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the #1 value in automation

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Vol. 67 Number 7

JULY 2020

ANSWERS

26-38 COVER: AM8000 series servomotors from Beckhoff Automation control numerous axes of motion across the modular system, including those on the application head. Programming for the application, TwinCAT 3 automation software provides programming for PLC, motion and safety. Courtesy: Beckhoff Automation COVER INSET: IEC 61131-3 Programming Languages offers languages suited to specific needs. Courtesy: ControlSphere Engineering

INSIGHTS 6 | International: COVID-19’s impact on Chinese automation markets 7 | International: AI and robotics; Efficiency TECHNOLOGY UPDATES

23 | Automation accelerates material manufacturing; Electronics made on flexible wooden film; Semiconductor group support for manufacturing chips in U.S.; Headlines online 25 | Think Again: Research: Controller programming methods, advice

26 | Which IEC 61131-3 Programming Language is best? Part 1 30 | Benefits of learning ladder logic for industrial programming 32 | Moving toward self-assembly machine automation systems 35 | Modular window film application system reveals high precision, throughput 38 | Top 5 VFD parameter changes explained 42 | Machine mount I/O devices are the data satellites of the machine

43 | Safety over EtherCAT conformance tests 45 | Five tips for selecting the correct process valve for the job

46 | Five tips for effectively drawing electrical schematics 48 | System integration project management, trust, pitfalls WEB | Seven ways automation design software helps IIoT INSIDE PROCESS

P1 | Separating process control and safety systems P4 | How to reduce pandemic risk with batch automation P7 | Process simulation benefits for manufacturers

CONTROL ENGINEERING (ISSN 0010-8049, Vol. 67, No. 7, 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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input #4 at www.controleng.com/information

JULY 2020

INNOVATIONS NEW PRODUCTS FOR ENGINEERS

60 | IIoT ecosystem for improved asset management; Line scan camera for machine vision applications; Industrial thin client for virtualized HMI systems; Asset performance platform with augmented reality; Absolute encoder series for motion control applications. See more New Products for Engineers at www.controleng.com/NPE.

BACK TO BASICS

61 | Four challenges and four recommendations for manufacturing in the COVID-19 pandemic Manufacturers face challenges and opportunities including disaster recovery, supply chains, staffing, transparency and investments.

NEWSLETTER: Industrial Networking • Five ways digital transformation metrics give manufacturers more flexibility • Control your move to remote operations • Five key ways an industrial Ethernet protocol can use TSN • IIoT-based industrial protocol upgrade to support process, factory automation industries • Engineers develop methods for AI bottlenecks with machine-learning algorithms. Keep up with emerging trends: subscribe. www.controleng.com/newsletters.

CFE EDU: Course on motors and drives Register for the course, “Introduction to Motors and Drives,” and learn about topics such as how motor sizing impacts efficiency and maintenance, understand motor repair processes, review repair best practices to maintain and improve efficiency, and more. One PDH is available. Learn more at https://cfeedu.cfemedia.com/courses/motors-and-drives

Control Engineering eBook series: Motors & Drives eBook Summer Edition Motors and drives make manufacturing plants run and keep them efficient. Featured articles in this eBook include knowing when VFDs are essential, seven things to know about OMAC, and variable speed drive downtime. 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.

www.controleng.com

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July 2020

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INSIGHTS INTERNATIONAL

Stone Shi, Control Engineering China

COVID-19, automation in China Initial impact of COVID-19 on the domestic Chinese automation market was less than expected. Negative effects on Chinese automation may increase by third quarter; growth opportunities exist.

Stone Shi is executive editor-in-chief, Control Engineering China. Courtesy: Control Engineering China

he outbreak of coronavirus already has caused a huge impact on the global economic and manufacturing industry. For the challenges faced by China after the outbreak, economists and international relations experts have expressed opinions and listed many challenges; a few experts see opportunities from the crisis. Leaving aside these macro-level discussions, discussion below covers the impact of COVID-19 on China’s domestic automation market, especially on the industrial automation market from three stages: short, medium and long term.

COVID-19 effects, automation in China

In the short term, the past three months of 2020 [first-quarter] have been the period of concentrated outbreaks in China, while the European and American countries are still in the initial stage. At this stage, in fact, the impact of COVID-19 on the domestic automation market is not as significant as expected. Although the performance of most enterprises declined, the overall decline was not significant. The main reason is most of the sales in the first quarter came from orders signed last year, which cannot fully reflect the impact of the epidemic on the market; at the same time, because the epidemic in Europe and the United States is still in the early stages, the negative impact of overseas orders is limited. The medium term looks at the next three quarters of 2020. The extent of control of KEYWORDS: COVID-19, COVID-19 globally and economic recovery automation impact, China are uncertain factors in the medium term. Due Limited impacts of COVIDto the continuous growth of overseas markets 19 were seen on first-quarter results in China, though such as engineering design and contracting second and third quarters businesses, mechanical equipment and overmay be more apparent. seas investment of domestic manufacturers in Automation users may recent years, the negative effects on the second expand market advantages, or third quarter may be more obvious. competitiveness, and services. Due to the dependence of domestic equipment on imported components, pressures such CONSIDER THIS as supply interruption, delay or substantial Is your company adding price increases may occur. The medium-term automation and digitalization investments because of automation market in China is not optimistic. COVID-19? Long term is defined as two to three years after 2020. At this stage, the global COVIDONLINE 19 spread seems likely to be controlled and www.controleng.com/ international economic order restored. After COVID-19 www.cechina.cn health impacts are mitigated, there will be

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recovery growth in the market, and some postponed investments will be recovered. At present, the mainstream view is the global manufacturing supply chain will be readjusted after COVID-19, and there is great uncertainty about how these adjustments will affect the global status and China’s manufacturing industry. In recent years, the cost of China’s domestic manufacturing industry continues to rise as well as the risk of a trade war and decoupling between China and the United States. At the same time, China also faces the challenge of industrial upgrading, which will be very important for China’s manufacturing industry in the next two or three years.

Post-COVID-19 supply chain changes

Regarding relocation or outflow of European, U.S. and Japanese production capacity in China after COVID-19 effects, experts estimate the influence would be limited. Foreign investments in new production capacity might be more cautious than before. From the product point of view, the COVID-19 impacts on the discrete and mechanical automation market will be much greater than the process and infrastructure automation. This is due to the discrete and mechanical automation industry’s dependence on overseas markets, Chinese government economic stimulus policies and the characteristics of industries served by different automation markets. Relatively speaking, the market of digital solutions should not be affected by COVID-19. At present, the leading Chinese customers of these products are mainly state-owned enterprises or large private enterprises with strong strength. Investments in digital solutions is relatively solid and sustainable. During the market downturn in China the past two years, many industry-leading manufacturing businesses have maintained growth, which means their market share has increased faster in the downward phase of the cycle. For leading manufacturers, the COVID-19 crisis may also be an opportunity to expand market advantages if they can continue to improve, enhance competitiveness, and provide customers with more needed services. ce

Stone Shi is executive editor-in-chief, Control Engineering China. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com. www.controleng.com

INSIGHTS

INTERNATIONAL: ROBOTS AND AI Control Engineering Europe

Four challenges and opportunities for AI and robotics Artificial intelligence (AI) and robotics have the ability to move forward in manufacturing thanks to advances in machine learning, better decision-making and increased efficiency.

rtificial intelligence (AI) has been the subject of considerable hype for several years, but is the manufacturing industry ready to move to the next stage and focus on how it can be sustainably implemented on the factory floor in robotics and industrial automation applications? Omron highlighted four key artificial intelligence (AI) trends it is seeing in robotics and industrial automation, which could have a major effect on the future of manufacturing:

1. Valuable machine data generated at the edge

The latest industrial automation and robotic developments in factories depend on the generation and collection of deep knowledge and data insights at machine level – that is, at the edge. The machine can learn from its human operators and subsequently improve the output. Technology controlled by AI can empower machine learning by predicting both product and equipment failure, using data generated by Industrial Internet of Things (IIoT) devices. The analysis and use of combined data enables users to rapidly predict potential machine errors, preventing disruptions and the deterioration of product quality.

2. Increased efficiency

through self-learning algorithms

With the move from mass customization to a high-mix, low-volume approach, efficiency must be improved by reducing human errors and machine downtime. AI with learning algorithms can help machine operators to achieve the best result in every change-over. Innovative control technology can also help employees to work alongside robots and machines to achieve manufacturing excellence. This is accomplished by using a broad range of factory automation equipment that enables IIoT-capable production or implements optimal AI algorithms in the equipment. An AI-equipped controller can be

designed to detect signs of any equipment irregularity. AI algorithms allow it to learn the repeated movements of equipment from precise data from sensors. This in turn provides feedback for status monitoring and the real-time control of machines.

3. Efficient decision-making with visualized data

Industry 4.0 and IIoT enable the accurate collection of historical data. However, many AI projects struggle with the visualization of new data. Predictive maintenance and control solutions, can align the control functions of manufacturing lines and equipment with AI processing in real time. They can support companies by generating new, rather than historic, data that is time-stamped and easy to visualize. The process of collecting raw data from machines is completely automated, using an AIenabled controller which operates on the “edge” within the machine. This can lead to higher data accuracy and consistency.

4. Sustainable technology

AI-assisted collaborative robots will play an increasingly important role beyond 2020. The aim is to create healthy and safe living and working conditions that cause less harm to the environment. Assembly and disassembly robots will have an important role to play here. The new generation of robots can learn from machine operators and collaborate with collaborative robots on a circular production line. They collect smart and intuitive data from their actions, assess the data using algorithms, advise the operator about the next steps, and implement efficient processes for each changeover. ce

M More INSIGHTS KEYWORDS: robotics,

artificial intelligence Robots and artificial intelligence (AI) are growing in popularity and so are their capabilities. Advances include better decision making and increased efficiency with self-learning algorithms.

ONLINE See additional articles from Control Engineering Europe at www.controleng.com/ international and links to other Control Engineering international partners.

CONSIDER THIS What are the next robotics and AI advances you see happening next and what benefits do you think manufacturers will gain from them?

This article originally appeared on Control Engineering Europe’s website. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.

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Innovative controls can help employees work alongside robots and machines.

www.controleng.com

control engineering

July 2020

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INSIGHTS

INTERNATIONAL: DISCRETE SIMULATION

Tim Bednall, Wood Automated Systems UK

Operate efficiently, productively Discrete event simulation (DES) on existing processes can help identify and unlock additional production capacity and improve operational efficiency for manufacturers.

utomation is a valuable asset to address many manufacturing issues. Many manufacturers remain under pressure to improve productivity and output. Adding machinery or automation is an option, though subtle changes to a process can help yield more production capacity. The challenge is identifying which areas can improve. Most automated manufacturing systems are designed to meet detailed technical specifications and production efficiency targets. Once installed, they are fine-tuned to meet the criteria, and the prime objective is to maintain production and up-time levels. Customers are pressurizing suppliers to increase production. The customer wants increased capacity quickly, and the manufacturer may not have the time or the capital to invest in more equipment.

Discrete event simulation

Discrete event simulation can analyze the existing process step-by-step and identify bottlenecks or areas where the process can be improved. Discrete event simulation exercises can reveal that perceptions do not match bottleneck reality. Discrete event simulation models break process into different events or smaller

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operational blocks, which can then be triggered as required. The process is effectively analyzed at the lowest levels including part traveling distances, locations, speeds and process times. One manufacturer was tasked to increase production from the current level of 30 units per hour to a throughput of 50 units per hour. An initial overview from the customer suggested that a specific part transfer operation was restricting line output. Running a discrete event simulation showed timing changes changes in various areas would allow 50 units per hour target. In another example, the customer was considering linking two consecutive process steps, carried out in separate systems, with a view to having dual systems, each of which performed both processes as a means of increasing throughput. We performed a discrete event simulation based upon the current configuration, operational sequences and timings of the existing equipment and then followed that with another simulation this time accounting for customer-proposed changes. The simulation outcome showed no benefit deriving from the proposed changes. Further evaluation of the application through the simulation model identified that, even with restricted floorspace, it would be possible to integrate more equipment to achieve desired output. Running discrete event simulation on processes or machines makes it possible to predict output and performance over an extended period, such as a year, in just minutes, by running the simulation at enhanced speeds. It is also possible to build in additional factors including mean-time-between-failure and meantime-to-repair to provide a holistic view of the process over time. There is little doubt that manufacturers will continue to seek ways to enhance productivity and output levels from existing automation systems in the most efficient way possible as a means of responding to customer demands and improving profitability. Discrete event simulations are very often used as a relatively quick and cost-effective contribution to a continuous improvement process, which can identify and unlock efficiency savings, quality improvements and additional production capacity. ce Tim Bednall is sales & marketing manager at Wood Automated Systems UK. This article originally appeared on Control Engineering Europe’s website. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.

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KEYWORDS: production efficiency, discrete event simulation Discrete event simulation (DES) can identify bottlenecks. DES can help predict output and performance over time. ONLINE: Link to more at www.controleng.com/international. Elektronik GmbH D-41372 Niederkrüchten Phone: +49 2163 577355-0 contact@w-e-st.de www.w-e-st.de

Our strengths:  Fast delivery, usually from stock  Competitive prices  Competent customer support  21 years of experience input #5 at www.controleng.com/information

CONSIDER THIS What benefits can discrete event simulation (DES) provide?

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INSIGHTS

TECHNOLOGY UPDATE Blake Griffin, Interact Analysis

Predictive maintenance: Smart sensors, machine learning, models Smart sensors and machine learning algorithms detect anomalies in industrial machines, and as algorithms become better trained, software can accurately predict when machines with industrial automation is risking failure. New business models for machine as a service (MaaS) may help overcome slow adoption of predictive maintenance technologies.

predictive maintenance elephant is in the room – manufacturing equipment producers make money when industrial machines break. While it is in the best interest of users to extend the working life of industrial equipment and ensure their manufacturing lines do not experience unplanned downtime, original equipment manufacturers (OEMs) lose replacement revenue the longer a piece of equipment is in commission. This conflict of interest between supplier and customer always has existed. How do equipment manufacturers maintain profitability with the advent of predictive maintenance technologies without cannibalizing revenue streams brought by replacement industrial equipment and service contracts?

M More INSIGHTS KEYWORDS: Predictive

maintenance, smart sensors, machine learning Predictive maintenance and machine as a service can optimize revenue for the OEM and customer. Smart sensors, machine monitoring, and machine learning help predictive maintenance. Smarter pricing and data models help machine as a service (MaaS).

CONSIDER THIS Where’s your bottleneck for predictive maintenance?

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

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Sensors, monitoring, software

Predictive maintenance technologies include industrial automation products: smart sensors (vibration sensors, temperature sensors, and others), portable monitoring devices, dedicated predictive maintenance software, and gateways dedicated for predictive maintenance functions. Industrial automation hardware measures the performance of equipment by collecting data on measurements, such as smart sensors for machine vibration and machine temperature. The software then applies machine learning algorithms to detect anomalies within these readings. Over time, as these algorithms become better trained by the vibration sensors and temperature sensors, the software can better predict when a piece of industrial equipment is at risk of failure.

Smart sensors enable monitoring

While the concept of condition monitoring has been around for some time, the market for more sophisticated predictive maintenance products is still very young. Smart sensors, an enabling product for predictive mainte-

control engineering

nance growth, became mainstream in 2016 when ABB launched its ABB Ability Smart Sensor at Hannover Messe to an audience including President Barack Obama and German Chancellor Angela Merkel. Most predictive maintenance solutions are sold on a per unit basis, with suppliers typically charging an annual or monthly price per sensor, which provides access to dedicated software used to perform analyses. This pricing method will continue to grow, but it does not directly address the conflict of interest between machinery supplier and machinery user (see figure).

Machine as a service, improves metrics

Changes in the use of these technologies can address this conflict of interest, and this approach will be a major trend for future predictive maintenance technology implementations. The concept is called machine as a service (MaaS). This approach takes the model for software as a service (SaaS), rethinks pricing, and applies it to machinery. Instead of pricing the solution as an annual subscription, it prices based on performance. Goals around key performance indicators (KPIs) are agreed upon between the customer and supplier; the price of the contract is determined by the extent to which these goals are met. For example, Pearson Packaging, offers various types of packaging machines under this model. Instead of selling the machine outright, Pearson retains ownership and charges the customer based on the number of cases palletized, erected or sealed. With this approach, the machine builder is incentivized to keep the machine running as long as possible and with as much uptime as possible – two areas which are addressed directly by predictive maintenance technology. Industrial data ownership is one barrier to predictive maintenance adoption the MaaS model helps overcome. Data ownership is a key discussion point between users of predictive maintenance solutions and industrial automation or original equipment manufacturer (OEM) suppliers. www.controleng.com

Figure: Pricing models for software as a service (SaaS) will continue to gain share although it does not directly address the conflict of interest between machinery supplier and machinery user. Courtesy: Interact Analysis

Research shows manufacturers are generally conservative when it comes to sharing the operational data of its plants because data could be used by a malicious party to glean trade secrets or operational information not publicly available. Manufacturers in Europe tend to be the most sensitive about sharing this data, the the U.S.; APAC region is least sensitive. Suppliers of predictive maintenance offerings will often commercialize data indirectly by using it to improve the capabilities of their products. (More data leads to better-trained algorithms.) There are fears predictive maintenance suppliers will employ more direct methods of commercializing the data by selling data to brokers or selling applications that allow customers to generate their own insight into trends within real-world operational data. The ability of predictive maintenance providers to sell operational data leads to safeguarding by customers. The first decision point is often the most difficult for suppliers to overcome. MaaS doesn’t completely solve the data ownership concern; but since data must be shared for this model to function, we believe MaaS to be the “thin end of a wedge” needed for people to share this type machine data. Aligning incentives between supplier and customer through the machinery as a service model puts the two on the same team, opens the door to cooperatively sharing data, and can optimize predictive maintenance for more effective machine operations.

