technologies, such as the CU81xx series from Beckhoff Automation, can protect any controller through flexible power delivery options and compact form factors. Courtesy: Beckhoff Automation

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KEYWORDS:

uninterruptible power supplies, UPS Many machines need a UPS for uninterrupted use in critical applications.

ONLINE Read this article online at www.controleng.com for other stories from the author and text on “UPS capacities, connections deliver flexibility.”

CONSIDER THIS How has a UPS saved your application?

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Quality Products. Service Excellence.

ANSWERS

POWER QUALITY

Mark Stephens and Alden Wright, EPRI

Improving power quality Industrial controls can provide built-in robustness to voltage sags.

esign options for industrial controls can provide built-in robustness to voltage sags. The controls already have capabilities installed and don’t require after-the-fact voltage sag mitigation for defense against the effects of voltage sags. Parts 1 and 2 of this article series explained and described the origins of industrial process sensitivity to power quality (PQ) events, or variations in the electrical power supply – specifically, voltage sags – as well as retrofit methods of mitigating those variations and help sensitive processes remain operating despite those events.

Main shutdown cause: Sags

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ANSWERS

KEYWORDS: power supplies, voltage sags Design options for industrial controls can provide built-in robustness to voltage sags.

ONLINE This article online has links to parts 1 and 2 of this series, 3 other figures and more on: -Effective use of existing PQ standards -Use of robust dc power supplies, ac components -Adjusting ride-through parameters on motor-drive systems

CONSIDER THIS How much could more reliable automation power quality save?

Voltage sags are the main culprit involved with industrial process shut down incidents – the 120-volt control circuit being most sensitive to voltage sags. Most voltage sags have sag magnitudes (voltage remaining) at or above 50% of nominal with durations at 0.5 seconds or less. Within the control circuit, several individual components common to most controls could be causing the controls, and thus the process, to shut down. These components are often the PLC, its I/O, dc power supplies, ac “ice cube” relays and contactors, and adjustable speed drives. Allowing the control circuit and the process to ride through voltage sags involves mitigating one or more component’s sensitivities to voltage sags or propping up the voltage of the control circuit for the duration of the voltage sag. While the latter may be accomplished

using a battery-based uninterruptible power supply (UPS), these require regular maintenance checks and full battery replacement after three to four years for lead-acid batteries. Newer technologies such as lithium-ion-based UPS units tout battery lifespans in the seven to eight-year range. “Battery-less” mitigation options need little or no maintenance, operate better in elevated temperatures, and do not require battery replacement. These may operate for 10 to 15 years. Control circuits may be designed to be more robust by requiring the incorporation of voltage sag standard-compliant components – SEMI F47 or IEEE Std 1668, or by requiring through the purchase order the entire process be compliant to those standards without requiring a battery-based UPS to maintain. The controls may be most robust by using only dc components supplied by a three-phase, universal-input dc power supply operated at the highest input voltages in its range, and at less-than full load. By keeping the control voltage up, the RUN signal to an ASD may be maintained, yet the drive may shut down for dc bus undervoltage. Most modern drives have adjustable parameters that may allow the drive to ignore the voltage sag for a period of time until full input voltage returns if enabled. These parameters may not be enabled by the manufacturer. Several methods of improving the voltage sag sensitivity of industrial controls can make industrial process more robust to voltage-sag effects. 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, cvavra@cfemedia.com.

PQ issues and uptime • Understand your PQ Environment – Prescribe solutions that fit your situation • Don’t assume battery-based UPS systems are needed; there are other technologies • Avoid use of sensitive ac components in controls • Embed robustness using ac- or dc-based controls that are compliant with IEEE 1668 or SEMI F47. • Utilize voltage sag ride-through settings in your motor drive systems.

Figure: Example of a universal input dc control circuit design. Courtesy: EPRI

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June 2020

control engineering

http://mypq.epri.com has tips to mitigate voltage sags in industrial automation systems.

www.controleng.com

Calling all system integrators... Control Engineering and Plant Engineering’s annual

System Integrator of the Year Awards Entries are due September 4, 2020 Who should enter?

If you’re a system integrator with demonstrable industry success, Control Engineering and Plant Engineering urge you to enter the 2021 System Integrator of the Year competition. Past System Integrator of the Year winners—Class of 2020, Class of 2019, and Class of 2018—are not eligible to enter the 2021 System Integrator of the Year program.

What’s in it for the winners?

The chosen System Integrator of the Year winners will receive worldwide recognition from Control Engineering and Plant Engineering. The winners also will be featured as the cover story of the Global System Integrator Report, distributed in December 2020.

How will the competition be judged?

Control Engineering and Plant Engineering’s panel of judges will conscientiously evaluate all entries. Three general criteria will be considered for the selection of the System Integrator of the Year: • Business skills • Technical competence • Customer satisfaction

Questions? Contact Tom Magna System Integrator Marketing Consultant CFE Media tmagna@cfemedia.com

For more information on how to enter and proper criteria, visit: www.controleng.com/events-and-awards/system-integrator-of-the-year-program

ANSWERS

SYSTEM INTEGRATOR ROUNDTABLE John Hopshire, PMP, and Bob Starkus, PMP, Maverick Technologies; Gary Humble, RoviSys

DCS migration, IT/OT projects

System integrators discuss an eight-year distributed control system upgrade and a 100-site IT/OT system integration to improve tagging and programming.

ontrol system integrators answered questions for a Control Engineering System Integration Roundtable article on oil and gas automation and control system integration. The two projects involved a distributed control system (DCS) migration, and integration project for better information flow between operational technology and information technology. Providing information about the projects were John Hopshire, PMP, oil and gas industry manager, and Bob Starkus, PMP, senior project manager with Maverick Technologies; and Gary Humble, director, oil and gas - RoviSys.

Q. Describe a recent oil and gas industry automation, controls, or instrumentation system integration project.

making key decisions based on limited and stale information.

Q. What was project scope and goals? Maverick Technologies: In modernizing its facility, a major oil and gas refiner needed help migrating a legacy distributed control system (DCS) to the same vendor’s modern DCS for multiple process units. RoviSys: A midstream oil and gas company with nearly 100 facilities spread across a wide geography was faced with various business and operational challenges. These challenges stemmed from limited visibility and latent data access across all their facilities and assets. Groups across the organization were

Maverick Technologies: The multimillion-dollar, eight-year program required a systematic multiphase migration approach of all process units. The team conducted a Level 2 front-end loading (FEL2) study to develop a detailed overall project execution plan, +/-30% estimate and a resource-loaded critical path integrated schedule for the program, which the customer could then use to support funding. The goal was to complete the long-term multiphase migration with little to no disruption to produc-

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tion while meeting schedule, quality and budget targets. All of the work was to be completed with zero safety incidents. RoviSys: The overall scope and goal of the project was to develop an operations technology (OT) to information technology (IT) information solution to provide business and operational value across their organization. Downtime reduction was accomplished by proactively monitoring critical assets like pumps, valves, metering, and vapor recovery units. Units have real time health checks to prevent unplanned downtime. An equipment optimization plan was implemented to lower overall operating costs by running units more efficiently. Improper routing of products to the wrong tank, truck or pipeline cost the company millions of dollars in product recovery and regulatory fines. The solution delivered real time tracking of the inventory and blending processes, automatically detecting anomalies and alerting operations.

that included data mining, identification of tagging structures, and programming disparities to effectively move forward. Second, to get buy-in of the solution across the customer organization, the biggest factor was earning trust through active engagement. RoviSys engineers worked directly with customer end-users throughout the lifecycle of solution design and implementation to build confidence in the coming changes and encourage adoption

Q. What were project challenges?

Q. Can you share positive metrics?

Maverick Technologies: One main challenge was to minimize downtime throughout each phase of the program. RoviSys: Two challenges stand out: 1. A technical challenge was data quality and normalization across nearly 100 facilities. Most of the facilities had aging or obsolete technologies, disparate technologies, and inconsistent configurations and operating standards. 2. Another challenge was the enterprise-wide impact to multiple different functional groups throughout the customers organization – across OT and IT. Development, testing, deployment and adoption required buy in from a diverse set of customer resources.

Maverick Technologies: The Maverick team has completed Phases 1 through 3 of the migration project, commissioned during a previously scheduled two‐week turnaround, minimizing disruption to production. The customer has deemed the project a success, including safety, budget and quality. The refinery readily obtained corporate approval for Phase 4 of the project, which is currently underway. The team begins each phase of the program by conducting a Level 3 front-end loading (FEL3) study in order to develop a detailed project execution plan, +/-10% estimate, and reverse-engineering the DCS configuration. During the course of the FEL3 study, the team worked with multiple contractors to develop a baseline scope and cost, along with appropriate levels of progress reporting of critical deliverables to support the execution phase of each project. This helped ensure all parties stayed on track and within budget. RoviSys: The real time product quality checks and alerts have prevented off spec product and erroneous product routing, saving millions of dollars in product recovery/disposal and regulatory fines.

Q. How were project issues resolved? Maverick Technologies: The project execution plan looked in-depth at the refiner’s turnaround schedule and process units. Migration cutover phases were scheduled in parallel with planned maintenance and turnarounds, reducing unplanned downtime to zero. RoviSys: First, RoviSys developed standard interfaces and data quality procedures to ensure compliance and a rapid scale out of the solution. It was necessary to audit each facility and develop a plan www.controleng.com

‘

Maverick Technologies: Upfront FEL best practices were used and the team worked closely with the company to manage all aspects of the program, including working closely with the customer on safety, contracting strategies, procurement planning, constructability, quality, execution planning, scheduling, contingency and budget. Biweekly project meetings with project stakeholders ensured keeping the project on track and within budget.

Migration cutover phases during planned maintenance and turnarounds, reduces unplanned downtime to zero .... Use cases were focused on scheduling and delivery optimization, predictive maintenance, and product quality.

of the new normal. RoviSys helped identify how the new solution creates a better operating environment for all.

Q. What were the resulting lessons

learned or advice you’d like to share?

’

RoviSys: Successful projects require a partner that addresses people, process and technology. Technology and process are typically the easier part of the solution. The people portion presents a different challenge, because success spans different layers of an organization. The RoviSys team focuses on people, starting with executive commitment and identification of key stakeholders. A collaborative environment keeps teams motivated and engaged throughout the life of each project. ce Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media, mhoske@cfemedia.com. Maverick Technologies is a Control Engineering content partner.

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KEYWORDS: DCS migration, OT/IT system integration A refiner’s legacy DCS system was migrated with nearly 7,000 I/O points and connections to more than 20 third‐party interfaces. An oil and gas company with nearly 100 facilities had wireless instrumentation was installed; edge devices consolidate information; networks were assessed and upgraded for cybersecurity/bandwidth; data collection, analytics, dashboarding and reporting software was developed; analytics drive critical notifications and alerts. CONSIDER THIS What system integration projects could make you more productive?

ONLINE If reading the digital edition, click on the headline for more on each project.

control engineering

June 2020

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ANSWERS

INSIDE MACHINES AND ROBOTICS Tanya M. Anandan, RIA

Cultivating robotics and AI Smarter machines help relieve aging agricultural workforce and fewer workers.

he issue of agriculture sustainability is a people problem. However, it might be the robots that save humanity. Automation and artificial intelligence (AI) will help relieve the effects of an aging agricultural workforce and a shrinking supply of field workers looking for less strenuous work. Self-driving agricultural machinery and autonomous drones mean farmers can spend more time focusing on more sustainable harvests and profits. Data mining and predictive analytics will become more common, enabling farmers to make better decisions, KEYWORDS: robotics, maximize resources and optimize yields. agriculture, food safety Robots and machine learning are helping Big Data, robots help facilitate new, more sustainable agricultural agricultural workers with crops. methods that take farming inside to conserve Machine learning helps resources, minimize chemicals and shortrobots grasp food. en time to market. With more sustainable, ONLINE fresher options from growers, greenhouses Read this article online at and vertical farmers, the world’s population www.controleng.com for more should be able to eat better, cleaner, smartabout robots in the agriculture er and more affordably. Farms are becoming industry, including: high-tech, better informed, and empowered -Big Data, better decisions to produce more with fewer resources. and a better crop

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-Machine learning for grasp planning -Improving food cleanliness and safety

CONSIDER THIS How can robots improve your applications?