Better service pricing models

Motor equipment manufacturer SKF has an “as a service” model for bearings. The solution offering defined its pricing around reducing the historical rate of failure of bearings. Again, this type of model aligns the incentives of supplier and customer as now both parties have a vested interest in extending the life of the equipment rather than haggling over the price of bearings. (A related product is SKF Pulse, a

www.controleng.com

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The model aligns incentives of the supplier and customer so both parties have a vested

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interest in extending equipment life. portable Bluetooth sensor and mobile application to monitor rotating equipment.) This type of model is certainly not “one size fits all.” The SKF model works well when selling to end-users. However, the question of “who pays what” gets more complex when selling to machine builders because the machine builder does not represent the end location of the equipment. This is not to say equipment manufacturers could not apply this model when selling to machine builders, only that more negotiations would be needed to iron out the details of who monitors the bearing health at the machine’s location. The model requires a more active sales process due to the need to negotiate specific goals for each unique customer and will probably be suited for the most critical of applications. Reduced capital expenditure of the machinery and alignment of incentives make the model attractive to manufacturers and is an effective way to differentiate an offering versus the competition. MaaS models are likely to become more prevalent over time and the predictive maintenance market will substantially grow as a result. The value proposition of predictive maintenance is becoming too large to ignore, and with the recent advent of smart sensors and new innovative business models, this market is primed for rapid growth. ce Blake Griffin is market research analyst, Interact Analysis. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com. control engineering

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INSIGHTS

TECHNOLOGY UPDATE Sanjay Barnwal, L&T Technology Services

Better data management for manufacturers during COVID-19 Will COVID-19 compel manufacturers to streamline connected data management?

builds, teams start

ecision-makers and executives understand the value and need for modelbased design (MBD), model-based engineering (MBE), and model-based systems engineering (MBSE). These have existed for decades and enabled thousands of high quality and extremely complex product design, development and support activities. Many projects are unable to apply the concepts for full product lifecycle right from design, development and manufacturing to support engineering activities. The result is disjointed systems, significant manual interventions with time to market impact, poor quality, high cost of ownership and poor customer satisfaction. Product lifecycle management (PLM) systems are still widely used as document management systems across enterprises for storing engineering artifacts. Quality aspects in the product design stage are managed in separate systems, processes, and often through Microsoft Excel and Word documents linked to PLM or other engineering systems.

returning to old

Reality of engineering transformation

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As engineering project timelines, costs and efforts start escalating and pressure

manual interven-

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tions.

Before COVID-19 disrupted industries globally, engineering transformation programs did not guarantee success because of the perception vs. reality factor. A. Real life vs. perceived values: Most of the new engineering programs start with the intent to follow the great design principles and methodologies with an understanding of great value. As the project timeline, costs and efforts start escalating and the pressure builds, teams start returning to the old ways of manual interventions. Newer ways take up too much of time, budget and efforts and may carry perceived risks. B. Live for today or sacrifice some for tomorrow: Leaders and executives have businesses to run. Disruptions with newer tools and technologies require upfront planning, communication and commitments. This is why, except for some areas (pure R&D, proof of concepts [POCs], digital technology groups), MBD, MBE and MBSE remain in beginning stages within engineering organizations. It’s no wonder they do not move to manufacturing, maintenance and repair operations (MRO) and aftermarket areas.

Getting to digital transformation

Engineering and aftermarket leaders understand the value that comes with connecting engineering

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data to aftermarket for spare parts leaflets, associated technical documents, training materials, videos, effective field performance analysis and improvements. In most cases, the concepts just stay on paper and seldom are implemented. Similar initiatives on making factories paperless, and generating a manufacturing bill of material (mBOM) from an engineering bill of material (eBOM) in a connected way, and performing virtual tooling, manufacturing and simulation activities to detect and fix issues early on remains a wish-list for many operation leaders. Key decision-makers of business units are optimistic and frustrated with the pace of transformation and outcomes these initiatives are generating. Some manufacturing plants have large-scale capital investments in robotics and automation. In some areas multi-million-dollar machines may reallocate workers with a $25-per-hour wage. Such robotics and automation projects are getting approvals. While critical data management projects that promise longterm value have been shelved off, automation and robotics have gained steady acceptance. Is automation a priority because a business case for headcount reductions is easier to create and understand? Is it difficult to create a business case for productivity, cost-avoidance opportunities and investments for linking engineering data models to manufacturing? The answers lie in addressing the fundamental challenges of how current teams are structured to meet cross-functional transformation needs.

Driving digital transformation

At an MRO facility for a tier 1 automotive customer, it was surprising to see the engineering team unaware of how to access 3D models of PLM system parts. Engineers were working with an outdated drawing and instructions. If a manufacturing plant works with Industry 4.0 technologies, it must do so with deep involvement. Even with the best intentions, engineers who are busy with activities only can provide part-time support to manufacturing plants. Mainstream companies need to overhaul structures to facilitate cross-functional collaboration.

IT/OT, digital transformation

Standalone functions such as engineering, manufacturing, aftermarket, MRO, digital and even information technology (IT)/operations technology (OT) www.controleng.com

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INSIGHTS

TECHNOLOGY UPDATE

Connected data management graphic explains implementation challenges, rootcause analysis, key drivers for change, and the pathway for improvement. Courtesy: L&T Technology Services

can be consolidated in one engineering division. A new structure can have better chances of success. 1. Engineering, manufacturing, MRO, and aftermarket as standalone functions are siloed. Merging each function can facilitate a seamless flow of data between disparate and disjointed processes. The teams can replicate standard operating procedures (SOPs) and leverage best practices and technology in tandem to drive long-term value. KEYWORDS: COVID2. If a manufacturing plant has to 19, manufacturing, data work with 3D models for work orders, management virtual tooling, testing then the manuMoney for robotics and al process changes in the factory can’t automation continue to flow happen without deep engineering in the pandemic, but data management funds have slowed involvement. for manufacturers. 3. MRO and aftermarket functions Productivity for Industry 4.0, also need constant engineering support to IIoT digital transformation drive seamless data management. requires streamlined data

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integration for manufacturers. Lack of data connections result in disjointed systems, significant manual interventions with time to market impact, poor quality, high cost of ownership and poor customer satisfaction.

CONSIDER THIS What data integration initiatives would improve manufacturing productivity?

ONLINE If reading from the digital edition, click on the headline for more resources. www.controleng.com/magazine www.ltts.com See the L&T Electrical & Automation listing in the Global System Integrator Database.

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Help digital transformation

For this restructured organization, the strategic and decision-making functions need to happen at the top, and then respective teams can figure ways to move forward. The company also will have to incur added costs of maintaining multiple technologies, tools and platforms. With thorough planning, companies can reduce valuable time lost in creating mundane POCs figuring out which path to take in connected data management journeys. No matter which tool, platforms and solutions are chosen, there will always be soft corners and shortcomings in meeting and satisfying all needs. This is where executives need to use the 80/20 rule, make clear decisions and save teams time, avoid-

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ing mundane POCs, experimentation and debates about the connected data management journey. When radical organizational changes are to be implemented, management consultants come into the picture frequently. This is not because they know more than company leadership. Management consultants bring an outside-in view while working on a given timeline with set objectives. They are flexible to work with and don’t come with preconceived notions of what’s possible and what isn’t. This is why organizations should explore collaborations with consulting organizations for data management initiatives. With a support system for requirement gathering to design, develop, and test, management consultants can ensure the success of a data management project end-to-end.

Looking beyond COVID-19

Transformation project capital has slowed. Kneejerk reactions are natural where key supplier resources and employees are getting laid off and only essentials are getting done. This is where supplier, non-core activities consolidations can free-up funds, and key resources can be funneled for technical data management transformations. Enterprises will need to rely on integrated data management to plan and structure organizational blueprints. Data is a strategic weapon and backbone of Industry 4.0. Everything depends on data, its seamless exchange and effective use. Organizations need to capitalize on this crisis, a stress test for transforming technical data management and capabilities. ce

Sanjay Barnwal is vice president of transportation and aerospace at L&T Technology Services, a Control Engineering content partner. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com. www.controleng.com

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input #8 at www.controleng.com/information

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TECHNOLOGY UPDATE: COVID-19 Siemens Digital Industries

Workplace distancing simulation and management: Facilities, manufacturing, offices To lower risk to COVID-19 exposure, use digital twin design and simulation software, wireless tags and receivers and asset tracking software help manage employee risks and enable workplace productivity. See nine questions manufacturers and facility owners need to ask about COVID-19.

ntegrating wireless, software, and hardware technologies can help with workplace distancing, offering the “next normal” of productivity in the COVID-19 pandemic, as explained remotely on June 4, from Siemens Digital Industries (DI), Plano, Texas, and other Siemens locations. While the presentation aimed at manufacturers, the same technologies can be applied to distribution centers, warehouses, and commercial and government facilities to lower COVID-19 risks related to employee safety, technology investments, restarting or expanding production, and additional operating costs. (See nine COVID-19 questions to ask, below.)

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KEYWORDS: COVID-19,

workplace distancing, manufacturers, facilities Facility owners can use wireless hardware and simulation and tracking software to help employees. The implementation can be deployed in a couple weeks. Post-COVID-19 pandemic, workplace distancing hardware and software can be redeployed.

CONSIDER THIS Is proactive workplace distance tracking and localized cleaning preferable to widespread shutdown and widespread cleaning?

Workplace distancing modeling, simulation, workspace validation

For manufacturers restarting, maintaining, or expanding operations during the ongoing COVID-19 pandemic, employee safety includes establishing production environments and workflows that address physical distancing requirements. Combining wireless hardware and tracking and simulation software, companies can: • Quickly and efficiently model how employees interact with each other, the production line and plant design • Build an end-to-end digital twin to simulate worker safety during the COVID19 pandemic

ONLINE

• Iterate on and optimize workspace layouts

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

• Validate safety and efficiency measures to help future-proof production lines.

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During and after the COVID-19 pandemic, the hardware and software can be applied to other uses to enhance more efficient workflows.

Bluetooth tags helps distance workers

Using Bluetooth-enabled wireless tags, companies can continuously measure distances among workers, provide real time visual feedback to employees regarding spacing from others and create a log of all movements and interactions over time to facilitates safe distancing during the COVID-19 pandemic. Combining the wireless tags with digital twin simulation software of the actual manufacturing environment permits companies to model and simulate how employees interact with the equipment and each other, enabling them to iterate and optimize safety and productivity in the short term, and validate a redesign of the operation before more costly physical changes are made to lower COVID-19 pandemic risk. “We are helping our customers create a safe work environment, which is extremely important as they look to produce efficiently and reliably under unprecedented circumstances,” said Tony Hemmelgarn, president and CEO of Siemens Digital Industries Software, commenting on workplace adjustments during the COVID-19 pandemic. “The combination of real time distancing management and digital simulations will help companies maintain safe work environments today and make educated decisions about ongoing and long-term optimization.”

Wireless badges as PPE to alarm safe distances

The real-time locating system transponders are embedded in badges worn as COVID-19 personal protective equipment (PPE) by all employees. RTLS receivers placed throughout the operation can then continuously track and record workforce movement. When two employees are in a risk scenario (such as less than six feet apart), their badges will display www.controleng.com

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The contents of this document are for informational purposes only and are subject to change without notice. Epicor Software Corporation makes no guarantee, representations, or warranties with regard to the enclosed information and specifically disclaims, to the full extent of the law, any applicable implied warranties, such as fitness for a particular purpose, merchantability, satisfactory quality, or reasonable skill and care. The results represented in this testimonial may be unique to the particular customer as each user’s experience will vary. This document and its contents, including the viewpoints, testimonials, dates, and functional content expressed herein are believed to be accurate as of its date of publication, May 5, 2020. Use of Epicor products and services are subject to a master customer or similar agreement. Usage of the solution(s) described in this document with other Epicor software or third-party products may require the purchase of licenses for such other products. Epicor, and the Epicor logo are trademarks or registered trademarks of Epicor Software Corporation in the United States, and in certain other countries and/or the EU. Copyright © 2020 Epicor Software Corporation. All rights reserved.

input #9 at www.controleng.com/information

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TECHNOLOGY UPDATE

Siemens’ Simatic Real Time Locating Systems (RTLS) transponders are embedded in badges as COVID19 personal protective equipment by all employees so transponders can track and record workforce movement in the Next Normal Manufacturing workplace distancing solution. Badges will display a warning, alerting them to risk. Data can be analyzed to identify “hot spots” where risk scenarios occur frequently. Courtesy: Siemens Digital Industries

a warning, alerting them to the situation. The data collected over time can be analyzed to identify “hot spots” where COVID-19 risk scenarios occur frequently. Such situations become actionable via the digital twin, which is provided by process simulation software and plant simulation software. Using the collected data, new manufacturing layouts or workflows can be simulated to provide the desired outcomes, which can then be implemented in the physical operation.

COVID-19 track and track in the workplace

Manufacturers can add traceability with onpremise or cloud-based software to help enable rapid, contact analysis in case of COVID-19 illness. All movement and contact with the affected employee can be visualized, enabling rapid notification of those who came into close contact and selective (rather than site-wide) deep cleaning of exposed physical environments. “Siemens is providing a powerful, rapidly deployable solution that helps manufacturers take control of their operations and achieve better safety, productivity and cost outcomes today and in the post-COVID era,” said Raj Batra, president of Digital Industries for Siemens USA. An implementation “can begin delivering results for most manufacturers in one to two weeks.”

Nine questions manufacturers and facility owners need to ask about COVID-19

In the presentation, Siemens offered nine questions facility owners and manufacturers should ask about COVID-19 employee safety, technology invest-

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ments, restarting or expanding production, and additional operating costs. 1. How do we improve employee, union and executive confidence to accelerate plant startup? 2 How do we ensure employees are following new guidelines? 3. How can we monitor employee interactions while respecting their privacy? 4. How can we address COVID-19 recovery AND protect their investment for future use? 5. How can we utilize this new data with digital tools for future safety/production improvements? 6. How can we ensure production line changes are optimal and employees are trained? 7. How can we modify shift change procedures to optimize production? 8. How can we keep cleaning and disinfecting costs down? 9. How can we avoid additional shutdowns and lost production? ce Siemens Digital Industries press release and news conference information edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com. 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

INSIGHTS

TECHNOLOGY UPDATE FDT Group

FDT IIoT ecosystem built to connect, empower intelligent industrial enterprise Easier digital transformation and innovative industrial automation business models are expected to result from the FDT Group’s platform independent FDT 3.0 – IIoT Server (FITS) platform to help with control system integration in automation supplier and end-user communities in the process, hybrid and discrete markets.

DT Group launched of the new platform independent FDT 3.0 – IIoT Server (FITS) platform to support “digital transformation and innovative business-models for the new era of industrial automation.” FDT Group plans to offer the architecture to standards bodies such as IEC, ANSI/ISA and GB/T (China). FDT Group, an independent, international, not-for-profit industry association based in Heverlee, Belgium, made the announcement on June 3. The new standard intends to help with industrial networking and control system integration for the automation supplier and end user communities in the process, hybrid and discrete markets.

The FDT IIoT Server (FITS) Architecture from FDT Group works with any web browser, in programmable logic controller (PLC) and distributed control system (DCS) environments, and is secure by design with air-gapped support for those who don’t allow internet control system access, said Glenn Schulz, managing director, FDT Group. Graphics courtesy: FDT Group

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Developer tool kit for control system integration

In addition to the FDT 3.0 standard that fully describes the FITS platform, FDT Group released the FDT 3.0 Developer Toolkits to help the vendor community begin development efforts with an Integrated Development Environment (IDE) to easily create and customize next-generation, crossplatform FDT 3.0 solutions. “The new FITS architecture is a powerhouse that is the enabler for scalable, remote access business solutions and services that are needed now to meet changing market demands,” said Glenn Schulz, managing director, FDT Group. “By delivering the FDT FITS specification and platform independent toolkits simultaneously, we are enabling the immediate deployment of this new technology. To meet the digital transformational needs for next generation smart plants and factories, the FITS architecture is scalable from skid to cloud, sits at a peer level with the control system and integrates all industrial control networks. This approach provides secure, remote access to live device and network data across the enterprise without PLC/DCS [programmable logic controller/distributed control system] host intervention. While the FITS standard is fully browser based, we have also built in a full OPC UA [OPC Unified Architecture] server to provide an industry standard conduit for IT and OT information integration.” Suppliers of industrial automation systems and devices want to seize emerging opportunities for Industrial Internet of Things (IIoT) solutions. They’re seeking to enhance their product offerings with standards-based, platform-independent, information-driven business models for the new era of automation. The FDT 3.0 standard www.controleng.com

will accelerate the evolutionary journey into the Fourth Industrial Revolution by enabling an ecosystem of FDT-based solutions to meet demands for IIoT and Industrie 4.0 applications.

Control system integration: FDT 3.0

FDT Group, founded by a group of automation manufacturers during the Third Industrial Revolution, developed FDT technology as an open, integration standards-based solution to fix interoperability issues for control system and device end users. The standard is “widely deployed as the defacto integration standard providing end users with the freedom to choose systems/devices that best fit their application and seamlessly connect and communicate independent of the chosen vendor or network,” FDT group said. The FDT standard has evolved from a singleuser, desktop environment (FDT 1.x) to a distributed, multi-user client/server approach (FDT 2.x) with OPC Unified Architecture (OPC UA) compatibility for enterprise-wide integration and asset management. The newly launched FDT 3.0 standard builds on prior versions with enhancements empowering an FDT Server embedded with OPC UA and web servers. The server delivers universal device integration and a data-centric platform to mobilize the industrial workforce with modern and diverse deployment options, including cloud, enterprise, edge, on premise, and single-user desktop environments. In 2016, FDT approved the transformation journey into the Fourth Industrial Revolution to empower an ecosystem of FDT IIoT-ready solutions. FDT 3.0 was developed based on industrydriven feedback and delivered by a collaborative team of experts in the industry. Schulz said, “Aimed at transforming manufacturing practices, FITS enables a cloud-based asset management solution with built-in security, scalable deployment, IT/OT integration, universal and backwards compatibility, and a single FDThub repository for FDT Device Type Managers.”