Self-steering combine uses sensor fusion, robotics and artificial intelligence to automate many harvesting tasks for precision farming. Courtesy: John Deere/RIA

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June 2020

Precision sensors, agriculture

John Deere is a global manufacturer of machinery for the agricultural, construction and forestry industries with annual sales of $37.4 billion. The Moline-based company providing innovative products and services to support those linked to the land. The 2017 Deere S700 Series Combines are its latest in

Intuitive touchscreen displays put a wealth of real-time data and analysis tools at operators’ fingertips so they can monitor, adjust and learn from their machinery while moving through the field. Courtesy: John Deere/RIA control engineering

smart grain harvesting technology. “It actually uses imagery to identify when an individual kernel of corn is being damaged,” said Joel Hergenreter, automation strategy lead for Deere’s Precision Farming Group. “The robotics knows how to adjust the combine to ensure that individual kernels are not damaged going forward.” The S-Series appeared at the Consumer Electronics Show in January. The gigantic multi-ton combine has onboard robotics and AI; Deere has been self-steering since 2003. Since AutoTrac’s introduction, Deere has added mechanical sensors and vision sensors (cameras) to identify crop rows and ensure the sprayers and harvesters drive between the rows and do not damage crop. Sensor fusion is used to combine the signals from the GPS receiver, mechanical sensors and vision sensors to automate steering. Most of the company’s large agriculture equipment is “self-driving capable” with sub-inch accuracy, increasin speed of operation up to 50%, Hergenreter said. Deere AI use enables using 10% of previous herbicide in some applications. “The machine processes one image every 50 milliseconds,” Hergenreter said. It compares them to 300,000-plus image library, targeting only weeds.

Autonomous robotic harvesting

Launched in 2018, Root AI is using traditional and proprietary robotics hardware combined with sophisticated software to expand the domain where industrial robots add value. Agricultural robotics has typically involved custom equipment focused on a specific task or a particular type of crop. Root puts a modular collaborative robot to work on the farm and adds AI. Virgo, the robotic harvesting system, is a standard, industrial-grade cobot on a mobile platform combined with computer vision for sight, custom endof-arm tools (EOAT) for grasping a variety of fresh produce, and onboard intelligence that enables the unit to do dexterous work in the field. Co-founder and CEO Josh Lessing said Root is focused on the AI technology, Recent advancements in algorithms, especially computer vision software for finding individual objects in complex environments, combine with cloud communication and machine learning to enable the robots to do physical work in complex, real-world environments. Virgo is testing by picking ripe tomatoes in large U.S. commercial greenhouses. Other specialty crops also require incredible amounts of skilled, dexterous labor. Variability makes automation challenging. www.controleng.com

Soft-actuating gripper handles varying sizes and shapes of food in the supply chain. Courtesy: Soft Robotics Inc./RIA

“By going after one of the single biggest unmet needs in the specialty crop industry, we have folks’ attention,” said Lessing; 30% to 40% of a tomato’s revenue goes to labor. Harvesting is very physically demanding and seasonal, and “the ability to source labor to meet demand is increasingly a struggle.”

Flexing grippers help the food supply

The Bedford, Mass.-based Soft Robotics Inc. CEO Carl Vause said labor shortages and inefficient processes are losing produce and other perishable foods in the supply chain when they can’t get to market in time. Soft Robotics grippers excel where applications have high rates of variety such as in e-commerce, store replenishment and delivery, sortation of produce by size and shape, meal kitting, and high-mix/ high-volume manufacturing such as cosmetics and consumer goods. Combined with machine vision to locate the lettuce heads and an automated blade to separate the heads from their stems, the Soft Robotics gripper helps harvest different varieties of lettuce and other leafy greens for a U.S.-based grower. Robotics and AI are up for the challenge as farms

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

Sophisticated vision sensing, artificial intelligence and custom end-of-arm tooling enable a collaborative SCADA robot to harvest ripe produce directly from the vine. Courtesy: Root AI/RIA

KNOW THIS FEELING? Then stop using complicated controllers for precision motion. You shouldn’t need a Ph.D. in control systems to program your controller. With Automation1, you can now reduce your set up time — in many cases, from days down to minutes — thanks to a user-friendly, intuitive interface and machine setup wizard. Automation1 is the most user-friendly precision motion control platform available.

input #15 at www.controleng.com/information

See how we make your motion easier. AT0520A-CSG

ANSWERS

INSIDE MACHINES AND ROBOTICS Mark T. Hoske, Control Engineering

Answers on robotic applications Learn more from system integrators from the RCEP webcast, “Robotic applications: What robots should and shouldn’t be doing.”

obotic application information about collaborative robots, robotic motion, automation pitfalls, power quality, and safety follow. Information came from presenters in the March 12 webcast, archived for 1 year, “Robotic applications: What robots should and shouldn’t be doing” at www.controleng.com/webcasts/past. Expert speakers for the webcast were Evan Gonnerman, controls engineer, and Ryan Wasmund, sales and marketing director, Concept Systems Inc., a system integrator with industrial robotic expertise. Also in the webcast, Control Engineering discussed survey results about robotic apps and conducted a poll of webcast participants to learn their reasons for the next robot purchase. Additional answers from the speakers follow. Question: How do you decide between a collaborative robot or traditional industrial robot?

Enabling robotic technologies include simulation, digital twins, machine learning, advanced sensors and more. Courtesy: Control Engineering webcast, Robotic applications: What robots should and shouldn’t be doing

Answer: The reasons for collaborative versus traditional industrial robots often is based around safety. If the automation tool will be used with humans on a regular basis a collaborative robot may be necessary. However, if the solution requires human intervention at certain points during the process a traditional robot can be used with safety rated laser scanners. Collaborative robots typically will have lower maximum speed profiles than traditionKEYWORDS: Industrial robot al 5- to 6-axis robots. applications

avoid is a “singularity” when discussing the most common 6-axis robotic implementations. There is a lot that goes into this but the 10,000-foot definition of a singularity is when the fourth and sixth axes of the robot are aligned. This situation can cause headaches especially when precise movements are necessary within this “zone” Besides singularities, it is important to understand the reach capabilities of the robot you are using as well as the payload capacity as these will define certain speed limitations.

M More ANSWERS

Applications include robots operating in collaborative applications. Robot movement is a consideration in industrial robot applications. Webcast provides more tips and tricks related to robot and robotic system applications.

CONSIDER THIS How are industrial robotic implementations helping your workflow?

ONLINE See this webcast and other robotic webcasts at www.controleng.com/webcasts.

•

June 2020

Control Engineering: Risk assessments are needed even with collaborative robots or industrial robots using sensors, software, and other padding to run in collaborative applications. (See more on safety, online.) Other reasons for collaborative robot selection may include simplified programming, setup, integration, and resetting for other applications. Q: Are there limits in robotic movements and challenges in speed control with respect to robotic movements? A: The biggest robotic movement to

control engineering

Q: Are there any pitfalls to watch for as we gradually transition from manual to automated process? A: Ensure that you have a solid maintenance and support team, or that you choose an integrator that can support you. The biggest issue that I have seen has been around companies putting in automation without the support structure in place to handle the robotic systems once they are in and running. This would include maintenance, programming support, and new product integration. ce Mark T. Hoske is content manager, Control Engineering, CFE Media, mhoske@cfemedia.com. www.controleng.com

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Now, more than ever, engineering innovation plays a vital role in the vitality of industrial manufacturing. We invite you to explore the profiles on the following pages and celebrate the success stories of these participating manufacturing innovators:

ABB Motors and Mechanical

Inductive Automation

AutomationDirect

Lenze Americas

Beckhoff Automation

Radwell, Inc.

Dataforth

SEW Eurodrive Inc.

Digi-Key Corporation

Siemens Digital Factory

EZAutomation

Stratus Technologies

Hammond Manufacturing

WAGO Corporation

View the 2020 profiles and videos at:

www.controleng.com/innovations

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ABB provides solutions. ABB provides solutions for efficient production, safe and reliable operations, and digital remote condition monitoring across most industrial plant equipment and systems.

ABB Ability™ Smart Sensors: Always know how your equipment is feeling The ABB Ability Smart Sensor monitors the health of your low voltage motors, bearings, gear reducers and pumps by gathering data on vibration, temperature and other parameters that can be used to gain meaningful information on condition and performance, enabling users to identify inefficiencies within their system and to reduce risks related to operation and maintenance. Maintenance can now be planned according to actual needs rather than based on generic schedules. This extends equipment lifetime, cuts maintenance costs, and reduces or prevents unplanned downtime due to breakdowns.

EC Titanium: High performance. Flexible solution. As energy regulations require higher total system efficiency, achieve IE5 efficiency in smaller spaces and with less maintenance by relying on the BaldorReliance® EC Titanium™ integrated motor drive. The EC Titanium is a highly efficient integrated motor drive that combines synchronous reluctance and permanent magnet technologies for a sustainable, wirelessly connected solution that improves your bottom line. This sustainable, IE5 solution runs out of the box, minimizes installation costs and increases facility safety.

Servo Motors: More torque. Less cogging. Superior performance. ABB’s family of servo motors was created for industrial, automated applications that require precise control for positioning, speed and acceleration such as packaging, labeling, wrapping, and cutting. Designed for durability in harsh environments, we also offer a wide variety of inertia, winding and feedback options.

ABB is the leading US marketer, designer, manufacturer and service provider of ABB and Baldor-Reliance® industrial electric motors and Dodge® mechanical power transmission products. With a long rich history dating back to 1878, the US ABB business is supported with manufacturing, R&D and support offices in more than 15 locations in Arkansas, Oklahoma, Missouri, Mississippi, Tennessee, Georgia, North Carolina and South Carolina.

input #17 at www.controleng.com/information

baldor.abb.com 479.646.4711

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AutomationDirect The company provides online tutorial videos through their web store at www.automationdirect.com as well as their YouTube channel. A Customer Forum provides peer support on technical and application questions.

Company headquarters located just north of Atlanta, GA

A well-recognized name in the industrial automation market, AutomationDirect provides quality products with FREE award-winning in-house sales and technical support. AutomationDirect provides customers with quick order and delivery through an online store and toll-free number. Prices on most products are well below the industry average and a 30-day money-back guarantee is offered on nearly all items. With tens of thousands of part listings, new products include the Productivity1000 PLC, the Do-more BRX PLC and the DURApulse GS4 AC drive. These products represent many years of design and development by AutomationDirect’s own engineering team as well as their strategic partners. The company also offers motors, sensors, pushbuttons, enclosures, circuit protection, cut-to-length cable, pneumatic supplies and more.

AutomationDirect’s customer support team has been rated top-notch by its customers. For 15 years straight, the Tech Support team was voted by readers of Control Design magazine as the best in service and support for various products. And, their own customer surveys consistently rank the company’s service as better than other suppliers.

Orders ship quickly from our state-of-the-art warehouse

The state-of-the-art headquarters facility near Atlanta is designed throughout for maximum performance. The majority of items are in-stock and ready for immediate shipping; orders over $49 ship for FREE. Some exclusions apply.

For an in-depth look at products offered, visit: www.automationdirect.com.

1-800-633-0405 | AutomationDirect.com input #18 at www.controleng.com/information

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XTS Delivers on Promise of Linear Transport Systems and Mechatronics The EtherCAT-enabled eXtended Transport System (XTS) offers paradigm-shifting capabilities for motion control and mechatronics by combining the advantages of proven rotary and linear motion principles into a new modular platform. With its compact and flexible design, the advanced mechatronic system can reduce machine footprint up to 50%. The XTS revolutionizes drive technology and promotes innovative, globally competitive machine concepts. XTS contains all functions necessary to support efficient integration for motion control applications in many industries. With attached mechanical guide rails, XTS motor modules feature directly integrated power electronics, EtherCAT communication and position measurement. An unlimited number of wireless XTS movers can be controlled with high dynamics at up to 4 m/s on extremely customizable paths. By harnessing the flexibility and scalability of EtherCAT, PC-based control and TwinCAT 3 automation software from Beckhoff, XTS enables flexible mass production down to lot size 1 for the smart factories of today. “Through the capabilities of XTS, Beckhoff once again empowers engineers and machine builders to take leading-edge machine designs to the next step,” said Kevin Barker, president of Beckhoff Automation LLC. “The launch of XTS in the United States will provide significant opportunities for customers in numerous industries to boost throughput, shrink machine footprint and increase flexibility while eliminating timeconsuming mechanical changeovers. This mechatronic system will be a key innovation driver for all companies that use it.”