FDT IIoT ecosystem: Server, desktop, components

The FDT IIoT ecosystem consists of FDT Server, FDT Desktop and FDT DTM components, which are deployable by using the IDE tools, known as Common Components. The advantage, FDT said, is that system and device suppliers can take a well-established standard they know and easily create and customize standards-based, data-centric, cross-platform FDT IIoT solutions – expanding offerings to meet requirements for next-generation industrial control applications. Each solution auto-enables OPC UA integration and allows the development team to focus on value-added features that differentiate their products, including WebUI and App support. FDT Desktop

www.controleng.com

FDT Group announced the launch of the new FDT IIoT Server (FITS) platform on June 3 to support digital transformation and businessmodels for the new era of industrial automation, serving process automation, factory automation and hybrid automation markets, said Glenn Schulz, managing director, FDT Group.

FDT Common Components support developers to create an IIoT ready solution, for platform-independent tool sets. Out-of-box ready common components are available for FDT server, desktop, and device type manager (DTM), said Glenn Schulz, managing director, FDT Group.

applications are backwards compatible supporting the existing installed base. FDT 3.0 specification license agreements and developer toolkits are available on the FDT website, www.fdtgroup. org. An IO-Link Interpreter DTM is under development along with FDT communication annexes for HART, Profibus, IO-Link and CIP networks slated for release in the second half of 2020. ce Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com. ONLINE

www.fdtgroup.org www.controleng.com/iiot-industrie-4-0/

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KEYWORDS: Control system design, control system integration FDT Group releases FDT 3.0 standard and related tools. FDT 3.0 – IIoT Server (FITS) platform supports digital transformation and business-models for industrial automation and control system integration and industrial networks. FDT Group is submitting the standard to U.S., Chinese, and international standards organizations. CONSIDER THIS What standards and tools are helping your organization improve automation, controls, and industrial networks?

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INTERNATIONAL: COLLABORATIVE ROBOTS Lee Ray, TÜV SÜD

Electro-sensitive protective equipment tests, collaborative robots Electro-sensitive protective equipment (ESPE), such as light guards and laser scanners, are crucial for collaborative robots, but inspection and testing are often neglected.

ecause collaborative robots are designed to work alongside human co-workers, they cannot be caged by a physical guarding mechanism. This means electro-sensitive protective equipment (ESPE), such as light guards and laser scanners, is more prevalent than ever before. However, ESPE inspection and testing is often neglected as many machinery owners are unsure how often it should be assessed. The International Electrotechnical Commission’s EN 61496 series specifies requirements for the design, construction and testing of ESPE designed specifically to detect persons as part of a safety-related system, employing active opto-electronic protective devices (AOPDs) for the sensing function. This is then used in conjunction with EN ISO 13855 to determine the correct installation location for the light guard, which should be verified after installation. The complete system for detection, actuation and stopping is not solely reliant on the electrical signals. There are normally wear components that are installed as part of that system to enable a shorter stopping time. Through the lifecycle of use, there is potential for these parts to wear and this could introduce a situation where access can be gained through a light guard, to a hazardous part of the machine, while it is still in KEYWORDS: collaborative robots, electro-sensitive run down. protective equipment The Amended Use of Work Equipment (ESPE) Directive (AUWED) places requirements on Collaborative robots machinery users to inspect and maintain the can enhance safety with equipment and safety critical functions of the electro-sensitive protective equipment (ESPE) such equipment. The testing frequency of the light as light guards and laser guard cannot be determined by the composcanners. nent manufacturer for the stop time, as they Inspection and tests must are not responsible for installing the system first be done when the as a whole. It is the light guard integrators complete ESPE and machine responsibility to select and configure the syspackage is installed. tem correctly, and the user must conduct testONLINE ing and maintenance to ensure this function Link to more at does not deteriorate. www.controleng.com/ Inspection and tests must first be done international. when the complete ESPE and machine packCONSIDER THIS age is installed, and thereafter when modiWhat other ways can fication or repairs have been made or the manufacturers enhance installation is relocated. In addition, EN IEC collaborative robot safety?

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62046 states in clause 7.3 that periodic inspection and testing should not be greater than 12 months unless local regulations state otherwise. This is to ensure deterioration has not occurred in the stopping performance for the lifecycle of the machine.

Local enforcing authorities, inspections

Following guidance from local enforcing authorities is strongly recommended. For example, in the UK the HSE has created HSG180 which defines the recommended maximum period between each periodic inspection and test as being six months for type 4 ESPE and 12 months for type 2 ESPE. This is still quite subjective as the guidance then says that the frequency of inspections ultimately depends upon on the equipment that the ESPE is fitted to and the risk as a whole. The good news for machinery end-users is that HSG180 requires the machine and the ESPE supplier to supply information relating to routine maintenance and inspection requirements. This should help the end-user to develop a robust inspection and set an initial test regime frequency. The guide also requires that the initial inspection and test is carried out by competent persons, such as an in-house inspector, the installer or supplier, or an independent assessor. The results of any inspections must also be recorded. The HSG180 guide also helps the inspector to ensure that the inspection and test process achieves a good general standard of performance. For example, it should not be possible for the dangerous parts of the machine to be set in operation while any part of a person is in such a position as to actuate the AOPD. In multiple instances the need for light guard testing has not been realized. While functional safety checks are recognized as good practice, they are no substitute for the required periodic testing. The stop time test (part of the periodic test), would detect any deteriorating system parts which no longer offer the required protection. This usually cannot be seen, like fixed guarding, so needs to be proven by testing. ce

Lee Ray is operations manager, TÜV SÜD. This article originally appeared on Control Engineering Europe’s website. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com. www.controleng.com

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NEWS

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

Automated system developed to accelerate R&D, manufacturing of materials Researchers from North Carolina State University and the University at Buffalo have developed a technology called “Artificial Chemist,” which incorporates artificial intelligence (AI) and an automated system for performing chemical reactions to accelerate R&D and manufacturing of commercially desirable materials. In proof-of-concept experiments, the researchers demonstrated it can identify and produce the best possible quantum dots for any color in 15 minutes or less. Quantum dots are colloidal semiconductor nanocrystals, which are used in applications such as LED displays. However, the researchers are quick to note that Artificial Chemist can identify the best material to meet any suite of measurable properties – not just quantum dots. Milad Abolhasani, corresponding author of a paper on the work and an assistant professor of chemical and biomolecular engineering at NC State, said Artificial Chemist is designed for solution-processed materials such as quantum dots, metal/metal oxide nanoparticles and metal organic frameworks (MOFs). “The Artificial Chemist is similar to a self-driving car, but a self-driving car at least has a finite number of routes to choose from in order to reach its pre-selected destination. With Artificial Chemist, you give it a set of desired parameters, which are the properties you want the final material to have. Artificial Chemist has to figure out everything else, such as what the chemical precursors will be and what the synthetic route will be, while minimizing the consumption of those chemical precursors. “The end result is a fully autonomous materials development technology that not only helps you find the ideal solution-processed material more quickly than any techniques currently in use, but it does so using tiny amounts of chemical precursors. That significantly reduces waste and makes the materials development process much less expensive.” The Artificial Chemist has a “body” for performing experiments and sensing www.controleng.com

Artificial Chemist is an autonomous system designed to intelligently navigate through the chemical universe and develop useful materials for manufacturing applications. Courtesy: North Carolina State University

the experimental results, and a “brain” for recording that data and using it to determine what the next experiment will be. The Artificial Chemist’s brain is an AI program that characterizes the materials being synthesized by the body and uses that data to make autonomous decisions about what the next set of experimental conditions will be. It bases its decisions on what it determines will most efficiently move it toward the best material composition with the desired properties and performance metrics. “We tried to mimic the process that humans use when making decisions, but more efficiently,” Abolhasani said. For example, Artificial Chemist allows “knowledge transfer,” meaning that it stores data generated from every request it receives, expediting the process of identifying the next candidate material it is tasked with. In other words, Artificial Chemist gets smarter and faster over time at identifying the right material. For their proof of concept, the researchers tested nine different policies for how the AI uses data to decide what the next experiment will be. They then ran a series of requests, each time asking Artificial Chemist to identify a quantum

dot material that was the best fit for three different output parameters. “We found a policy that, even without prior knowledge, could identify the best quantum dot possible within 25 experiments, or about one-and-a-half hours,” Abolhasani said. “But once Artificial Chemist had prior knowledge – meaning that it had already handled one or more target material requests – it could identify the optimal material for new properties in 10 to 15 minutes. “We found that Artificial Chemist could also rapidly identify the boundaries of materials properties for a given set of starting chemical precursors, so that chemists and materials scientists do not need to waste their time on exploring different synthesis conditions. I believe autonomous materials R&D enabled by Artificial Chemist can re-shape the future of materials development and manufacturing,” Abolhasani said. ce Matt Shipman, research communications lead, North Carolina State University. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com. control engineering

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

NEWS

Critical communications component made on flexible wooden film Research by a University of WisconsinMadison engineer leverages wood to make the flexible microwave circuits that power modern communications. In industrial automation applications, it may decrease size of control system devices and systems, saving plant floor, cabinet space, or enabling new distributed wireless sensors, transmitters, controls or actuators. Flexible electronics will help with designs of foldable phones, rollable tablets, and paper-thin displays, beyond widely developed wearable sensors that monitor health data. Developing bendy products means using novel materials like new plastics and thin films to replace the rigid circuit boards and bulky electronic components that currently occupy the interiors of cell phones and other gadgets. Zhenqiang “Jack” Ma, a professor of electrical and computer engineering, and his collaborators made a functional micro-

wave amplifier circuit on a substrate of cellulose nanofibril paper, a wood product. For more than a decade, Ma has been creating microwave flexible electronics, including thin-film transistors and other components. Microwave components, which are used in wireless communication, have proved difficult to produce in a flexible form and are typically constructed on integrated semiconductor chips or printed on circuit boards. Flexible versions, however, could have widespread applications in wearable devices, drones and as part of large-area microwave arrays used in 5G and advanced communication systems. Prior attempts to produce flexible microwave amplifiers used rigid semiconductor-based integrated circuits that were thinned down and moved to flexible substrates, expensive and cost-prohibitive. In the new amplifier, Ma and his colleagues began with cellulose nanofibril paper as the

Semiconductor group announces support for manufacturing chips in U.S.

acing a 50% decline in the U.S. share of global semiconductor manufacturing capacity over the past 20 years, Congress has introduced the Creating Helpful Incentives to Produce Semiconductors for America Act (CHIPS for America Act), highlighted by a federal investment tax credit (ITC) strongly supported by SEMI, the global industry association representing the electronics manufacturing and design supply chain. The bipartisan legislation would improve the competitiveness of semiconductor research, design and manufacturing in the United States, resulting in the creation of thousands of new jobs and bolstering national security. The Act’s 40% refundable federal ITC for semiconductor manufacturing facilities and equipment would quickly provide a significant, direct and transparent incentive to all companies investing in new and expanded U.S. semiconductor facilities. The semiconductor supply chain accounts for approximately 240,000 highskill and high-wage jobs nationwide, said Ajit Manocha, president and CEO of SEMI. “The ad-hoc incentive packages offered by some states have helped attract and sustain semiconductor manufacturing facilities, but individual governors and state economic development officials are often outmatched by whole-of-government initiatives from other nations. SEMI has long advocated for a tax credit to help level the playing field, and we strongly support the CHIPS for America Act to do so.” About 12% of global semiconductor manufacturing capacity is in the U.S. – Edited from an SEMI press release by CFE Media.

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substrate. The paper is made by breaking wood fiber down into a nanoscale fibrils, or tiny slender fibers, then recombining them to produce a strong, flexible, transparent and biodegradable film. Instead of layering the entire wood substrate with expensive gallium nitride, currently the highest performing microwave transistor material, the team used just a speck of the compound. “We have a new strategy here,” Ma said. “We use a tiny bead of the expensive substance, 500 microns by 500 microns, and the rest is wood. Compared to the gallium nitride, the cost of the wood is essentially nothing. The final outcome is an amplifier that works very well.” The flexible circuit can output 10 milliwatts of power beyond 5 gigahertz. The cellulose nanofibril substrate is as compatible with microwave components as polyethylene substrates. ce - Jason Daley is science writer at University of Wisconsin-Madison. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.

Headlines online Top 5 Control Engineering articles June 15-21, 2020 Most viewed-articles include manufacturing in the COVID-19 pandemic, cybersecurity, HMI/SCADA software, digital transformation and DCS migration and IT/OT integration. Method developed to measure temperature within 3D objects University of Wisconsin-Madison engineers have made it possible to determine a 3D temperature profile for semi-transparent objects in the infrared spectrum, which couldn’t be done before. COVID-19’s impact on wastewater treatment facilities The COVID-19 pandemic has affected wastewater treatment facilities, including maintenance, operations and safety. Improving machine performance and reliability with predictive maintenance Predictive maintenance helps improve efficiencies and minimize unplanned downtime. www.controleng.com

INSIGHTS ®

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www.controleng.com/EAB Doug Bell, president, InterConnecting Automation, www.interconnectingautomation.com David Bishop, president and a founder Matrix Technologies, www.matrixti.com Daniel E. Capano, 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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Research: Controller programming methods, advice Control Engineering 2020 controller research said ladder logic still dominates programming, software integration and simulation capabilities are increasing, and survey respondents offer advice.

hose answering the survey for the 2020 Control Engineering Programmable Controllers Report said ladder diagram programming is most used while mobile alarms, simulation and software integration are increasing. Advice includes maintaining software flexibility and performing regular programmable controller hardware and software upgrades.

Six software changes

Since the 2018 survey, six softwarerelated changes have impacted engineers and how they approach controller programming. 1. Programming languages/methods in use for programmable controllers: Ladder logic (ladder diagram) continues to dominate, still more than 20 percentage points ahead of number two, function block diagram. Structured text increased from 38% to 44%. C programming remained at 31%. 2. Mobile interfaces for alarm functions in programmable controllers increased significantly from 25% in 2018 to 41% in 2020 among software applications for industrial controllers. 3. Communication software methods in use with programmable controllers: OPC Unified Architecture increased from 45% in 2018 to 52% in 2020. Use of MQTT increased from 6% to 15%.

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See five articles on programming in this issue, pages 26 through 41 and online. Link to the full 2020 Control Engineering Programmable Controllers Report with this article online. See more research at www.controleng.com/research.

4. Software integration functions for programmable controllers: Capability with prior versions decreased from 66% in 2018 to 59% in 2020, possibly from greater IT influences and/or from the need to upgrade from unsupported versions for cybersecurity reasons. Integration with higher level systems increased significantly. IIoT-cloud integration increased from 15% in 2018 to 25% in 2020; MES integration increased from 16% to 21%, and ERP integration increased from 10% to 16%. 5. Software programming, topology, setup for industrial controllers: Simulation capabilities jumped, perhaps to serve digital transformation, increasing from 25% in 2018 to 32% in 2020. 6. Software sales, services, support for industrial controllers: Online training jumped from 38% in 2018 to 50% in 2020, like increased by COVID-19.

Controller software tips

The survey asked for advice. Below see three of nine tips related to industrial controller programming and software below, lightly edited; see more online. 1. Seek the ability to incorporate code from a variety of programmable controller languages into the preferred language of choice. 2. Tear down the proprietary software/ hardware model for industrial controllers. 3. Keep the number of different programmable logic controller (PLC) brands and software brands down to manageable number; upgrade PLC processors and software regularly. Think again about how industrial controller programming and software can help optimize manufacturing and other automated operations. ce Mark T. Hoske is content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com. control engineering

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ANSWERS

COVER: AUTOMATION PROGRAMMING Gary L. Pratt, P.E., ControlSphere Engineering

Which IEC 61131-3 programming language is best? Part 1 With so many programmable logic controller (PLC) programming languages and standards from which to choose, what is the right choice for automation and controls applications?

rogramming language choices for programmable logic controllers (PLCs) are many. It is said the great thing about standards is there are so many to choose from! While this is meant as sarcasm, in the case of IEC 61131-3 Programming Languages, it is an advantage to have several language standards from which to choose. Many students enter my training classes with the mindset they will choose the language best for them and then specialize in that language. At the beginning of class, they often ask what language I recommend. Or, “What is the best language?” I usually respond to this question by asking, “What is the best number in the Arabic number system?” or “What is the best word in the English language?” (A student recently said the best English word is “spork,” but I think that answer is still awaiting universal consensus). A good analogy is to ask which is the best office productivity software tool – a document editor, a presentation editor or a spreadsheet editor? While presentations and spreadsheets can be created with a document editor, is that the right way to go? Likewise, presentations and documents can be created in KEYWORDS: IEC 61131-3 a spreadsheet tool, and documents and Programming Languages, LD, spreadsheets in a presentation tool. Does SFC any of this make sense to do, though? Is IEC 61131-3 Programming it worth the effort to learn all the tricks Languages are LD, SFC, FBD, CFC and ST. required to make one tool serve multiple Ladder Diagram remains purposes, or is it more efficient to learn popular because of its graphical only the key features of the tool meant nature. for the job? Sequential Function Chart is As with office software, it is most a graphical language great for efficient to use the best programming expressing state machines and appeals to the graphical nature of language for the application, to avoid engineers. the complexity of driving the square application peg into the round tool hole. CONSIDER THIS With IEC 61131-3 programming lanWhat IEC 61131-3 programming language best fits your task? guages, PLC programming and mainte-

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nance are enhanced when the strengths of all the languages are used.