Beckhoff establishes the new linear motion principle The application possibilities of XTS are virtually limitless: Movers can accelerate, brake, position and synchronize themselves on the ﬂy with automatic collision avoidance provided by TwinCAT 3 software. They can take up absolute positions and positions relative to each other; they can group themselves and accumulate; they can create clamping forces in motion, drive through curves and along straights, recover energy through regenerative braking and use both the return and outward paths for transport purposes.

input #19 at www.controleng.com/information

(952) 890-0000 | beckhoff.usa@beckhoff.com | www.beckhoff.us/xts

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Digi-Key Offers Products for your Automation and Control and Safety Applications Digi-Key Electronics is a preferred supplier for Automation and Control and Safety products. With more than 10.2 million components from 1,200+ trusted suppliers, Digi-Key has what you need to take your design to the next level. Learn more about these latest technologies from our authorized supplier partners: Banner Engineering Wireless Solutions Kit for Vibration and Temperature Monitoring - The fully integrated solution enables users of any experience level to reduce downtime and increase productivity with visualized data and alarms. Setup is simple with no programming required. KUKA Robotics Corporation AGILUS KR 3 R540 Robot Kit Unrivaled in their payload categories, KUKA AGILUS robots can perform even unusual tasks in any installation position. The robots feature six axes, high speed, short cycle times, and an integrated energy supply system for cost-effective performance requiring minimal maintenance. Schunk Miniature Pneumatic Flexible Robotic End-Effector FGA MPG+ Kits - The FGA MPG+ kits come in four sizes and are the perfect solution for gripping and moving extremely small to medium-size workpieces with high precision and high speed in clean environments. Phoenix Contact Machine-to-Machine (M2M) Portables for Remote Support - The M2M portables enable integrators to ship units on-site for startups or support, while cellular remote access allows users to access their equipment virtually anywhere. Sensata-Crydom PM67 Series Panel-Mount Solid-State Relays (SSRs) - The PM67 series compact 3-phase SSRs feature built-in overvoltage protection and optional overtemperature protection enabling use in demanding heating, motion, and lighting applications. UL approved and VDE certiﬁed, these powerful and versatile SSRs offer a panel mounting layout compatible with standard hockey puck SSRs and large cage clamp terminals that reduce installation cost and time. Digi-Key provides 24/7 technical support, and our diverse selection and extensive inventory allow our customers to set up even complex processes quickly. With a wealth of online tools and reference materials, engineers can innovate faster with Digi-Key.

sales@digikey.com | 1-800-344-4539 | www.digikey.com input #20 at www.controleng.com/information

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50 Years of “Innovation by Design”, 30+ Patents, Made in America sold Factory Direct@Great Prices. Introducing 7 New Product Lines. EZTouch EZ7 Series: EZAutomation is introducing a brand new EZTouch, the EZ7 Series, where the Front Module housing the Display and the Touchscreen is detachable from the back, connected with just an HDMI cable. No cutout is needed, just a small ¾” hole for the cable. Front is metal, NEMA 4/4X. Same strong specs: LED display 400 NITs for 75K hours @ 55 deg. C. 7”, 8”, 10”, 12’’ models. Backend CPU is common to all sizes. Plant user can replace a defective/ damaged Touchscreen or Display in less than 5 minutes. New 12” model is priced quite attractively. Quite often, plants want to increase the size of their screen over a period of time. This innovation makes it possible to do so at a minimal cost. EZ7 has full capability to talk to DH+ networks. EZTouch.miniPLC: EZAutomation is breaking a price barrier and establishing a new norm with its new EZTouchminiPLC. 3.5” or 6” display, with 10 DI, 8 DO, 4 RLY, 2 Quadrature in @250 KHz, 2 Analog in and 1 Analog out. This extremely compact unit features robust removable plug-in terminal blocks for ease of maintenance. All IOs have LED status indicator right at the terminal. EZTouchPLC & EZTouchRackPLC: EZAutomation being the first company to come out with an advanced HMI and a fully modular PLC packaged in one in 2005, called the EZTouch. PLC, is expanding this line to add 306 new models, with 6 to 15” displays, up to 112 modular IOs all contained in same unit, and communication to all networks including DH+, ModBus+, CCLink, Profibus, and all Ethernet protocols. EZ Programmable Power Supply: EZ PPS is a darling of plant personnel. 12 or 24 DC small footprint DIN mount UL approved power supply with Voltage and Current Readout, is loved by one and all because it is such a great aid to troubleshoot your DC power distribution system. No need to disconnect wires and insert Volt and Amp meters to figure out what component is drawing too much current. Right now it is available up to 10 Amp output.

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1-877-774-3279 | www.ezautomation.net | sales@ezautomation.net

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Inductive Automation Offers New and Improved Solutions for Digital Transformation

For many industrial organizations, digital transformation is difficult. Often, they encounter problems such as difficulty collecting data at the edge of the network, challenges with turning data into action, obstacles in project development and deployment, and prohibitive costs. Inductive Automation recently announced significant improvements to three products, and a new development resource. All four make it easier for organizations to realize their goals in digital transformation. The four solutions relate to Ignition by Inductive Automation®, an industrial application platform with tools for building HMI, SCADA, and IIoT solutions.

New and Improved Products for Ignition Edge - Ignition Edge is a line of lightweight, limited

Ignition software solutions designed for embedding into field and OEM devices at the edge. With new products recently added, the lineup includes Ignition Edge Panel, Ignition Edge Compute, Ignition Edge Sync Services, Ignition Edge EAM (Enterprise Administration Module), and Ignition Edge IIoT. For more information, visit inductiveautomation.com/ignition/edge.

Expansion of the Ignition Onboard Program - The Ignition Onboard program now provides easier access to industrial hardware that comes with Ignition already installed, configured, and licensed. Numerous device manufacturers are embedding Ignition and Ignition Edge into their devices — including Advantech, OnLogic, Opto 22, and more. For more information, visit inductiveautomation.com/onboard. Improvements to the Ignition Perspective Module - The Ignition Perspective Module now has more features to help turn data into smart industrial applications. It lets users easily build mobile industrial applications in HTML5 for monitoring and control of their processes directly from their mobile phones. For more information, visit inductiveautomation.com/ignition/modules/perspective. A New, Free Resource for Developers: Ignition Exchange - Ignition Exchange is a new, online

space where developers can get free, time-saving Ignition resources provided by Inductive Automation and the Ignition community. For more information, visit inductiveautomation.com/exchange. These new and improved solutions from Ignition make digital transformation not just possible, but also easy. accountservices@inductiveautomation.com 800-266-7798 inductiveautomation.com input #22 at www.controleng.com/information

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The best machines and production facilities around the world use Lenze As a global specialist in Motion Centric Automation, Lenze offers you innovative products, drive solutions, complete automation systems, and engineering tools and services from one single source. We support you throughout the entire machine development process, and partner with you to provide the best future-proof machine automation solutions.

Lenze X4 Remote – an integrated solution for cloud-based remote services. With Lenze X4 Remote, we offer an integrated and ready-to-use solution which is so simple that any machine manufacturer can set it up and configure it independently. Easily add value to your service, reduce downtime, and increase productivity. Make your company fit for the future by accessing all your most valuable insights in one place. Offer remote maintenance, monitor your machines, set up alerts, and create meaningful data dashboards – all with a few clicks.

i950 servo inverter

i950 – the multi-talented servo inverter. The i950 servo inverter is a match for any operational scenario thanks to its three different modes of operation. It can be freely programmed or serve as an actuating drive under a CiA402 motion control, but the most common mode of operation is with the use of Lenze’s integrated FAST technology applications. With FAST, Lenze’s modular software system, preconfigured and tested technology applications can be used immediately with the i950 and adapted to the respective machine task via parameterization.

i550 frequency inverter

Compact i550 frequency inverter – a new solution for decentralized applications. Well-protected with IP66 (NEMA 4X), and wellconnected with many popular industrial fieldbuses, the i550 protec sets out to conquer a wide range of decentralized drive tasks. Even outside the control cabinet, the available space in machines and systems is quite limited. With the i550 protec, Lenze is launching an exceptionally compact device in comparison to others on the market. The design of the IP66 (NEMA 4X) devices ensures maximum protection against adverse environmental conditions such as high temperatures, dust, dirt or water jets during cleaning operations. It is particularly suitable for large-scale machines, distributed applications in material flow or apparatus engineering, or wherever control cabinet space is expensive.

marketing.us@lenze.com | Phone: 508-278-9100 or toll free 800-217-9100 | www.Lenze.com input #23 at www.controleng.com/information

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Unwanted Inventory Taking Up Valuable Space? Radwell International’s Asset Recovery program is an exceptional resource for your company. We offer cash for parts and products you don’t need. In many cases, selling your excess inventory to Radwell gives you the opportunity of adding dollars to your bottom line. With extensive knowledge of what’s being used – and discontinued – in the industry, Radwell stocks and sells new and certified preowned industrial automation, MRO, pneumatic, motion, electronic, hydraulic, HVAC and electrical control equipment for plant floor and facilities maintenance machinery. The process is easy. Call Radwell for a free recycling bin, gather and box your surplus, then call Radwell for free pick-up. Need more information? Radwell has highly trained and experienced asset recovery and surplus team members ready to help you make your business thrive. Organizations that need to off-load equipment are able to do so; organizations that still need to buy that equipment can easily find and purchase certified equipment; and less e-waste ends up in landfills. Asset Recovery is a win-win for everyone! Benefits of Asset Recovery • Lowering warehousing costs • Reducing Aging inventory • Reducing slow moving inventory

• Increasing warehouse space • It increases cash flow with no labor costs • Eliminates used overstock inventory

It is important to note that any equipment being sold to or sourced by Radwell International must meet the highest standards of functionality and use. However, not all equipment sold to Radwell via the Asset Recovery program has to be brand-new. Radwell has a team of in-house engineers and technicians who can refurbish equipment to a like-new state, granting it the Radwell Certified PreOwned stamp of approval, which comes with Radwell’s two-year warranty. The types of equipment Radwell most often purchases and upcycles includes industrial automation equipment, PLCs, drives, motors, electronic parts, circuit boards, meters, sensors and all types of industrial controls. However, if your company has other types of surplus inventory that you’re looking to offload, please feel free to contact us at 800-884-5500 ext. 824. To learn more about Radwell International’s Asset Recovery Program visit https://info.radwell.com/en/asset-recovery-program

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Technology Updates and Automation Expertise from SEW-EURODRIVE

SEW-EURODRIVE — Much More Than Gearmotors Our team of (MAXOLUTIONS) automation engineers provides the expertise, project planning, software, commissioning, and worldwide support for your most challenging motion control projects. They can serve as a valuable extension of your engineering team, reducing the stress and demanding workload.

MOVIGEAR® and MOVI-C® for Decentralized Installations MOVIGEAR is the mechatronic drive system that combines the gear unit, IE4 motor, and electronics in one compact unit. Recent updates include fully integrated Ethernet/IP communications and digital motor integration. This advanced single-cable technology carries power, feedback information, and control signals along a single hybrid cable between decentralized devices. MOVI-C modular automation system is a one-software, one-hardware, automation platform that combines fully integrated components, control electronics and software.

Our experts provide a solution of perfectly matched SEW components that work together seamlessly — because we designed them that way!

Complete Drive Maintenance and Management SEW-EURODRIVE now offers a full complement of drive maintenance and management services. Our CDM® Maintenance Management service provides a 24/7 online portal as well as a complete overview of your drive components, the condition of your units, drive usage, and service details. Plus, our new on-site Pick-Up Box Service will free up your maintenance team for other tasks. Just place your drives that need repair in the supplied box and we’ll handle the pick-up and return of your units.

About SEW-EURODRIVE Engineering excellence and customer responsiveness distinguish SEW-EURODRIVE, a leading manufacturer of integrated power transmission and motion control systems. SEW-EURODRIVE sets the global standard for high performance and rugged reliability in the toughest operating conditions. With global headquarters in Germany, its U.S. operations include a state-of-the-art manufacturing center, five regional assembly plants, more than 63 technical sales offices and hundreds of distributors and support specialists. This enables SEW-EURODRIVE to provide local manufacturing, service and support, coast-to-coast and around the world.

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P: 864-439-7537 F: 864-439-7830 www.seweurodrive.com

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Industrial Edge – from the field to the cloud The optimal use of data is becoming increasingly important for industry. Many companies have already recognized this fact and are analyzing machine and plant data on industrial PCs using their own software. Although this method delivers a great deal of valuable knowledge, it’s resource-intensive and requires frequent manual updates to ensure that the software, operating system, and cybersecurity are always secure and up to date.