Programming languages: LD, SFC, FBD, CFC and ST

“Which IEC 61131-3 Programming Language is best? Part 1” (this article) discusses the strengths and best applications Ladder Diagram (LD) and Sequential Function Chart (SFC). “Which IEC 61131-3 Programming Language is best? Part 2” will discuss Function Block Diagram (FBD), Continuous Function Chart (CFC), Structured Text (ST), and how they can be mixed and matched for optimal results.

What is ladder diagram (LD) programming?

Ladder diagram programming, or LD, traces its history back some 100 years to relay ladder logic (RLL), which was created to describe systems of electrical components such as relays, timers and motors. In the early days of automation, when PLCs were replacing relays and timers, it made perfect sense to create a programming language familiar to the user base and similar to the tool it was replacing. Unfortunately, as controllers became more capable and evolved past relays and timers, the original LD language was pressed into services it was never intended for and was poorly suited. This situation was exacerbated by the slow pace at which PLC vendors provided new languages better suited to PLC and programmable automation controllers (PAC) applications. This was particularly true with controllers originating in North America, which explains the global differences in the enduring popularity of LD.

Strengths of LD programming

The strength of LD and the key to its enduring popularity is its graphical nature. Of all the generalizations one can say about engineers (as is often www.controleng.com

COVER: Figure 1: IEC61131-3 Programming Languages offers languages suited to specific needs. Diagrams courtesy: ControlSphere Engineering

illustrated in your favorite Dilbert cartoon), it is safe to say engineers tend to be graphically oriented. (Who among us can effectively communicate without paper and pencil, or a white board?) Early on, most LD programming alternatives were text-based languages that did not resonate with engineers’ graphical nature. This led to further reluctance to move on from LD. Fortunately, that situation is changing. LD remains a great language for which it was originally intended – complex Boolean logic. Staying within this realm, LD logic is simple to design and simple to debug. Figure 2 illustrates this point by showing the same Boolean logic in several IEC 61131-3 languages. Say we are expecting “Inspect” to be TRUE. How easy is it to determine why the result is not as expected? In LD, the answer is quickly determined by observing where the path of solid blue contacts is interrupted (GantryIsRight is not TRUE). In CFC and FBD, the issue also can be determined by observing the progress of the blue path, but it does require mentally evaluating the ANDs and ORs. Evaluating the issue in text is a challenge.

What is sequential function chart (SFC) programming?

Sequential function chart (SFC) is a graphical

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To create effective industrial controls programs, it is important to have the right languages and know how to use those

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languages effectively.

language great for expressing state machines, and, like LD, appeals to the graphical nature of engineers. To provide better context, this programming language discussion will be broken into two parts: 1) State machines in general, and 2) The language to implement a state machine.

What are state machines?

State machines date back many years, but only more recently have been applied to industrial programming. State machines are a very powerful method for expressing a system whose behavior depends on past history, such as any logic with: 1) Set coils or reset coils 2) Seal-in logic (Boolean feedback) control engineering

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COVER: AUTOMATION PROGRAMMING 3) Internal flags that are set by the code to affect the behavior of the code on future scans. In reality, even the simple TON On-Timer and R-Trig one-shot are state machines. Their next behaviors depend on previous inputs and behaviors. State machines offer many benefits over other coding techniques: 1) They’re easy to design because it clearly describes the states a system can be in, how the system transitions between those states and the actions the system should take while in those states. 2) During runtime, it is easy to see exactly what state a system is in, what it is doing in that state, and what will cause it to move to the next state (or why it isn’t moving to the next state if something has gone wrong in the process). 3) It promotes well-conceived and well-organized designs. It assures all possible eventualities have been handled (thus eliminating the chance of being called in the middle of the night to fix code that didn’t properly address an unusual condition). 4) Easy to determine that every possible eventuality has been properly tested. Just print out the SFC and cross off each state and transition as it is exercised. When everything is crossed off, testing is complete (and the programmer’s confidence level is 100%). State machines can be implemented in different ways.

How to implement a state machine

Figure 2: Diagram compares languages for complex Boolean logic as implemented in Codesys.

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While state machines can be implemented in almost any language, they require a specific coding technique, which consists of steps, transitions, branches/jumps, and actions. Steps describe the states of which a system can reside; transitions indicate when a system should move from one step to the next; branches and jumps indicate what that next step should be; and actions specify what operation should be performed while in that step (or entering or exiting that step). Due to its graphical nature and specialization for the job, SFC is the most natural choice of language for state machines, as shown in Figure 3. Figure 6 [online] shows an example of a state machine for a loading system as displayed in the online mode where the current states are displayed in www.controleng.com

Figure 3: Diagram shows programming components of a sequential function chart (SFC).

blue. Notice this example has three simultaneous parallel branches that run independently of each other. Also notice how simple it is to determine the current state of the system, what the system is doing in the current state, what the next states are, and what conditions are required to move on to the next states. For systems requiring unusual complexity or flexibility, state machines also can be implemented in text-based languages. For organizations locked into using LD, state machines can even be implemented in LD by using a coil for each state, transition logic to energize/deenergize each coil to move the system from one state to the next, and separate logic that uses state-coils to implement the actions. Some vendors also provide an implementation of unified modeling language (UML) state diagrams as a more powerful and flexible alternative to SFC, but this comes at the price of a longer learning curve and limited acceptance in the industrial controls community. When it comes to state machines, the choice of language is secondary to the choice of technique within the language. In SFC, the language forces the use of the state machine technique. In other languages, it’s up to the discipline of the engineer to use the proper technique. If the functionality depends on previous history, it’s a state machine. For optimal code, implement it as such. [A Control Engineering archived article explains “UML use cases, sequence diagrams: easily converted into executable code.” See this article online for a link or search on the headline at www.controleng.com.]

Use the right language for control system programming

To communicate effectively in the English language, it’s important to have the right vocabulary and know how to use that vocabulary effectively. To create effective industrial controls programs, it

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is important to have the right languages and know how to use those languages effectively. IEC 61131-3 provides the languages, and this article has provided guidance on effective use of LD and SFC. See Part 2 for use of FBD, CFC and ST. Go forth and program effectively with IEC 61131-3 Programming Languages. ce Gary L. Pratt, P.E. is president of ControlSphere Engineering. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com.

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If reading from the digital edition, click on the headline for diagrams on using the right tool, two common state machines, and SFC branches and links to referenced articles and resources. www.controleng.com/magazine www.controleng.com/control-systems/plcs-pacs

FOR MORE, SEE Video demonstration of each language and configuration from a csv file. Object Oriented Industrial Programming (OOIP) article. More programming downloads from Object Oriented Industrial Programming Foundation. www.ooip-foundation.org Codesys integrated development environment (IDE) from 3S-Smart Software Solutions, used for examples in this article can be downloaded at no charge, including a software-based PLC that will run for 2 hours between resets. For a Control Engineering article with programmable logic controller programming instructions, terms, logic circuits and more, see “Support-focused enterprise controls: PLC Basics.” control engineering

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COVER: INDUSTRIAL PROGRAMMING David Breen, Breen Machine Automation Services

Benefits

of learning ladder logic for industrial programming Ladder logic is challenging for industrial programming, but it is a valuable skill for engineers looking to enhance their skill set.

started programming as an early teen, received a bachelor’s degree in computer science and I’ve worked as a software and web developer for over a decade. I’ve been a programmer before attaining the degree: teaching myself, learning new languages and trying new things. Transitioning to industrial programming was the biggest changeup in my history, but also a valuable one.

Adding ladder logic into industrial programming

The first thing when adding ladder logic to industrial programming is it looks like a bad visual integrated development environment (IDE). Like somebody tried to give you a flowchart you could drag and drop onto. Considering it’s mostly a mix of logical gates, it really does behave like that. Once you start to tinker and get your head

around it, it’s usable. Basic structures like loops are a mess, sure, and the variable structure is ugly. The whole program is stuck in an infinite loop. The thing that’s going to slow you down the most is how much you need a mouse. With object-oriented language (OOL) such as Java, Visual Basic (VB), or any common scripting language, navigation requires very infrequent mouse usage. Get to the place you want to edit and start typing. There’s a double-click here and there, but it’s mostly typing because it’s all characters and symbols. To speed things up, many IDEs have an auto-completion function built-in.

Navigation inside PLC programming

In ladder logic, keyboard shortcuts can keep things moving, but navigating between rungs with only the arrow keys can be tedious, slowing down the execution, and derailing your train of thought.

Learning ladder logic can be challenging, but it is a valuable skill for those working in industrial programming. Courtesy: Breen Machine Automation Services

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PLC programming is not fun, not efficient and not easy to maintain. The manufacturing industry needs

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fresh ideas and modern concepts.

Ever walk into a room and forget why you went in there? Imagine that happening every 10 seconds. OOL and a modern IDE provide autocompletion of variables and method names, easy navigating, better code organization and structure and more effective use of screen real estate. Instead of a bunch of boxes and arrows to space things out, all that appears are letters and numbers. The user can see much more information without having to scroll around. The biggest hurdle when switching to industrial programming is how slow it is. It’s a beast of its own in a variety of ways, and there’s only so much that can improve speed. Things are going to take longer to write in ladder. It’s a given.

Looking forward: PLC programming needs more PC programmers

As for the other issues, they’re remnants of the early days of an industry that has been slow to adapt. That is exactly why I think the industry needs more PC programmers. The manufacturing industry hasn’t seen significant changes to its programming methodologies in decades despite immense improvements in other fields. It needs fresh ideas and modern concepts. PLC programming is not fun, not efficient and not easy to maintain. And yet, it remains a very worthwhile skill. Frankly, the more PC people who learn it, the faster we can help the industry evolve its methods to more accessible and maintainable solutions. ce

David Breen, lead programmer, Breen Machine Automation Services, a CFE Media content partner. This article originally appeared on Breen Machine Automation Services’ blog. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.

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Smart IoT compressed air device delivers system advanced diagnostic and energy efficiency Saving energy is easier than ever before thanks to the MSE6-E2M. Achieve your energy efﬁciency and sustainability targets while optimizing process equipment performance. Intelligent assembly features include: •

KEYWORDS: PLC programming, ladder logic, object-oriented language Ladder logic is a challenging programming language to learn for those not familiar with industrial programming. Users familiar with object-oriented language (OOL) may not be used to the more manual nature of ladder logic. Ladder logic is a product of an industry that has been slow to adapt to the more modern approaches.

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Zero compressed air consumption in standby mode Monitors the system for leaks Ensures maintenance in the event of leaks Enables effective monitoring of relevant process data www.festo.us

ONLINE Read this article online at www.controleng.com for additional stories about ladder logic, also called ladder diagram (LD).

CONSIDER THIS

August 5 to 6, 2020

What benefits did you gain from learning ladder logic? control engineering

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Virtual tradeshow with product demonstrations, presentations and networking opportunities.

More info and free registration at festoexperience.vfairs.com input #10 at www.controleng.com/information

ANSWERS

COVER: MACHINE PROGRAMMING Keith McNab, Emerson

Moving toward self-assembly machine automation systems Evolving PLC and PAC platforms, networking, and programming methods are leading to self-assembled machine automation systems, reducing risk and user integration efforts.

utomated factories and processes are often created by integrating many smaller machines or equipment subsystems, requiring significant system integration effort and customization. For years, users have desired a better approach to simplify this integration work, to save money and reduce risk. Automation self-assembly is increasing and hardware, communications, and software advances are streamlining system integration and decreasing time from engineering to productivity. Although machine automation products and practices have improved over time, roadblocks to achieving integration still exist. Many times the hardware, communications protocols, and software programming have relied on incompatible technology, hampering system integration efforts. In the most difficult cases, achieving interop-

erability among various equipment became an extremely complex, expensive and time-consuming project. Fortunately, the situation has improved. Even for mission-specific hardware like programmable logic controllers (PLCs) and programmable automation controllers (PACs), efforts to modularize programming have gained traction. Networking methods and protocols have advanced to provide comprehensible information exchange. Building on these developments, PLC- and PACbased automation technology is moving towards self-assembled machine automation system applications, allowing modular subsystems to be easily integrated into the overall system.

What is automation self-assembly?

Manufacturing facilities of all types commonly incorporate various automated subsystems. A typical beverage producer may have: • Bulk raw product storage tanks • Blending and processing skids • Bottle fillers • Material handling conveyors • Packaging equipment • Water filtration systems • Steam and compressed air utilities.

Figure 1: When automated equipment is developed using modern products and practices, it can be integrated into supervisory systems following a concept called self-assembly. Images courtesy: Emerson

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Other industries might use a mix of equipment, but generally there are many specialized suppliers for any production facility. End users are often more focused on the equipment mechanical interoperability and performance. They may find it impractical or impossible mandating some level of uniformity among associated PLC and PAC control platforms. Therefore the packaged equipment suppliers will end up delivering a variety of automation systems, each programmed using different practices. Some of those elements may even be secured www.controleng.com

and untouchable for intellectual property or operational performance reasons. Each of these packaged equipment “islands” will feature its own and often unique controller, input/ output (I/O), instrumentation, and human-machine interface (HMI) elements (Figure 1). These will likely need to interact with some combination of upstream equipment, downstream equipment, peer systems, and a supervisory system. In fact, many end users prefer subsystem PLCs and PACs to be supervised and perhaps even orchestrated by a larger overall control platform. System integration is the effort of coordinating these interactions. It’s no surprise integrating the disparate systems into a cohesive whole is quite difficult. However, if each subsystem could define the available data and functionality, and then expose these attributes to other systems, it would make system integration efforts more efficient. This ability can be referred to as self-assembly, which leads to simpler, less costly and quicker implementations.

Automation system integration evolution

Basic self-assembly may require an export of the subsystem PLC or PAC configuration, which is manually imported into the supervisory control platform. In more advanced situations, the subsystem could self-announce (or publish) its capabilities to a supervisory system capable of responding in kind. This could even occur dynamically through change event notifications. Self-assembly relies on several fundamental features. PLC and PAC platforms and practices have improved along an evolutionary path for many years and have gained many of the necessary abilities including: • PLC, PAC, and networking hardware acquired sufficient power to allow for programming and data modularity, reusability, and communications. • Networking protocols added models so data could be transmitted in context. • System-level modular configurations concepts leveraged the previous developments to make self-assembly possible. The following sections explore how each of these stages progressively support the goal of achieving industrial automation self-assembly.

PLC, PAC and edge control building blocks improve system integration

PLCs were the original mass produced digital industrial automation platform. The earliest models used rudimentary ladder logic and were

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Figure 2: Data structures which include semantics allow receiving systems to interpret data from sending systems and receive notifications of updates.

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Automation systems are easier to use, more capable and have concepts similar

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to object-oriented programming. proprietary from vendor to vendor. Programming each new project required at best copying and pasting or rewriting at worst. Some PLCs eventually gained the ability to encapsulate frequently used routines. As these automation platforms gained more features, suppliers began to designate them as PACs. PACs included better provisions for creating user-defined and original equipment manufacturer (OEM)-specific librarybased objects, which could be configured to protect intellectual property and help guarantee performance. Edge controllers have become available the last few years. They merge PAC capabilities with PC-like computing functionality, combining operations technology (OT) deterministic control with more information technology (IT)friendly processing and networking.

KEYWORDS: Machine

automation, programmable logic controller, PLC PLC- and PAC-based automation is moving towards self-assembled machine automation system applications, allowing modular subsystems to be integrated into an overall system. Module type packages (MTP) and machine-as-an-object (MaaO) elevate raw data and basic functionality into contextualized information and capabilities.

ONLINE Read this article online at www.controleng.com for additional stories about PLCs and PACs.

CONSIDER THIS What improvements could your plant gain from self-assembly machine automation?

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ANSWERS

COVER: MACHINE PROGRAMMING Shared database concepts made it easier for multiple control elements like PLCs, PACs, edge controllers, HMIs, and motion control systems to interact. Automation systems also became easier to use and more capable and have gained some concepts similar to the object-oriented programming (OOP) found in commercial systems for promoting creation, use, improvement, and reusing code. However, progress of logic and data handling has remained largely focused at the machine automation level.

Using Ethernet for industrial automation

For connecting PLCs, PACs, edge controllers, HMIs, and other machine automation elements, Ethernet has become the medium of choice. Of course there are still some use cases, such as motion control or hazardous locations, where a more specialized industrial fieldbus offers a performance advantage. For most in-plant situations, though, Ethernet has delivered the fundamental networking performance needed to transition from basic data transfer to comprehensive information interchange. Many protocols are available for industrial Ethernet applications. Some of them transfer raw data and require extensive user planning for the sending and receiving systems to handle scaling, descaling, tag grouping, and poll rates. More advanced protocols — such as OPC UA — include reference, variable, object and data types, which allow end users to formulate information models with semantics. Semantics enhance the raw data with context, including descriptive and scaling information, enabling the creation Figure 3: of object-oriented information that can The NAMUR modbe comprehended by system components. The ule type package information model also has the capability to notistandard defines fy receivers of the information (clients) about its the automation existence and whether changes to the structure or aspects which need semantics have occurred. to be exposed so For instance, when a pump type is instantiated in a automated equipPLC program, discovery services can notify client sysment can be easily tems a new pump object exists and where to find it. self-assembled into The pump object could include data tags for running a supervisory sysstatus, speed command, and inlet/outlet temperatures tem. and pressures (Figure 2). If a bearing temperature tag is later added to the pump, the data structure could be updated, and client systems notified. Using semantics, receiving systems can automatically interpret data from originating systems. The machine automation systems can effectively talk to each other using the same language.