Cloud or edge? Thanks to Industrial Edge, there’s no question. You can choose whatever you need. With Industrial Edge, everything is easier, more flexible, and more. You enjoy all the benefits of edge and cloud computing – optimally tailored to your company’s specific requirements. Industrial Edge allows you to analyze all the data at the machine or preprocess it quickly and instantly. The optimized data points can then be transferred more quickly to the cloud where, for example, you have access to more computing power and larger storage capacities. Among other things, this permits a precise analysis of data over longer periods of time. Based on your application, you decide whether and how you want to use the cloud in addition to Industrial Edge.

Industrial Edge for production machines and plants With Industrial Edge, you can implement applications and solutions that far exceed the functions of a traditional controller. Whether as a direct part of the controller or with industrial PCs, Industrial Edge offers a flexible and innovative platform with long-term availability that accompanies you throughout the digital transformation of your company.

Industrial Edge for machine tools Thanks to tailored software, Siemens’ SINUMERIK Edge offers you a machine-level platform for apps that digitally support and optimize production. The analysis of high-frequency CNC data is practically feedback-free for the CNC.

Edge Computing – more than a hype? Get to know the world of Siemens Digital Industries in our Talking Digital Industries podcast. Listen to Siemens podcast on your podcast app or on Spotify and take deep dive into edge computing.

input #26 at www.controleng.com/information For more information, please contact our Customer Support Center. Phone: 1-800-241-4453 | E-mail: fa.marketing.us@siemens.com | usa.siemens.com/industrial-edge

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Stratus Edge Computing Solutions Simplify, Protect and Automate Our Digitally Transforming World As more and more computing takes place at the edge of corporate networks, companies are revisiting and optimizing the architecture, deployment, and management of their Edge Computing infrastructure. For leaders digitally transforming their operations in order to drive predictable, peak performance with minimal risk, Stratus Technologies ensures the continuous availability of businesscritical applications by delivering zero-touch Edge Computing platforms that are simple to deploy and maintain, protected from interruptions and threats, and provide autonomous monitoring and control. For 40 years, we have provided reliable and redundant zero-touch computing, enabling global Fortune 500 companies and small-to-medium sized businesses to securely and remotely turn data into actionable intelligence at the edge to the data center and the cloud - driving uptime and efﬁciency.

Our Products ftServer Ensures Your Applications Experience the Highest Availability Stratus ftServer is a fully integrated, continuously available hardware and software solution for running tier 1 business critical workloads and manufacturing The Stratus ftServer provides the highest levels of operations and control applications. Offering better application availability for many of the world’s than 5 nines availability, ftServer eliminates unplanned fortune 500 companies. downtime and data loss, and ensures all transactions are processed and applications are available, helping companies maximize revenue, production quality, and productivity. Unlike other high availability solutions, ftServer is easy to deploy, manage and service, making it ideal for remote locations, or environments with IT resource constraints. A single, turnkey solution leverages industry standard components to deliver industry leading RAS, accelerating time to value, simplifying management, and lowering total cost of ownership.

ztC Edge for Zero-touch Edge Computing That is Simple, Protected and Autonomous Stratus ztC Edge is a zero-touch, reliable, secure, highly automated computing platform that is simple to deploy and ensures the highest levels of business operations and application uptime and security while functioning autonomously for remote monitoring. Purpose-built for operational technology (OT), Stratus’ ztC Edge is a rugged, virtualized Edge ztC Edge is easy to set up, configure and manage. Computing platform that is specifically designed for With built-in virtualization and availability layer, industrial edge environments. automated data protection and application recovery, ztC Edge significantly reduces the dependence on IT for virtualized computing at the edge. Its self-protecting and self-monitoring features help reduce unplanned downtime and ensure the continuous availability of business-critical industrial applications. To learn more about how Stratus can help you meet your digital transformation and Edge Computing goals, visit https://www.stratus.com/edge-computing/. 5 Mill & Main Place, Suite 500 Maynard, MA 01754, USA | +1 978-461-7000 input #27 at www.controleng.com/information

A DV E R T I S E M E N T

What’s New with WAGO: 2020 Product Innovations WAGO Corporation provides innovative Automation, Interconnect, Terminal Block and Electronic Interface solutions. Equipped with CAGE CLAMP® Spring Pressure Connection Technology, WAGO products are user-friendly, vibration-proof and maintenance-free. From terminal blocks to PLCs and more, our compact products deliver safe and reliable solutions for any factory, process or building application. Innovations include:

The Pro 2 Raises the Power Supply Industry Standard The new Pro 2 Series power supplies are setting new industry communication and parameterization benchmarks. The Pro 2 incorporates an interface allowing it to be tailored to any application requirement. The units also offer monitoring functions that provide continuous power supply data information and signal errors for application monitoring. With six power supplies ranging from 120 – 960 W, the Pro 2 Series provides an energy conversion efﬁciency of up to 96 percent. Learn more: www.wago.com/us/power-supply-pro2

Aesthetic Design Meets High Performance with Touch Panel 600 The Touch Panel 600 line brings high-tech screens and high quality visualizations together to allow users to accompany their machines with advanced features. The engine has a Cortex A9 multicore processor providing fast operating speeds. Onboard security includes a built-in Firewall and VPN to help users address cyber attacks. All panels are equipped with the future-ready Linux operating system and support HTML5 technology. The Touch Panel 600 line includes three versions: Control, Visu and Web Panels. All offer practical features such as an energy-saving standby function, integrated sensors for automatic brightness adjustment and an easy-to-mount design to make installation and operation simple. Learn more: www.wago.com/us/touchpanels/600

Expanding the TOPJOB® S line to include Functional Terminal Blocks with Push-Buttons A chance to change the industry with the mere push of a button led to the expansion of the TOPJOB® S push-button function terminal blocks. These terminal blocks are modeled after the successful rail-mount terminal blocks with open tool slot. They offer the convenience of simple and intuitive push-button operation while also incorporating disconnecting fuses, fuses (pluggable and pivoting) and component holders that allow for added components such as diodes and LEDs. As with all TOPJOB® S terminal blocks, these function blocks offer dual row jumpering. Learn more: www.wago.com/us/topjobs.

input #28 at www.controleng.com/information

Info.us@wago.com | (800) DIN-RAIL | www.wago.us

Dataforth Celebrates 35 Years with Ongoing Growth and Innovation Expanded Capabilities for MAQ®20 Family - The powerful MAQ20 Industrial Data Acquisition & Control System, Dataforth’s 3rd generation DAQ system, now numbers 21 modules, with seven more about to enter the market. Current modules include voltage and current, thermocouple, RTD and potentiometer, strain gage, and frequency analog input modules; voltage and current analog output modules, and discrete input/output modules. The new modules will provide isolated voltage and isolated current analog input capability, expanding MAQ20’s outstanding versatility and functionality – while still offering the industry’s most affordable price per channel. All MAQ20 modules are designed for installation in Class I, Division 2 hazardous locations and have a high level of immunity to environmental noise. MAQ20-eagle.io Partnership - Dataforth has recently partnered with eagle.io to enable customers to use their MAQ20 system and eagle.io’s cloud-based software to build an IoT cloud-based remote monitoring system that is worldwide accessible and exceptionally secure. Eagle.io runs from any Internet-enabled device with a web browser; extremely fast, it works across multiple platforms and is designed speciﬁcally to remotely monitor environmental sensors. It also supports the acquisition and storage of up to 20,000 records per data source per day. The MAQ20-eagle.io interface became available to MAQ20 users in May 2019. sales@dataforth.com | 800-444-7644 | dataforth.com input #29 at www.controleng.com/information

Enclosure Quality Supported by Superior Service Hammond Manufacturing offers a broad range of industrial and commercial electrical enclosures. Their focus on providing industry leading service to support their quality enclosures includes extensive inventory for immediate delivery, coast-to-coast ﬁeld sales support and an easy to use enclosure website, www.hammondmfg.com.

Polycarbonate Watertight Enclosures Hammond Manufacturing offers several series of watertight polycarbonate and ABS plastic enclosures available from stock. Ideally suited for mounting printed circuit boards or DIN rail mounted components, with several series offering optional subpanels. Gasketed lids with two-piece “tongue & groove” construction provides protection against access of oil, dust and

water. Polycarbonate versions are cUL and UL508A listed and are designed to meet NEMA Type 4, 4X, 6, 6P, 12 and 13 ratings – exceeding IP ratings up to and including IP68. Replaceable gasket is one piece made from high temperature, U.L. listed silicone. Optional mounting accessories include external feet as well as pole mounting brackets. Modifications are also available to customize any enclosure with holes, cutouts and screen printing. For CAD files and detailed specifications visit: hammfg.com/electronics/small-case/industrial

Contact sales@hammfg.com | Phone: 716-630-7030 | www.hammondmfg.com

input #30 at www.controleng.com/information

INNOVATIONS

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

NEW PRODUCTS FOR ENGINEERS

Mobile app for maintenance, operations management

Festo’s Smartenance app consists of two parts: a mobile maintenance calendar as an app for smartphone and tablets on the shop floor and a desktop web-browser interface for managing and documenting maintenance tasks in the office. Team coordination through real-time information makes maintenance management more efficient. There are three levels of Smartenance and a free trial offer. Smartenance Basic enables the creation of maintenance tasks with an option for incorporating supporting images, PDFs, and videos. Plant floor personnel can provide feedback, including images and an overview of current status. Smartenance Advanced adds a plant logbook, incident management – reporting, editing, and closing incident tickets – and mobile knowledge search. Smartenance Premium adds event-driven maintenance tasks, a link to MES/ERP, and provides additional document storage capacity. Smartenance can be downloaded through the Apple or Google App stores. Festo Corp., www.festo.com

Input #201 at www.controleng.com/information

Loop-powered temperature transducers

Phoenix Contact added six loop-powered universal temperature transducers to the MACX MCR family. The modules include two non-Ex and two Ex I versions in two mounting formats: Head-mount and DIN railmount. The temperature transmitters support more than 28 temperature sensors. The modules also will accept -20 mV to 100 mV and linear resistance ranges from 10 ohms to 2 kohms. On the output side is a dedicated 4-20 mA signal with HART communication. At just 12.5 mm wide, the DIN rail-mountable modules save space in the cabinet. Both Ex and non-Ex DIN rail-mount versions can be ordered preconfigured by the factory, along with certificates of calibration. A head-mount, hockey puck format also is available. Phoenix Contact, www.phoenixcontact.com

Input #202 at www.controleng.com/information

Wireless cloud display device

Voodoo Robotics V2 cloud display device is designed to help warehouses further improve picking accuracy and productivity. The new wireless pick-to-light devices support a display capable of displaying barcodes, QR codes and icons. It also has six distinct colors that can be assigned to different pickers or different priorities/sequences. It also has support for up to five lines of text. It has support for directional icons, to show inventory above, below, left or right of the device. These prove very useful for new pickers, unfamiliar with a warehouse layout. They also allow one device to be used for multiple adjacent locations. Voodoo Robotics, www.voodoorobotics.com Input #203 at www.controleng.com/information

Safety laser scanner for mobile applications

Sick’s nanoScan 3 safety laser scanner combines safety functions with excellent measurement data quality for accurate and reliable localization. The sensor can be used wherever machines and vehicles require maximum performance, but with minimal mounting space. This enables manufacturers to use small automated guided vehicles (AGVs) or mobile robots in applications where space is critical. Features include two pairs of OSSD safety output and up to 128 freely configurable fields and monitoring cases. It has direct static and encoder inputs for flexible monitoring case switching and a protective field range of three meters with a scanning angle of 275-degrees. Sick Inc., ww.sick.com

Input #204 at www.controleng.com/information

Power over Ethernet switch

Wago’s compact Power-over-Ethernet (PoE) industrial grade Ethernet switch, the 8521411/000-001, is ideal for all applications with limited space. The wide voltage input of 24 to 57 V dc makes the 852-1411/000-001 makes it useful for all PoE applications. The switch supports PoE operation modes A and B, with all of the ports supporting 10/100/1000 Mbits/s. This PoE switch is unmanaged, supplies 30 W of power per PoE port and has an operating temperature of -10 to 60 ⁰C. It eliminates the need to run both an Ethernet cable and power cables to end devices, reducing overall costs. It is designed for energy applications including coal, hydro, nuclear and wind. Wago Corp., www.wago.com Input #205 at www.controleng.com/information

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June 2020

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June 2020

EDUCATION for ENGINEERS June 3, 2020 11AM PT | 1PM CT | 2PM ET

ONLINE COURSE: Introduction to Motors and Drives Preparing for the Thaw: Solidifying A Maintenance Strategy Post COVID-19

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