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Machine-as-an-object benefits for suppliers, manufacturers

The preceding advancements for logic, data, and encapsulation have been necessary precursors for achieving an overarching machine-asan-object (MaaO) concept. When a supplier configures their equipment using MaaO practices, they are encapsulating the machine automation system so it can announce itself and be self-assembled into other systems. Industry standards such as NAMUR module type packages (MTP) have been instrumental in elevating the concept of modularized and encapsulated systems (Figure 3). MTP identifies certain aspects of automation and indicates how they are exposed for interactions with outside or supervisory systems. When MTP-based automated equipment is attached to a supervisory system, the system can understand the equipment as a functional machine object. MTP provides a way for developers to identify and define the available equipment functionality, and how to invoke it. All the necessary data tags are exposed in context for commanding, monitoring, alarming, and diagnosing the subsystem. Even the HMI displays can be developed by the subsystem supplier and imported into the supervisory system. A machine configured using MTP may contain significant logic and data tags for internal use. However, a supervisory system can access just what is needed for high-level operation. For instance, a packaged PLC-controlled mixing tank subsystem could be integrated with a supervisory system using MTP. The supervisory system could call for fill, mix, and drain cycles. The machine’s automation system would then handle the details of timing, opening and closing valves, operating the mixer, and generating status and alarm tags.

The path toward self-assembly machine automation

The evolution of industrial automation has been leading toward systems which are more integrated, and concepts like MTP and MaaO elevate raw data and basic functionality into contextualized information and capabilities. Forward-looking companies are ensuring their PLCs, PACs, edge controllers, software, and networking platforms are ready for self-assembly, providing end users with the ability to assemble and reconfigure production plants using modular subsystems. ce

Keith McNab is technical product manager, Emerson. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com. www.controleng.com

ANSWERS

COVER: AUTOMATION PROGRAMMING CASE STUDY James Figy, Beckhoff Automation LLC

Film application system has high precision, throughput PDS IG Equipment doubles window film throughput compared to the industry standard by using EtherCAT and PC-based control.

utomation programming software and an industrial PC-based control architecture helped with a high-throughput, modular machine design doubling throughput. “During construction projects, glass windows face significant risks from splashing concrete, dirt, debris and other hazards, such as tradespeople carrying tools and materials,” said Michael Rapp, vice president of sales and partowner of PDS IG Equipment. “Applying window film during the manufacturing process not only protects the window, but it also allows contractors to simply peel off anything that might have stuck to it.” To ensure the polyester (PET) film is applied with high repeatability, short cycle times and robust data acquisition capabilities, PDS IG created a modular automated solution to protect insulating glass (IG) units of all sizes during manufacturing, shipping and installation. The PDS IG Equipment technology portfolio includes a broad range of window production machinery. PDS IG built its window film application system after recognizing a lack of efficient automated systems for the process, which is nearly impossible to complete manually. Beyond offering high throughput, the modular machine design allowed greater control and flexibility for facilities operators and managers.

Machine design system requirements

The system uses multiple modules, beginning with an intake conveyor module. Operators or robots carefully load glass onto the conveyor, which transports each piece into the film applicator module. During this process, the machine measures each insulating glass unit individually, according to Steve Polkinghorne, automation controls engineer at PDS IG. “The machine measures the length by taking a position latch of the rising edge and the falling edge as the units enter, and it uses a measurement sensor for the height,” he said. “Then while applying the film, the machine takes a highspeed snapshot of the unit’s position relative to the axis position to fine-tune all of the measurements.”

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COVER: AM8000 series servomotors from Beckhoff Automation control numerous axes of motion across the modular system, including those on the application head. Images courtesy: Beckhoff Automation

The application head covers the surface with as many passes as necessary using 12- to 16-inch rolls of PET film. Once film is applied on one side, the IG unit moves into a glass-flipping station that turns the workpiece 180 degrees horizontally and conveys it into the second film applicator to cover the other side. Finally, an operator or robot offloads the fully protected glass.

Real-time communication, precision

When PDS IG engineers began to design the system in early 2018, they knew real-time communication was key to ensuring precision. The film applicator needed to leave a consistent “cutback.” This is a thin strip around the edges that remains uncovered, allowing the glass to be installed in the sash without film becoming stuck behind the frame. “These windows range from 12 inches by 12 inches up to 96 inches by 140 inches,” Polkinghorne said. control engineering

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ANSWERS

COVER: AUTOMATION PROGRAMMING CASE STUDY “Our equipment needs to keep that cutback the same across that area.” In addition to accurate measurement, this level of precision requires reliable motion control. In fact, it takes 28 axes of motion to properly control the conveyors and the X- and Y-axis movements of the film application head. PDS IG needed flexible and open automation technology to ensure that the system and its vari-

ous modules remained customizable. This way, they could easily integrate into customers’ existing systems and provide data for process optimization. As a result, they collaborated on the machine design with local sales and applications engineers from Beckhoff Automation. PDS IG first began using the company’s controls and components in 2011 at its Infinite Edge Technologies facility. Don Seichter, area sales manager for Beckhoff, said this partnership has provided significant technological advantages: “Over the years, the ability to support numerous technologies in one control platform has helped PDS IG realize innovative applications that would have required multiple PLCs [programmable logic controllers] and black box technologies to come close to the same results.”

Automation adds flexibility, openness

The PDS IG Equipment window film application system offers a modular design that easily integrates with existing equipment in manufacturing facilities. Images courtesy: Beckhoff Automation

The PDS IG window film application system relies on numerous automation technologies. For its operator interface, the system uses built-in panel PCs. These panels, which combine a 15-inch touchscreen and a PC-based controller, are mounted to small electrical cabinets hung from the machine modules. They’re able to run the human-machine interface (HMI) and a thin client to improve modularity, according to Polkinghorne. “Depending on how many modules are used, a machine line that makes IG and applies protective film could span 100 feet. The thin clients allow users to navigate HMI screens for every machine module from any control panel.”

Programming: PLC, motion, I/O, safety

AX5000 series Servo Drives from Beckhoff Automation power all axes of motion with space-saving One Cable Technology that provides power and feedback in a single cable.

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The machine control relies on a control cabinet Industrial PC (IPC) and automation software. The automation software combines all functionality on a real-time control platform and enables programming of the machines’ PLC, motion control, I/O and integrated safety in one environment. The CPU core-isolation capabilities of the automation software allow PDS IG to designate these functions to run on a specific core of the IPC’s processor. Before running the PLC, safety or other programs on the IPC in the field, engineers can design and test them using the object-oriented extensions of IEC 611313, computer science languages found in Microsoft Visual Studio, a variety of built-in function blocks and other options in the graphical editor. Polkinghorne said the database server also allows flexibility to collect production information in SQL databases on a controller or network connected to the Internet: “We have the flexibility to give customers the right data with the right frequency so that they turn it into actionable information to enhance production.” Further increasing efficiencies, the automation software can scan and automatically configure devices over ADS and the EtherCAT industrial www.controleng.com

Ethernet network, including third-party devices. This reduces point-to-point connections with USB cables during commissioning. EtherCAT provides the fast deterministic communication necessary for precise measurement and film application. In particular, high-precision digital input terminals offer timestamping with a resolution of 1 ns. EtherCAT also enables the use of TwinSAFE integrated safety technology to implement custom safety logic programmed via control programming software and to communicate safety data over the standard EtherCAT network using a “black channel” approach. “TwinSAFE allows us to implement TÜV-recognized safety in a standard control platform and display safety-relevant information on the HMI,” Polkinghorne said. TwinSAFE programs load directly onto I/O modules with built-in logic, including a safety PLC terminal, and other devices such as servo drives. The window film application system uses a variety of motion control products for its 28 axes across the standard setup. The modules and film application head move with the help of servomotors. The servo drives provide control and power to the servomotors via single-cable technology. This has benefited multiple PDS IG applications, according to Polkinghorne: “One of our IG spacer application robots has 16 servomotors, so having just one cable for each is crucial for space savings in that solution as well as the window film applicator.” The servo drives also implement integrated safety through the addition of TwinSAFE drive option cards. The cards offer drive-integrated safe stop, speed, position, acceleration and rotating direction functions. “Without hardwiring integrated safety logic, we can provide unique, flexible solutions to customers while still adhering to all safety requirements,” Polkinghorne said.

Simpler design, doubled throughput

The PDS IG Equipment window film application system improved repeatability, flexibility and cycle times before going to market in the secondquarter 2019. Using the high-speed measurement of EtherCAT terminals, the applicator has a cutback precision of +/- 1/8 inch, even across the largest glass units it handles. “When applying this film on a 7- or 8-foot-long window, that consistency is pretty remarkable, especially considering how the film can stretch,” Rapp said. Maintaining this high precision ensures IG units can be installed into the window sash without film becoming stuck when the time comes to peel it off. The flexibility and scalability of PC-based control reduced hardware requirements and offered valuable data to PDS IG and its customers. Accomplishing these results with another vendor would have required

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TwinCAT 3 automation software provides a universal engineering platform for all functions, from PLC to functional safety via TwinSAFE.

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additional hardware PLCs and motion controllers. These reduced overall costs while KEYWORDS: industrial PC, increasing openness, Seichter said, with servomotor, programmable “one controller without the need for a spelogic controller cialized, single-purpose black box.” PDS IG created a modular PDS IG provided customers with automated machine to protect insightful machine health and perforinsulating glass (IG) units of all sizes during manufacturing, mance data to help them maintain the shipping and installation. system’s high throughput. While glass They used industrial PCs, dimensions vary from piece to piece, the servomotors and EtherCAT PDS IG solution roughly doubles what technology to improve cycle is possible through other systems on the times, productivity and innovation. market, according to Rapp. ONLINE “Our cycle times average 25 to 30 secFor more information: onds per window, so the throughput for an www.pdsigequipment.com eight-hour shift is about 1,000 to 1,200 IG www.ethercat.org units, compared to others in the industry www.beckhoffautomation.com that produce 500 to 600 in that same timeCONSIDER THIS frame,” he said. “With flexible and scalable What improvements can technology, our expandable system could your facility make to improve add further modules to increase per-shift productivity and efficiency? throughput to 2,000 IG units – even if each one has a different SKU.” With the ability to create more efficient window production and finishing lines, PDS IG sees a future of continued innovation to better build and protect IG units, from the factory to installation. ce James Figy, senior content specialist, Beckhoff Automation LLC. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com. control engineering

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ANSWERS

COVER: PROGRAMMING VFDS Christopher Jaszczolt, Yaskawa America Inc.

Top 5 VFD parameter changes explained Programming variable frequency drives (VFDs) to fit most industrial applications requires only the most basic settings to operate the motor. Understand these 5 VFD parameter changes to optimize VFD programming.

ariable frequency drives (VFD) are electronic devices using fast-acting switches or insulated gate bipolar transistor (IGBT) to convert three-phase input power to a variable frequency and voltage output for motor speed control. VFD settings contain programming, and five parameter changes account for most applications. Through VFDs, electric motors can be used to run a wide array of applications to achieve control not possible with across-the-line operation or mechanical means. With VFD-controlled motors, users can optimize system efficiency by matching motor speed to maintain exact system demand. Most VFD applications improve system efficiency and provide a return on the VFD investment in energy savings in typically less than a year. KEYWORDS: Variable frequency As with all electronics, VFDs have drive programing, VFD advanced in capability and function, configuration providing more system control to help Setting five parameters eliminate external devices and programcan take care of most VFD mable logic controllers (PLCs). Due to programming. these innovations, it is understandable Consider VFD control method, one may be overwhelmed by the prosmotor FLA, acceleration and deceleration times. pect of programming a VFDs for an Also consider speed and run application. However, most applications source and fault rest. require only the most basic settings to operate the motor. This is because VFDs CONSIDER THIS are designed and engineered to make the What is needed to program or configure VFDs to fit an complicated simple. application? In most cases, the VFD’s default settings will be sufficient for an application ONLINE and not require adjustment. Typically, no If reading from the digital edition, click on the headline for more than a dozen settings are adjusted more resources. for an application. See a list of the top five www.controleng.com/magazine parameter settings programmed by VFD www.controleng.com/ installers.

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discrete-manufacturing/ motors-drives www.controleng. com/online-courses/ introduction-to-motors-and-drives

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1. Control method influence

What is a control method as it applies to VFDs? The first setting commonly set

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by VFD installers is the control method. The control method dictates the capabilities enacted by the drive to regulate motor speed. These control capabilities can be classified into three groups: volts-per-hertz control, self-sensing vector control, and closed-loop vector control. Volts-per-Hertz (V/f) control is the most commonly used motor control method. It is the most basic of the three topologies. V/f control fixes the drive’s output to a predefined voltage and frequency curve for the motor to follow as the VFD’s speed command is adjusted. These V/f patterns can be adjusted to provide high starting torque or reduced to optimize efficiency for variable torque loads that do not require constant voltage to frequency relationships. Self-sensing vector control is a control method that provides a more fine-tuned control of the motor’s speed. VFDs can implement this control using various different and complicated control schemes. In essence, complicated algorithms are used to monitoring, interpret and respond to current feedback to provide precise motor control. However, the simplest way of viewing this control method is to view it as precise motor control without the need for an encoder. Closed-loop vector control is the most advanced motor control method available. As its name indicate, closed-loop vector control uses a motor encoder to provide precise speed feedback and eliminate any error in VFD control generated by responding to current feedback. Adding the encoder tells the VFD what the motor is doing and how it is responding to the load.

Why adjust the control method?

Adjusting the control method is a function of meeting needs of the motor-drive application. Some applications are simple and only need to run at an approximate speed, while others need precise and dynamic motor control. Each of these control schemes achieves an application need and/or limits programing www.controleng.com

involved to get the system up and running. V/f control is commonly used for systems that do not require precise speed control, such as fans or pumps. In the most basic of V/f control methods, the motor is allowed to slip (drift) away from the commanded speed. The slight change in speed does little to impact the overall system performance because other drive programming will adjust the speed to maintain system demand. For example, if a fan is being asked to run at half speed and cannot maintain demand, then most system configurations, through the VFD’s proportional-integral (PI) loop or with an external device, will boost the speed command provide the motor speed needed to meet demand. V/f control is the most commonly-used control method because it requires little to no programming to implement. Most drive manufacturers, through years of application experience, have their default settings already configured for most pump and fan applications. These defaults offer optimum energy savings with little to no programming requirements. Even non-variable torque applications, such as a compressor, can take advantage of V/f control for its easy of setup. Self-sensing vector control methods improves process control and reduces maintenance. For example, self-sensing vector control regulates motor speed to within 1/200th of motor rated speed, provide dynamic speed control, high starting torque down to low speeds, and limits current and torque without external devices. To provide these advanced motor control capabilities, the VFD requires specific motor characteristic information, such as motor no-load current, resistance, and inductances. To obtain this information, the VFD would run through a simple motor tune requiring basic motor nameplate data such as rated current, voltage, and speed to be entered through the keypad. Applications that benefit most from this control include mixers, washing machines and punch/stamping presses. Closed-loop vector control’s added speed feedback signal to maximize process control and minimize maintenance. Closed-loop vector control allows for precise speed control down to one RPM, high starting torque at zero speed, zero speed control, and torque regulation. These features are used in applications that cannot deviate more than a few RPM or else the product output will not meet its designed specifications. For example, many extruders use encoder feedback to maintain motor speed to precise requirements to ensure the product meets its specifications. Encoder feedback also ensures accurate torque monitoring to allow the VFD to react to high torque conditions that may clog or damage the machine. The same motor tuning requirements made in self-sensing vector control are required in closed-loop vector control to optimize motor control and reduce compensation needed by the encoder feedback. The better the VFD understands a motor’s charwww.controleng.com

Figure 1: VFDs have preconfigured overloads to account for many different motor types including 40:1 speed range variable torque loads, 100:1 speed range constant torque loads, and even nonconventional motors such as permanent magnet motors. All figures courtesy: Yaskawa America Inc.

acteristics, the better it can run the motor. This is true with or without motor feedback. Application such as extruders, high-speed spindles and constant tension unwinders take advantage of closedloop vector control.

2. Motor full load amps (FLA)

What is motor full load amps? Since most VFD’s control method setting is already defaulted for their most common application, the real first setting programmed by any VFD installer is the motor’s full load ampere (FLA) or motor rated current setting. Motors are designed to allow for continuous operation at their nameplate rated currents when operating at rated power and rated voltage. Programming a VFD with the motor’s FLA rating configures the VFD’s electronic thermal overload for the motor being operating. Although VFDs are natural soft starters, motors can exceed their rated currents for brief periods of time such as during start, impact loading, rapid deceleration, or excessive application cycling. However, high currents for long periods of time will lead to excessive heat in the motor, which can lead to reduced lifetime and premature failure. Locked rotor conditions also may occur due to mechanical damage in the load or coupling. Over time load wear also can result in increased current draws that may be in excess of motor FLA. To avoid motor failure, a VFD’s motor FLA setting would be programmed for the motor’s nameplate FLA. Enacting the VFD’s electronic thermal overload within the drive satisfies the requirement for motor overload protection required by the National Electric Code (NEC) and local codes. control engineering

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COVER: PROGRAMMING VFDS

Figure 2: Using an appropriate acceleration and deceleration time will significantly reduce motor inrush current at start and current surges when changing speeds. Less inrush current increases motor (less heat) and powertrain life (less dynamic high torque changes). The VFD also isolates these currents from the line.

Using the VFD’s electronic thermal overload allows the user to eliminate a mechanical motor overload, which eliminates cost, a potential point of failure, and any maintenance requirements associates with maintaining the integrity of the overload’s contacts. A VFD’s electronic overload protection function estimates the motor overload level based on output current, output frequency, thermal motor characteristics, and time. When the VFD detects a motor overload a fault is triggered and the VFD output shuts off to protect the motor from thermal failure. These overload curves can be set to the capabilities of the motor. Many pump fan motors are designed for variable torque loading, which means they are not designed for rated current at reduced speed. Reduced continuous overloads are provided to reduce maintenance and ensure motor operational lifetime is maximized. VFDs have preconfigured overloads to account for many different motor types including 40:1 speed range variable torque loads, 100:1 speed range constant torque loads and nonconventional motors such as permanent magnet motors (see Figure 1).

3. Acceleration and deceleration times

What are acceleration and deceleration times for a motor-drive system? VFDs are natural soft starters. They reduce inrush current when changing speeds. To accomplish this a VFD starts and stops the motor based on programmed acceleration and deceleration times. These times or ramp rates define

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control engineering

how long the drive will take to get from zero speed to maximum frequency. There can be fixed rates or multiple sets of rates that adjust based on operation conditions or through commands sent to the VFD (see Figure 2). Using an appropriate acceleration and deceleration time will significantly reduce inrush current at start and current surges when changing speeds. This leads to increased motor (less heat) and powertrain life (less dynamic high torque changes). The VFD also isolates these currents from the line. So, no large surges need to be supplied by the transformer, which could cause unnecessary heating or effect its supply voltage, which may impact the VFD performance or other loads on the system. Lower inrush currents mean demand charges by the utility due to current/power surges are eliminated. VFDs are defaulted to the most commonly-used acceleration and deceleration times based on their intended application. Fan/pump drives would have longer ramp times, while general purpose industrial drives would have shorter ramp times. This helps simplify the installation process. However, not all defaults work for every application. Adjusting these ramp times would be needed to keep currents within the limits of the drive and the motor. Based on the inertia of the load, it is possible to start/stop a load quicker than what allowed based on the current capabilities of the drive/motor. Aggressive acceleration/deceleration rates will lead to higher currents that may tax the drive and motor and lead www.controleng.com

to overload or overcurrent faults. Setting the correct acceleration and deceleration time ensures proper system performance while ensuring no fault operation. The pivotal points in an acceleration/deceleration curve occur at the start and stops of each ramp. This is where the most torque or current is required to make the desired motor movement. So, in situations where the overall ramp times need to remain low, adjustments to these points can be made to reduce the total ramp time. These points are called the jerk or s-curve timing adjustments. These settings extend the time at the high stress points of the acceleration or deceleration ramp to reduce impact on the overall start/stop times (see Figure 3).

4. Speed and run source

What is the speed and run source? A VFD requires two things at every moment of its operation: a run command and speed reference. The run command tells the drive it should operate the motor, while speed reference tells the VFD what frequency to run. Both inputs are required to provide motor control. Otherwise, the motor sits idle. The setup or lack of setup is one of the most common technical support troubleshooting calls a VFD installer will make. Setting the VFD’s speed and run command is more about how one chooses to run the motor and less about whether or not they want the motor to run. Most manufacturers default their drives to operate from digital and analog inputs. Contacts and relays are fed to the drive to enact the drive’s run command. Analog inputs are then used to feed a speed reference to the drive. These analog references can be 0-10 V dc, +/-10 V dc, 0-20 mA, or 4-20 mA signals. Each reference source has its own benefit. A voltage reference is simple to generate and easy to understand, while current signals propagate longer distances without being easily affected by nearby electrical noise. Other avenues of control are accomplished through direct keypad control or via network communications. Each of these references provides the VFD with the exact speed required to run the motor. The more accurate a VFD’s motor speed control reference, the more accurate the VFD is at achieving system demand. Accurately meeting system demand means higher energy saving benefits achieved by the VFD. The goal of any command interface is to achieve the control needed for the system that maximizes efficiency, quality and safety.

5. Fault reset

What is a fault reset on a VFD? There are many conditions external to the drive that can result in operating conditions that are outside their specifications. To maintain product lifetime and prevent failure, VFDs incorporate and trigger faults to protect themselves. Examples of conditions that may

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Figure 3: The pivotal points in an acceleration/deceleration curve occur at the start and stops of each ramp, where the most torque or current is required to make the desired motor movement. When overall ramp times need to remain low, adjustments to these points can reduce the total ramp time. These points are called the jerk or s-curve timing adjustments.

cause a VFD fault include aggressive start times, aggressive stop times, loss of power, and a locked rotor condition. Many VFDs incorporate automatic fault reset capabilities. This feature allows the drive to detect a condition outside the scope of its programming and trigger a fault to protect itself, the motor, and the rest of the mechanical system. The fault reset feature allows the user to detect events and if eliminated reset the drive back into normal operation. The purpose of the auto reset is to overcome nuisance faults and maintain continuous operation. Downtime costs money and an auto reset features allows the system to maintain operation for events that have not been deemed necessary to stop production until examined by certified staff. An example of this would be a voltage spike caused by a thunderstorm. These are rare occurrences that should not need further analysis. The drive stopped its self from operating in such a condition, thus protecting itself. The auto-reset feature allows the drive to start backup without user intervention, saving time and money.

Be sure to set top 5 VFD parameters

There are many ways to implement VFD technology to automate motor control needs. VFD setup can be complicated but the majority of applications require few adjustments to get up and running. Moreover, VFDs have streamlined the installation process. One way is through application startup routines or wizards. These routines walk the installer through the process of programming their drive using question and answer menus to ensure the application is programmed to operate as needed. VFDs are designed for ease of use and to maximize their return on investment (ROI) by optimizing efficiency, quality and safety. ce

Christopher Jaszczolt is a product manager, Yaskawa America Inc. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com. control engineering

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ANSWERS

I/O MODULES, SYSTEMS Raj Rajendra, Siemens Industry Inc.

Machine mount I/O devices are machine data satellites

Machine mount I/O devices are expected to support simple digital and analog inputs and outputs and other modules with intelligence built in.

he controller and the input/ output (I/O) devices are not always best mounted in a cabinet away from dust and moisture. There are times I/O is required at the machine level exposed to the elements. The hardware needs to be designed to meet required protection levels by the industry. Cabinet-free configurations must be rugged, made with metal or plastic reinforced enclosure, making them resistant to shock, vibration and dirt, as well as being watertight. Furthermore, fewer additional components are required, which saves on cabling, at the same time not compromising on response times. I/Os mounted on a conveyor in an automotive assembly plant must withstand the vibrations and continue to operate without failure.

Machine-level I/O adds intelligence

In the absence of the controller, at least the I/Os are required at machine level in different configurations. Sometimes in a modular fashion with them assembled with the right amount of I/O for that part of the KEYWORDS: I/O devices, I/O machine or as blocks of I/Os spread out modules as required. Input/output devices can be rugged enough for machine Machine mount I/Os are expected to mounting. support simple digital and analog inputs I/O devices can include and outputs and other modules with intelligence to support other intelligence built in like motor starters, devices. variable speed drives (VSDs), communiCONSIDER THIS cation modules and radio frequency idenHow will more advanced I/O tification (RFID) tag readers. Integrated devices help your applications? safety is another aspect that is important ONLINE for, such systems instead of hardwired If reading from the digital solutions or separate systems that are edition, click on the headline for cumbersome and difficult to maintain. more resources. There are applications where the I/O www.controleng.com/magazine must be mounted of on machines that Find related New Products for move at higher speeds where the weight Engineers at www.controleng.com/NPE of the I/O is important so it does not add

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Simatic DP, ET 200eco PN, F-DI 8x24V /F-DQ 3x24V 2A , M12 PROFIsafe, up to PL E (ISO 13849), up to SIL 3 (IEC 61508), protection IP65/67 is a distributed fail-safe peripheral module from Siemens, particularly suitable for use in harsh industrial environments. Courtesy: Siemens Industry Inc.

to the inertia. I/O mounted on a fast-moving robot arm must be lighter in weight yet rugged and have protection against dust and moisture. Support for all basic functional modules like discrete and analog modules are a must. In addition, the option to connect multivendor sensors and actuators on standardized I/O technologies is a strong advantage. The blocks must be mounted on limited space available on such machines, and it is important they can be mounted in any orientation unlike cabinet mount I/O.

Environmentally rugged

Sometimes, I/O are required to be mounted outdoors like a loading bay where the inbound and outbound logistics are handled in a manufacturing environment. This requires the blocks to be made with metallic casing that are of rugged construction, resistant to UV exposure, and withstand higher ambient temperature range. No matter the application, all such I/Os must be capable of reporting faults on the module and bring extensive diagnostics information to the controller. The I/Os also must support protocols used in industry for field bus connections. The machine builder benefits from smaller machine concepts, material savings, planning and engineering effort with machine mount I/O. ce

Raj Rajendra is a product consultant/manager with Siemens Industry Inc. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com. www.controleng.com

ANSWERS

I/O MODULES, ETHERNET SAFETY Christiane Hammel, EtherCAT Technology Group

Safety over EtherCAT conformance test benefits The Safety over EtherCAT (FSoE) conformance test is required for manufacturer to prove the safety of a device, and increases reliability, freedom from errors and interoperability of secure communication.

n industrial safety applications where life and limb are at stake, or where valuable machines and manufactured goods require protection, safety devices help ensure the necessary safety measures in the field. In the event of a fault, they trigger mechanisms at lightning speed such as forcing an emergency stop of a machine to ensure the safety of the application and, above all, the operator. To confirm this high level of safety, the manufacturers of these devices are subject to official requirements during development, testing and implementation. Certified safety devices include safety I/O modules, safety programmable logic controllers (PLCs), drive controllers, encoders, and programming software for safety. The EtherCAT Technology Group (ETG) offers manufacturers of Safety over EtherCAT (abbreviated FSoE for FailSafe over EtherCAT) devices an ecosystem with a wide range of support services such as tools, tests, documents and consultation. The central component of these support services is the FSoE Conformance Test, which is mandatory for manufacturers.

Is a conformance test mandatory?

The development of functional safety devices is associated with a rigorous formal effort, which on the one hand results in high quality hardware and software, and on the other hand also ensures verifiability. Finally, before the market launch, a recognized test center must prove the entire implementation meets the requirements of the desired safety integrity level (SIL). In addition to the actual safety-relevant function of the application (such as safe emergency stop or safely limited speed for a drive), proof must also be provided for the reliable and standard-compliant implementation of the Safety over EtherCAT protocol. One option for this is theFSoE Conformance Test, which is carried out by an officially recognized FSoE test service provider in the EtherCAT Test Center. According to the FSoE Policy, each manufacturer is obliged to perform this test, which in itself already constitutes a subset of the formally required proof overall. Even if the FSoE Conformance Test only repre-

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KEYWORDS: Ethernet,

EtherCAT The EtherCAT Technology Group (ETG) offers manufacturers of Safety over EtherCAT (FSoE) devices a conformance test. The test is required for safety device manufacturers to ensure they are in compliance with safety standards. Workshops and plug fests can help manufacturers in the planning, development and testing of FSoE devices.

ONLINE Learn more about FSoE at www.ethercat.org/en/ safety.html

CONSIDER THIS What benefits could your plant get from FSoE devices?

Figure 1: Acceptance process for Safety over EtherCAT (FSoE). Figures courtesy: EtherCAT Technology Group www.controleng.com

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I/O MODULES, ETHERNET SAFETY table also has been approved by TÜV and covers the tests for FSoE slaves as well as masters, enabling every device manufacturer to implement it in their own test environment. Through the integration of these tests into the EtherCAT Conformance Test Tool (CTT), the tests can also be automated and performed in a repeatable manner. This also is done during the official FSoE Conformance Test and serves device manufacturers during the development and integration of the FSoE stack into their devices and, in preparation for acceptance in the EtherCAT Test Center.

EtherCAT interoperability tests

Figure 2: FSoE Conformance Test Tool (CTT) for automatic verification and conformance test.

sents a relatively small part of the obligation to prove the safety of a device, it nevertheless provides great added value for the manufacturer – especially in connection with the other test options offered by ETG. The conformance test increases the reliability, freedom from errors and interoperability of secure communication and ultimately customer satisfaction.

What is an FSoE Conformance Test?

The prerequisite for the FSoE Conformance Test is the EtherCAT Conformance Test, which checks if the basic EtherCAT implementation works reliably. If not, and if errors already occur in the underlying communication, the safety function is often triggered in a machine, which makes it a supposedly safe machine, but drastically reduces its availability and throughput. If the device passes the test for the EtherCAT protocol, the conformance test checks the implementation and integration of the FSoE protocol. In Germany, the FSoE Conformance Test is carried out by TÜV Süd Rail, which is recognized as one of the world’s leading institutions in industrial device testing and verification. The test is also internationally recognized by other test facilities commissioned by the manufacturer for the overall verification, such as TÜV Nord or TÜV Rheinland. In addition, the FSoE Conformance Test is based on a world of specifications already confirmed by TÜV Süd: The FSoE specification ETG.5100 was certified in 2005 and has been part of the international standard IEC 61784-3 FSCP 12 (Functional Safety Communication Profile) since 2010. The ETG.7100 test definition in the form of a test

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The EtherCAT Technology Group offers manufacturers additional assistance in the planning, development and testing of FSoE devices. An important document is the Safety over EtherCAT Implementation Guide, which provides relevant information for implementation best practices. It contains all references to specifications and documents as well as the available facilities for training, support, development products and services and testing. In addition, developers have the opportunity to participate in EtherCAT plug fests, which take place worldwide several times a year and are considered a pragmatic approach to testing the functionality and interoperability of their own devices and stacks with those of other manufacturers. In addition EtherCAT plug fests, where tests specific to both EtherCAT and FSoE protocol can be performed and questions can be answered, there is a special plug fest once a year for only FSoE device manufacturers. The interoperability of FSoE slaves, masters and configuration tools is tested here. At plug fests manufacturers can validate their own implementations in the prototype stage and prepare for the EtherCAT and FSoE Conformance Test. As with the EtherCAT base protocol, the EtherCAT Technology Group offers an ecosystem around FSoE implementation, testing and release. The organization’s goal is to support manufacturers of FSoE devices in realizing implementation as quickly and successfully as possible and to go through the acceptance process as smoothly as possible.

FSoE testing process

The FSoE conformance test is carried out by TÜV Süd Rail at the EtherCAT Test Center in Nuremberg, Germany. There, the device manufacturer can have the EtherCAT Conformance Test, which is mandatory as a basis for general EtherCAT implementation, done in one day. If this test is passed, the FSoE Conformance Test is usually performed the following day. ce

Christiane Hammel is public relations at EtherCAT Technology Group, Nuremberg, Germany. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com. www.controleng.com

ANSWERS

INDUSTRIAL VALVES Matthew Glicksman, Festo

Five tips for selecting the correct process valve Choosing an industrial valve for process applications depends on a variety of parameters: Use these five tips to help with process valve selection.

any times, the choice of valve type – ball, butterfly, gate, angle seat, or solenoid – rests on installed base or tradition. For example, a water treatment facility tends to use butterfly and gate valves for cost effective throughput. Some applications fall into a gray area where multiple valve types could fulfill the application’s requirements. In these cases, there is not always a right answer or a clear preference for industrial process valve selection. Below are five tips and tricks to help determine which process valve is most suitable based on a variety of parameters. The comparison between valve types is intended to be a guideline for most general-purpose applications and may not apply to more unique or extreme conditions.

TIP 1: Butterfly and gate valves are typically the best fit for lines greater than 2 in.

The principal reason to consider butterfly and gate valves for pipes 2 in. and larger is because these valves scale up to larger sizes more cost effective than ball, angle seat, and solenoid valves. Butterfly valves have the best price of the two, and they are the easiest and most cost-effective to automate. Gate valves, on the other hand, are best for slurry, sludge, high particulate media and proportional control valve applications. With this article online, see how the two standard industrial valves compare in relative terms to important considerations for automated applications.

TIP 2: For high pressure and high temperature, ball and angle seat valves have a clear advantage

As pressure and/or temperature increases, ball and angle seat valves provide an overall advantage due to the standardization on highly-resilient materials like stainless steel housings and polytetrafluoroethylene (PTFE) seats. PTFE is a plastic said to have a low coefficient of friction and good

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insulating properties. However, the larger an angle seat valve becomes, the lower its pressure rating, losing some of its advantage in this category. See Figure 2, also with this article online.

TIP 3: Angle seat and solenoid valves are tops in terms of number of cycles

For high-cycle-rate applications, like filling machines, start by exploring angle seat valves for pneumatic automation and solenoid valves for electric automation. These have the highest lifecycle ratings, while ball and butterfly valves have the lowest. In applications where the valve may only open a few times per day, the number of life cycles are less of priority, and ball and butterfly valves can be still a good choice.

TIP 4: For small footprint, look at angle seat and solenoid valves

When size or weight is an issue – skid applications, for example ‒ angle seat and solenoid valves offer an advantage for automated solutions due to their compact nature with integrated actuating mechanisms.

TIP 5: The fastest valve on the block is the angle seat

The design and internal actuation make the angle seat the best selection for fast open and close rates. These valves often are found in high-speed filling applications to provide precise and accurate volumes. ce

Matthew Glicksman is product manager – process automation, Festo. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com.

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KEYWORDS: Industrial process valves, valve selection tips Choosing and industrial valve depends on the application. Sometimes more than one valve type can be used. Tips can help break the tie in selecting the best industrial valve. See tables online. CONSIDER THIS Industrial process valve selection tips can help in choosing the best valve for the application.

ONLINE If reading from the digital edition, click on the headline for more resources. www.controleng.com/magazine Valve testing: Understand partial-stroke testing www.controleng.com/ process-manufacturing/ sensors-actuators

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ANSWERS

AVOID SYSTEM INTEGRATION ERRORS Jon Breen, Breen Machine Automation Services

Five tips for effectively drawing electrical schematics Industrial automation schematics drawings communicate design intent from the engineer to the assembler, troubleshooter and maintainer. See five tips on making electrical schematic drawings better for easier system integration.

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After creating a drawing set, save it for future use

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as a template.

very piece of industrial automation will have schematics (we hope!) These drawings communicate design intent from the engineer to the assembler, troubleshooter and person doing maintenance. With pages showing power distribution, input/output (I/O), and safety circuits, a well-organized print set can be invaluable for the life of the equipment. Knowing how important these are, it’s surprising how few resources are available for a professional to learn how to create schematics. In my experience, most of industry draws schematics with AutoCAD LT from Autodesk. I learned to use AutoCAD in college drawing 2D representations of mechanical parts. I wasn’t well prepared for electrical schematics in industrial automation when I entered the workforce. Architectural courses are on the internet, but learning to draw toilets and countertops doesn’t really close the gap. After years of trial and error, reading and modifying other people’s drawings, and mentorship, I finally developed a process and skillset to produce schematics cleanly, efficiently, and with

an eye towards the future. For those seeking to improve their skillset, consider five tips to learn with less frustration.

1. Keep automation design simple

The first rule is to keep it simple. A lot of details could be included in a schematic – for example: every wire color, gauge, rating – but if the detail isn’t necessary, it’s just visual clutter. It’s important for a technician to be able to quickly understand the machine by paging through these drawings, and more detail makes it harder to understand at a glance. Sometimes a detail like wire color is helpful in the schematics, and gauge is better left for a pull sheet. Sometimes wire color can be safely assumed, as with blue and white/blue for 24 V dc and 0 V dc, respectively. Depending on context, those details can be omitted.

2. Leave space in automation design drawings

I often see drawings with every page chock full of devices and wires, and page numbers laid out consecutively with no empty pages left. This is harder to read because of the density; it also leaves no room for future changes. These drawings need to support the machine for its whole life – easily 20-30 years where the control system is concerned, and well beyond if the control system gets updated. If a page seemslooks like it’s going to get crowded with devices, spread those devices over more pages. And leave unused page numbers for each section of the schematic – power distribution, input/output (I/O) information, drives, etc. Someone may need to add an I/O module and a drive in the future.

Schematic drawing communicate design intent from the engineer to the assembler, troubleshooter and person doing maintenance. Courtesy: Breen Machine Automation Services

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3. Provide enough realism in automation designs

Prints should not be photo realistic representations of the part we’re drawing, but adding detail to components helps them be quickly identified. For example, a schematic representation of a servo drive may start with a rough drawing of how the drive actually looks followed by adding terminals for the sake of the schematics. Many times, a dwg/dxf file can be downloaded from the manufacturer’s website to provide a good starting point. If you decide to use these drawings, it’s good practice to simplify by deleting unnecessary details/extra lines and colors. Don’t forget the first rule when applying this one. Keep it simple.

4. Reusable blocks

of automation design

AutoCAD supports reusing chunks of drawings with what they call “blocks.” The architects use these to add toilets to their drawings without having to draw the toilet every time. We use blocks to add things like proximity switches, PLCs, drives, and panel components. Almost every device in my drawings is a block. This saves considerable time and brings a level of uniformity to the drawings. Blocks can be purchased for this type of drawing, but it’s better to make your own so they all feel like

they belong together. If your company has existing drawings or blocks, use those as a starting point.

5. Use a template for

automation design

It’s hard to start with a blank page. After you’ve gone through the effort of making a drawing set, save it for future use as a template. It doesn’t have to be a special template file. Just keep one of each type of drawing in a folder somewhere and copy that whole folder when starting a new project. Doing so fills in the title sheet, power distribution, I/O, drives, etc., saving time. Just adjust the information to the new design. It’s good practice to delete any customer-specific information before saving the template set to avoid any chance of information accidently going to a different system integration or automated machine design customer. ce

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KEYWORDS: industrial automation, electrical schematics, system integration Drawing electrical schematics is a time-consuming process, but there are ways to make it easier. Keeping the drawings simple and leaving space for changes are good first steps. Work with an established template to make subsequent drawings easier. ONLINE Read this article online at www.controleng.com for more from Jon Breen on programmable controllers and ladder logic.

CONSIDER THIS What processes have you found effective in drawing electrical schematics?

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

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IIoT Inventory Management Troubleshooting techniques for motors

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ANSWERS

AVOID SYSTEM INTEGRATION ERRORS Joe Martin, MartinCSI

System integration project management, trust, pitfalls Project management for system integration projects may need to overcome frustration, anxiety and resentment to build trust. Project documentation, project communications, and project planning help with system integration project management.

hen working on a system integration project, it’s easy to find refuge in the engineering world where outcomes result from hardened formulas, natural laws and proven processes. Doing so may sidestep the more abstract, but critical practices of preparation, communications and documentation for system integration project management. Preparation, communications and documentation practices are central to successful professional engagements for engineers learning about system integration project management. When it comes to working well with others, these practices create a three-legged stool of trust. Deficiencies in any leg manifests emotionally, typically as frustration, anxiety or resentment about the system integration project. Any one of these pitfalls can erode trust.

System integration project management: Three emotions

Three common emotions in system integration project management are: 1. Frustration: Those involved may think there’s a better (or faster) way, and as a result, assume something is wrong and, therefore, someone is to blame. Sometimes this feels like anger. 2. Anxiety: Circular thinking that occurs when we’re unsure about an outcome. This can turn into fear once we can be specific about the outcome. 3. Resentment: It rears its ugly head when we think we’re being treated unfairly. This can result in an antagonist relationship where those involved never discover the reasons for the animosity.

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Trust is built and maintained through critical project management practices including project documentation, communication, and project planning.

System integration project documentation

We’re going to start at the end. Documentation serves as everlasting evidence of work done and therefore must be self-explaining. Consider the reader as an inexperienced technician at 2 a.m. troubleshooting a system using only the documentation. One technique is, at the beginning of the project, create a checklist of sorts, as the system engineering, fabrication and commissioning progresses. Include part numbers, process steps, engineering calculations, system features, manual/automatic/ maintenance operations, etc. Another tip is to keep a separate notebook during the project for snippets of text, screenshots and code that serve as reminders to go back and complete sections of text. Finally, type a comment on every rung of logic or every line of structure text. Try not to overthink this as it can be polished and reordered later. Photographs, screenshots and drawings can often replace paragraphs of text. They should be labeled and annotated so the text can make proper reference. Sometimes a picture or drawing can eliminate unforeseen questions and confusion when working in the field.

Project communications for system integration

Project management improves when all involved are intentional about communications. That advice is meant to be literal. Think about the surgical suite where everyone is masked, gowned and gloved. Requests are made simple and clear. They are confirmed by the person responding. Most surgeons www.controleng.com

Project management for system integration projects may need to overcome frustration, anxiety and resentment to build trust. Project documentation, project communications, and project planning help with system integration project management, according to MartinCSI, a CSIA Certified control systems integrator in Central Ohio. Courtesy: MartinCSI

will verbalize what they are doing, or intend to do, for all to hear. Everyone is aware of what’s happening in real time. In such an environment, clarifications or corrections can be made in real time, often before something happens. Regardless of project leader, manager or engineer, everyone needs to be on the same page. Stating “I intend to…” lets everyone know what’s going to happen next and gives them a chance to react. For more on this, see “Turn the Ship Around,” a book by David Marquet from Penguin Random House. It’s a true story about using this communications style to create an award-winning environment on a submarine.

Project preparation for system integration

When preparing for an upcoming system integration project, focus on what success looks like. How does quality documentation and unified communications fit into a successful pre-bid meeting look like? What does a successful award meeting look like? What does a successful kickoff meeting look like? Asking the questions helps shape the outcome. Knowing the expected level of communications and documentation, be prepared to explain in detail throughout the system integration project. Consider modeling it (leading by example). Also, consider expectations and declare them in writing. Think about what a “quality” job looks like and take the time to describe it on paper. Consider what expectation is the most important and explain it as the mission. If you want to be hands off, put it in writing with parameters set. Identify the project team and each person’s role. Include contact information and what kind of decisions that person can make. Expected perfor-

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Prepare a method to identify what things are slipping and determine how

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they will be resolved.

mance criteria would be helpful to have in writing but also have a discussion so the person can repeat it. Don’t fret about things that slip through the cracks because some things will. Instead, prepare a method to identify what things are slipping and determine how they will be resolved.

Project preparation helps overcome frustration

Engineers don’t always realize when emotions are triggered while pursuing technical endeavors. Frustration, anxiety and resentment create additional difficulties and cloud thinking. With appropriate preparation, communication and documentation, trust is created and upheld on system integration projects. Being mindful and deliberate in system integration project managements helps avoid producing future project pitfalls. ce

Joe Martin is founder and president of MartinCSI, and a Control Engineering Editorial Advisory Board member. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com.

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KEYWORDS: System

integration, project management Managing system integration projects requires documentation, communication, and planning System integration projects should avoid frustration, anxiety, and resentment.

CONSIDER THIS How should your next system integration project differ from your last one?

ONLINE If reading from the digital edition, click on the headline for more resources, including MartinCSI’s listing in the Global System Integrator Database. www.controleng.com/magazine www.MartinCSI.com

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ANSWERS

INSIDE PROCESS: SAFETY Scott Hayes, Maverick Technologies

Separating process control and safety systems Keeping process control and safety systems separate is crucial, but knowing what to separate and integrate and why is critical. Learn about safety instrumented function (SIF) and layers of protection analysis (LOPA).

rocess safety functions help prevent unplanned substance releases (such as hazardous material) that could result in a major incident. For instance, an operator interacts with a control system – typically a distributed control system (DCS) or programmable logic controller (PLC) – to control a chemical process. If a hazard occurs and the control system can’t achieve the required risk reduction on its own, a safety instrumented function (SIF) is implemented to reduce the hazardous risk to an acceptable level. This application of separate layers of protection to reduce the risk of a hazardous event is often called layers of protection analysis (LOPA). If one protection layer fails to mitigate the occurring hazard, an additional layer is added.

Degrees of separation for control and safety systems

An ongoing process safety discussion centers around the degrees of separation required between

the layers of the control system and the safety functions. Keeping process control and safety systems separate is important, and various industry standards (ANSI/ISA-84.01/IEC 61511, Functional Safety – Safety Instrumented Systems for the Process Industry Sector, Parts 1-3) require it. How separate is separate, though? A strict interpretation would be to use a safety instrumented function (SIF) with disparate devices, such as different transmitters, logic solvers and final elements from different manufacturers and programmed by different individuals. In a simple example, a control system fills a tank with a level transmitter and control valve on the fill line. An SIF could be added to prevent overflow that includes a separate level transmitter, a separate logic solver and a separate valve to stop the inlet flow. While these layers of protection are independent of each other, but common failures can still occur that could prevent both level transmitters from working. What if the tank was intended to be a certain capacity but was changed to a smaller capacity at some point? Both transmitters could have an incorrect range, though. This common cause failure could occur even if the transmitters included different sensing technologies and were calibrated by different people.

2 failure types defined: Common cause, common mode

According to industry standards, an analysis is required to confirm protection layers are independent. This analysis determines whether the overall required risk reduction is achieved. It looks at two types of failures:

If a hazard occurs and the control system can’t achieve the required risk reduction on its own, a safety instrumented function (SIF) is implemented to reduce the hazardous risk to an acceptable level. Courtesy: Maverick Technologies

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• Common cause failures, which occur when multiple (often identical) components fail due to shared causes. Typical examples of shared causes include impact, vibration, temperature, contaminants, miscalibration and improper maintenance. www.controleng.com

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ANSWERS

INSIDE PROCESS: SAFETY • Common mode failures, which occur when several subsystems fail in the same way for the same reason.

Know when to integrate process safety functions

Are there advantages to integrating the separate process safety functions? In the earlier simple example, if both level transmitters are shared between the two logic solvers, the following advantages are possible:

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Integrated alarms and actions provide a clear picture of the process. A common system can increase operator understanding of performance.

• Simulation ease – It is easier to simulate the entire system.

• Either process transmitter crossing the safe setpoint could close both valves.

• Minimal training – If the design environments are integrated, fewer trained resources are requireds.

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ONLINE

Go to www.controleng.com for more stories about process safety under the process manufacturing section.

CONSIDER THIS What challenges have you encountered with process control system integration and how have you overcome them?

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• Integrated action – If a safety function is tripped, what else needs to happen? Integrating allows easier programming of other actions like stopping pumps or parking columns after the trip occurs.

• The two measurements can be compared and even a minor discrepancy can be brought to the operator’s attention. This could allow a faulty transmitter to be replaced or other action taken before the problem in the process even begins.

Certain safety precautions are prudent when sharing instrumentation. For instance, the process transmitters should be powered by and wired to the process safety logic solver. The measurement can be communicated to the process control system for control or interlock action. If the communication fails (even if it is hardwired), the control system should still take the safe action. Most companies and experts agree that integrating or sharing transmitters is acceptable, if correctly analyzed and implemented. The topic gets more heated when discussing integrating the logic solvers. Some people believe in the stricter interpretation to keep the process conKEYWORDS: process safety, process manufacturing, trol and safety systems separate with system integration different manufacturers. Others believe Process safety functions help one manufacturer can provide both, prevent unplanned hazardousbut in separate processors, on the same substance releases that could network and with the same operator result in a major safety incident. visibility. Many factors affect the safety of an integrated control and safety Some feel a separate programming system solution. environment is required, while others Process safety system and do not. Some even propose the sepacontrol integration should involve rate functions be executed on the same a trained safety professional. redundant processors.

• Improved (or better) operator experience – Integrated alarms and actions provide a clear picture of the whole process. A common system can allow the operator to better understand the way the system performs.

5 advantages of integrated control and safety systems

Many factors affect the safety of an integrated process control and safety system solution. If the risks and failure modes and causes are analyzed and found acceptable, there are advantages including:

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• Ease of maintenance – More common spare parts and equipment simplify and improve maintenance activities.

2 areas of caution with integrated control and safety systems

The biggest issues, however, with integrating control and safety systems, include: • Common cause failures – The risk that a failure in the control system will also affect the safety system. These common cause failures can take many forms: – Hardware – Failure of a component – Software – A firmware or application bug could have the same effect on separate logic solvers. • Operating and engineering discipline – If the systems are integrated, the programming is more likely to inadvertently change a safety protection. The same is true for technicians working on a transmitter. The bottom line is integrating control and safety systems is possible and has many advantages, but facilities should carefully weigh the pros and cons. Regardless of the safety system and solutions used, consider consulting a trained safety professional who understands the process standards requirements and can perform an upfront process safety analysis and make recommendations regarding the complicated required protection layers and devices. ce

Scott Hayes is a program manager at Maverick Technologies, a CFE Media content partner. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com. www.controleng.com

ANSWERS

INSIDE PROCESS: LOWER COVID-19 RISK By Michael McEnery, PE; McEnery Automation

How to reduce pandemic risk with batch automation Investing in batch automation to limit your facility’s risk in a future pandemic will most likely pay for itself in many ways that were not originally considered.

he effects of the COVID-19 pandemic on the manufacturing industry illustrates the need to move operators away from the process equipment and into a controlled, and possibly remote location. Automated batch control systems can meet this need while providing additional benefits to manufacturing plants willing to invest in them. The most significant benefit may be enabling a workforce transformation when operators stop performing physical tasks and are given digital tools to improve process performance. As the COVID-19 fallout has shown, significant ways to reduce risk and keep businesses operating safely during a pandemic is to reduce the overall number of people within an area, maintain safe distances between people, and keep all common worksurfaces cleaned and sanitized. Therefore, it would benefit manufacturers to reduce the number of operators physically required for a process, increase the flexibility of operator location while performing tasks and reducing hands-on operator activities. Automated batch systems can address each of these and can provide additional benefits to assist with project justification return on investment (ROI). These include improved personnel safety, material tracking and tracing, regulatory reporting, reduced opportunities for operator error, increased production throughput, increased product consistency and quality, increased energy efficiency, reduced material costs and increased profits. A significant long-term benefit is that by moving operators away from the process equipment and reducing repetitive and physically demanding tasks, and by providing modern control software tools for their use, it provides an opportunity to transform the role of the operators. It empowers them to identify ways to improve process efficiencies, prevent shutdowns and improve product quality.

process area input/output (I/O) devices on the HMI graphics, operators can monitor and control batch system equipment from a control room environment, or any other location away from the process equipment. This allows companies to space employees away from each other as well as removing the operator from the process area environment. This can reduce safety issues related to slips and falls, or health issues related to exposure to chemicals, dust, loud noise or hazardous equipment. It also can lead to a more productive employee by providing a comfortable atmosphere to work and think. Tablet PCs can increase the flexibility of the operator’s location and reduce sharing computer equipment and are sanitized between shifts. While operators are in process areas, which will always be required to some extent, taking this portable HMI with them will provide real-time batch and equipment status. Figure 1: A typical human-machine interface (HMI) graphic for a batch vessel using ISA101 Best Practices, which includes a small trend chart available as a popup for operators to monitor PID loop performance. Courtesy: McEnery Automation

HMIs enable remote and safer working

Transitioning to human-machine interfaces (HMIs) is key to allowing operators to work from a remote location. By displaying information from

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INSIDE PROCESS: LOWER COVID-19 RISK

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Modern batch control systems also present process information on the HMIs in an intuitive manner to allow operators and maintenance technicians to observe process upsets, manage alarms and address equipment performance issues before these cause downtime or quality issues.

Batch automation often requires significant

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modifications to the process equipment. Procedural control

Manual batch systems typically have variability in the procedure used by individual operators, which can be eliminated by an automated system. Examples of this include starting, stopping and setpoints for auxiliary equipment such as mixing, recirculation, heating and cooling. These can introduce quality concerns, which can cause scrap, slow production times and customer satisfaction problems. Other factors that can be controlled to reduce product variability include the rate of material additions and the order in which ingredients are added.

Safety benefits from process equipment modifications

Batch automation often requires significant modifications to the process equipment. For example, automatic additions of ingredients currently added by hand may require the installation of new hoppers or tanks loaded from supersacks or totes. Piping changes may be required to add flowmeters for individual ingredients and control valves for each flow path. Accommodations to existing tanks will likely be required, such as adding placing tanks on load cells, and adding level, temperature, pH and pressure sensors. While these equipment changes may be an expensive upfront cost, they may provide safety benefits significant enough to justify the project. These systems will likely eliminate repetitive heavy lifting or the need for an operator to be working on a platform and climbing stairs. It also can limit exposure to dust, chemicals or hazardous locations.

Information systems

Another significant benefit of batch automation is capturing and storing process data for use throughout the production and business enterprise. Engineering can use data to improve equip-

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ment design and operation. Production can use it for scheduling, material tracking and inventory management. Quality assurance (QA) can use it to ensure product quality, material tracing and regulatory documentation. Maintenance can use it for scheduling preventive and predictive maintenance. Most importantly, this data is available to the process operators. Software tools can present this information in meaningful ways in real time, allowing them to observe in detail how the process is running, what has gone wrong, what is about to go wrong and how to improve it. Because operators no longer have to spend their day on the plant floor using their body to start and stop pumps, open and close valves and lift bags and buckets of ingredients, they can dedicate significant amounts of time and effort to putting their minds to work at improving the process instead.

moving operators away from the process equipment, allowing them to stop performing physical tasks, and empowering them to improve process performance with new digital tools. This approach allows them to become proactive thinkers and becoming a huge asset to the company. ce

Michael McEnery is president of McEnery Automation, a certified member of the Control System Integrators Association (CSIA). Edited by Jack Smith, content manager, CFE Media and Technology, jsmith@cfemedia.com.

Reducing risk and transforming a workforce

Automating a batch process provides benefits at many levels. Investing in batch automation to limit the facility’s risk in a future pandemic will most likely pay for itself in many ways that weren’t originally considered. The most significant benefit is likely enabling a workforce transformation by

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KEYWORDS: COVID-19, batch

manufacturing, automated batch control systems It would benefit manufacturers to reduce the number of operators physically required for a process. Moving operators away from the process equipment and reducing repetitive and physically demanding tasks empowers them to identify ways to improve process efficiencies, prevent shutdowns and improve product quality. Automated batch systems control most ingredient additions and can provide increased consistency and accuracy of additions.

CONSIDER THIS Has your facility considered ways to reduce the overall number of people within an area, maintain safe distances between people, and keep all common worksurfaces cleaned and sanitized? control engineering

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ANSWERS

INSIDE PROCESS: PROCESS SIMULATION Philip Lyman, CRB

Process simulation benefits for manufacturers Process simulation can be an invaluable tool to compare alternatives and justify the cost for manufacturing and manufacturing-related processes.

imulation is sometimes used interchangeably with modeling, but simulation is the result of running a model. The model comes first; that model is then used to perform simulation studies. Typically, a process model is used to either reproduce a historical period (for validation purposes) or to extrapolate data to predict the future (for what-if studies). Users may perform many simulations with a single model exploring additional alternatives or replication with each simulation. The main purpose of the computer model for manufacturing and manufacturing-related processes, such as batch documentation, material replenishment/warehousing, and quality testing

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A good model is a simplified version of the true system that captures essential relation-

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ships, leaving out unimportant details.

A process model is a computer representation of a real-world system or process. Images courtesy: CRB

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laboratories is to act as a substitute (from a behavioral standpoint) for the real thing. It may be too expensive or disruptive to experiment on the real process; or perhaps the real process does not yet exist and is still being designed. Regardless of the scenario, a computer model can perform experiments or “what-if ” studies that can add to the understanding of the real-world system and can identify and compare alternatives that improve the system in some way, usually to reduce costs or increase the throughput. Another argument for using computer-based modeling is that the real-world system is often very complicated involving many interactions between variables that may be unknown or poorly defined with significant variability that tends to hide the underlying relationships. A good model is a simplified version of the true system that captures the essential relationships while leaving out unimportant details. If variability exists and can be quantified, then this can be included in the model to provide a more realistic result.

Benefits of simulation

With these definitions of process modeling and simulation, what benefits can we expect from this technology? There are two ways where it really shines: Design phase – The facility is being designed or will soon be designed. It’s best to start as early as possible in the design process. Changes to the design, prompted by process simulation results, are more cheaply made early in the design. Renovation – A facility exists already and it needs to be improved in some way. Typical objectives are increasing throughput, reduce manufacturing costs, lower inventories or some combination of these. The improvements that come out of a study for an existing facility may or may not include equipment changes. Sometimes improvements can be made simply by changing the operating procedures or product scheduling alone. www.controleng.com

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A process model can be used to evaluate alternatives, ensure changes are cost effective and

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maintain desired throughput. Simulation used in the design phase or new facility

Process modeling of a new design can provide the right number and size of necessary processing and supporting equipment. This is particularly valuable for equipment shared by multiple-unit procedures such as clean-in-place (CIP) skids, utility system designs and powder bins and tablet totes in an oral solid dosage (OSD) facility. The overall production process may have an equipment bottleneck; the model will identify the bottleneck and ensure it does not constrain production to a value less than the business objectives for the facility. The model also will examine other potential bottlenecks. If their constraint is close to the desired bottleneck, then schedule disruptions or other variability may result in a constraint lower than the design, effectively substituting a more restrictive bottleneck for the desired one. Changes occur frequently during the design process. Engineers find better alternatives and management may change the product mix of volumes the facility will be expected to make. In these instances, having a process model of the design is especially beneficial. The model can be used to evaluate the alternatives and ensure the changes are cost effective while maintaining the desired throughput. Staffing levels and shift schedules also can be compared with a model. This helps with cost justification of the design change.

Modeling during facility renovation

A model of an existing facility can provide the same benefits as in a design model with two important differences. First, there is historical data that can be used to give a better model and to validate the performance of the model against. This helps to prevent process modeling errors and provides greater confidence in the model results. Secondly, the model is more likely to be used for operational decisions, such as production schedules and shift schedules. Equipment changes are still possible, but the scale of the possible changes may be lower if the facility footprint is fixed. Intermediate inventories may be fixed for the same reason, creating other problems for manufacturing. Models of existing facilities tend to be more realistic and detailed, which requires more engineering time to build, validate and use the model.

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Process modeling of a new design can provide the right number and size of necessary processing and supporting equipment.

A process model, at the right detail level and properly validated, is a valuable tool to compare alternatives and justify their cost. These benefits apply to new facilities during the design phase and to existing facilities that need renovation or operational changes. Further benefits accrue when each facility has an up-to-date model. Usually good decisions must be made quickly and this is only possible if the time and effort has been invested in a process model beforehand. ce Philip Lyman, PhD, director, process simulation, CRB. This article originally appeared on CRB’s website. CRB is a CFE Media content partner. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.

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KEYWORDS: process simulation, process modeling Users may perform many process simulations with a single model exploring additional alternatives or replication with each simulation. Process modeling and simulation is valuable in the design phase and during renovations. A process model is a valuable tool to compare alternatives and justify project costs.

ONLINE Read this article at www.controleng.com for additional stories from CRB.

CONSIDER THIS Has your company used process simulation for a project and what were the results? control engineeering

July 2020

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IIoT and Sensing on the Edge Ryan Williams National Product Manager – Services and Solutions, Endress+Hauser USA

Smart instruments have been available since the mid-1980s when 4-20mA HART devices entered the market, quickly followed by fieldbus-based devices. These digital communication technologies made it possible for instruments to provide more than just a process signal. Using digital interfaces, these devices were now able to send status, diagnostics and other information.

Endress+Hauser estimates that of the 40 million of its process instruments installed worldwide, 90% are digital, smart devices. These smart instruments provide an incredible amount of information at “the Edge” that is of immense benefit to a wide range of host systems and IIoT applications, such as maintenance management, asset management, inventory control, MES, ERP, etc. But one major problem facing industrial plants is: How do we manage all this data? Because of the immense amount of data, and the problems involved in managing it, Endress+Hauser estimates that 97% of the data is not being used. Instead, automation systems use the flow, pressure, temperature, level and other data needed to control the process, and ignore or discard the status, diagnostic and other data. Major instrument manufacturers are aware of the problem, and several are now providing solutions to acquire data from the Edge and provide it to specialized IIoT software—all without affecting or involving the automation system. This article explains how these concepts work. Download the white paper at: https://eh.digital/39ONOe7

info.us.sc@endress.com www.us.endress.com input #15 at www.controleng.com/information

PQ Problems Affecting Your Processes? Ask EPRI! Mark Stephens and Alden Wright | EPRI PQ Services Group

Are Power Quality Issues Causing You Headaches? Is your production downtime keeping you up at night? Lightning, storms, fallen trees or tree limbs, animals—these and more cause power quality issues. EPRI’s Power Quality Services Program (PQServices@epri.com) was established to help electric utility, industrial and commercial enterprises deal with increasing numbers of process upsets as more sophisticated control systems appeared in their processes. EPRI has knowledge and expertise going back decades in conducting investigations into industrial process sensitivity and identifying methods of mitigating that sensitivity. Years of on-site investigations, laboratory testing, research, and development on the parts of many individuals have allowed EPRI to amass a huge data base of relevant information, mitigation techniques—and control design tips to reduce control system sensitivity without necessarily requiring external mitigation. EPRI offers PQ Services that include industrial facility assessments, testing, design consulting, training in power quality, process control sensitivity to PQ, mitigation methods—all super-powered through the Power Quality Investigator (PQI) expert tool. The EPRI PQ Team works with plant management, engineers, and process operators to understand shutdown issues and their relation to power quality at the facility as revealed by the available PQ data at the site. Examination of available shutdown logs and process control drawings allows specific component sensitivities to be identified as well as mitigation options. Specific components may be tested at EPRI’s laboratory to confirm PQ sensitivity and its limits. In this way, PQ mitigation solutions have been tested and their efficacy confirmed. The PQ Team not only provides recommendation for improving the facility PQ robustness, but also provides the economic analysis justifying the cost of mitigating the problem. For those interested in learning more about EPRI’s capabilities and how these may be of help to those organizations experiencing problems due to variations in power quality and their effects on process control systems, EPRI has published a white paper available through this publication outlining EPRI’s expertise, its approach to PQ facility assessments, and its tools. Download the paper at: mypq.epri.com/documents/Are_Problems_Affecting_Your_Process.pdf

EPRI | PQServices@epri.com | mypq.epri.com

input #16 at www.controleng.com/information

INNOVATIONS

NEW PRODUCTS FOR ENGINEERS

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

IIoT ecosystem for improved asset management Endress+Hauser’s Netilion Industrial Internet of Things (IIoT) solution platform is an ecosystem combining digital services and system components to improve the lifecycle and asset management, maintenance, and support of instruments and analyzers. Netilion enables users to keep track of their installed base, documentation and data management, and instruments’ performance and health status. Netilion system components such as field gates and edge devices can be used to upload installed base information and create lists of the instruments, without having to interact with the control system. These digital services can be used separately or in concert to improve the management, maintenance, and support of instrumentation systems—regardless of instrument or analyzer type or vendor. Endress+Hauser, www.us.endress.com

Input #200 at www.controleng.com/information

Industrial thin client for virtualized HMI systems

The BTC14 from Pepperl+Fuchs is a compact industrial box thin client and is designed for use in harsh industrial environments. Intel Apollo Lake and AMD Ryzen processors support modern operator workstation setups with up to four monitors. It has four DisplayPort connections for quad video applications. It also supports D++ (allows connectivity to an HDMI monitor via a passive DP-to-HDMI cable) and multi-stream transport protocol (daisy chaining multiple monitors to one display port). The thin client features the state-of-theart VisuNet RM Shell 5 firmware, the latest generation of thin client firmware for industrial-grade security and stability. It has a safe operating temperature range of -20°C to 60°C and no internal moving parts. Pepperl+Fuchs, www.pepperl-fuchs.com

Input #201 at www.controleng.com/information

Absolute encoder series for motion control applications

Applied Motion’s TruCount Encoders make use of a special energy harvesting technique to enable batteryless functionality. When power is removed from the motor and the shaft is free to turn, any movement of the motor shaft generates sufficient energy to power a dedicated electronic circuit that captures and retains the new encoder position. This can happen repeatedly and for any duration of time so that all changes in motor position are captured during power-off states. The use of these encoders in motion control reduces downtime by shortening machine power up sequences and eliminates the need for homing runs after power cycles and emergency stops. With the ability to track more than 65,000 revolutions of the motor shaft, the integrated drive electronics track the absolute position of the motor shaft over a large working range. This reduces downtime and changeover time by eliminating time-consuming homing routines, which is advantageous in numerous applications including linear actuators with long strokes. Applied Motion, www.applied-motion.com Input #203 at www.controleng.com/information

Asset performance platform with augmented reality Emerson Reliability’s Augmented reality (AR) for Plantweb Optics helps organizations improve safety, productivity, and efficiency—capturing knowledge and using it to upskill the workforce that will operate plants in the coming decades. AR helps bring personnel up to speed faster with constant, intuitive access to analytics data overlaid on the real world through mobile devices. AR for Plantweb Optics delivers situational awareness, data integration, and live remote assistance to make field operators more confident and efficient. AR for Plantweb Optics is designed to improve situational awareness with navigation tools that help users quickly locate one asset among thousands. Users also can view the field through a mobile device to see overlays that identify assets by name and provide an easily understandable health-status report. Emerson Reliability, www.emerson.com Input #202 at www.controleng.com/information

Line scan camera for machine vision applications Teledyne Dalsa’s Linea is a short-wave infrared (SWIR) line scan camera designed for machine vision applications. The Linea SWIR features a sensor in a compact package suitable for a variety of applications including food and packaged good inspection, recycling, mineral sorting and solar and silicon wafer inspection. Linea SWIR is a 1k resolution camera with 12.5 µm pixels, 40 kHz line rate, cycling mode, programmable I/Os, power over Ethernet (PoE) and precision time protocol (PTP) and more. It also has a GigE interface and selectable 8- or 12-bit output. Teledyne Dalsa, www.teledyne.com Input #204 at www.controleng.com/information

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July 2020

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INNOVATIONS

BACK TO BASICS: COVID-19 Jerry Grillo, Georgia Institute of Technology

Four recommendations for manufacturing in the pandemic As the economy grows after the COVID-19 pandemic slowdown, manufacturers face challenges and opportunities: Disaster recovery, supply chains, staffing, transparency, and investments.

s the world contemplates moves past the lockdown implemented in response to COVID-19, it’s fair to wonder what will happen as the engines that drive the manufacturing industry come back to life again. Vinod Singhal, who studies operations strategy and supply chain management at the Georgia Institute of Technology, has ideas on how to ease the transition to the new reality, though it hard to predict.

Supply chain challenges, opportunities

COVID-19 represents a new kind of mystery when it comes to something as complex and critical to the world’s economy as the global supply chain, for a number of reasons that Singhal highlighted: 1. The global spread of the virus and duration of the pandemic. “We have no idea when it will be under control and whether it will resurface,” Singhal said. “With a natural disaster you can kind of predict that if we put in some effort, within a few months we can get back to normal. But here there is a lot of uncertainty.” 2. The demand and supply side of the global supply chain are disrupted. “We’re not only seeing a lot of factories shutting down, which affects the supply side, but there are restrictions on demand, too, because you can’t just go out and shop like you used to, at least for the time being,” he said. “And all this is taking place in an environment where supply chains are fairly complex – intricate, interconnected, interdependent, and global.” 3. Longer lead times. “We get close to a trillion dollars of products annually from Asian countries, about $500 billion from China,” Singhal said. “Most are shipped by sea which requires a four-to-sixweek lead time. The fact that logistics and distribution has been disrupted and needs to ramp up again will increase lead time. So, it will take time to fill up the pipeline, and that is going to be an issue.” 4. Supply chains have little slack, and little spare inventory. While giants such as Apple, Boeing, and General Motors have more financial slack to carry them through a massive economic belt tightening, their suppliers, spread out across the globe, come in different sizes and tiers, “And these smaller companies don’t have much financial slack,” said Singhal. Singhal offered suggestions on what to address

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and how to help speed up the recovery and bring supply chains to whatever normal looks like next: 1. The ability to bring capacity online, especially for small and medium-sized companies. “Facilities and equipment may need some time to restart,” he said. “Staffing is a big issue. How quickly can you get people back to work? Can you get the raw materials and build up the inventory to support production? That may be tough when pent up demand is being released and everybody” competes for finite supplies. 2. Distribution. Lead times already are long, he notes, and a sudden increase in demand for logistics and distribution services as everybody ramps up again could extend lead times. 3. Prevent bankruptcies. Government programs need to be established (like the U.S. stimulus package) to keep small- and medium-sized firms in business. This concern extends to second- and third-tier suppliers, and large firms like Apple or Boeing or GM, should do the same for their most critical suppliers. 4. Build slack. “Preserve cash, get new lines of credit or draw down lines of credit, maybe cut dividends or stock repurchases,” Singhal said. “And build inventories of critical components.” Singhal stressed the need for supply chain transparency: “What that means is, companies need to have a good understanding of what is happening to their cusKEYWORDS: COVID-19, supply tomers and suppliers, but not just their chain, manufacturing supply chain immediate, first tier customers and suppliThe global manufacturing supply ers, but also their customers and suppliers, chain has been disrupted by the COVID-19 pandemic. and so on up and down the line.” Challenges include the global It will be very important for the next spread of the virus and the lack of several months to monitor the health of flexibility some companies have. the supply chain from both the customImprovements can be made in er perspective and a supplier perspective, distribution and building slack and because this is a new world, Singhal said, flexibility to avoid bankruptcies. who adds an optimistic postscript, “It’s a ONLINE crisis situation now, but I think we can put Learn more about the latest it back together.” ce COVID-19 developments related to

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Jerry Grillo, communications officer, Georgia Institute of Technology. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.

manufacturing at www.controleng.com.

CONSIDER THIS What do you think is the biggest challenge facing the manufacturing supply chain?

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July 2020

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EDUCATION for ENGINEERS

ONLINE COURSE: IIoT Series: Part 3: Edge, Fog and Cloud SUMMER EDITION

Motors & Drives

Big thinking on miniature circuit breakers

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Articles inside

International: ESPE, collaborative robots

International: COVID-19’s impact on Chinese automation markets

Better data during COVID-19

How to reduce pandemic risk with batch automation