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Large, small, or no screen at all, the C-more Headless HMI lets you decide

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

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Automation is easy and affordable... ...when using a controller designed that way. The CLICK PLC family provides the right amount of control for small systems and beginner projects without unnecessary cost and complexity. Low-cost hardware and FREE low-learning-curve software make CLICK the go-to choice for simple control. • Multiple stand-alone PLC units available with diﬀerent I/O conﬁgurations (relay, analog, AC or DC discrete I/O) • Support for Modbus RTU, ASCII, Modbus TCP and EtherNet/IP communication protocols • All CLICK PLC units use our FREE programming software with a simple but practical instruction set • Easy, streamlined PID gets your process under control in record time (Ethernet PLC units only) • Easily expand your CLICK PLC with snap-on I/O modules for up to an additional 128 discrete or 48 analog I/O points

“Very easy to use and interactive little PLC. Love that modules can be added to create exquisite systems. Cannot be beaten for the price. Programing is easier than Micrologix and it is free.” Joshua in LAKE LYNN, PA “Super easy to use. Ethernet setup is simple. Easy to integrate with C-more products.... you will look like an expert...” Tim in LAKEWOOD, NJ “The C0-04RTD module makes the job as easy as it could possibly be. Just connect your sensors to the inputs, and point your logic or HMI objects to the appropriate registers, and the temperatures are there. No scaling or anything else. It’s done.” Brian in TACOMA, WA “Very easy to use, powerful for the price... Programming is easy, intuitive, and help menu well done.” Sylvain in JOLY, QC

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Vol. 67 Number 8

ANSWERS

AUGUST 2020

16 | How edge computing will unleash IIoT 18 | Embedded HMIs excel in automation applications 22 | Augmented reality tools: A digital bridge for the skill gap 26 | What industrial wireless network should I use?

30 | 5G wireless for industrial use: Six answers

efficient and productive; the Industrial Internet of Things (IIoT) can help

32 | How to build a system integration business case for automation, controls

COVER: Many manufacturers use edge computing to become more make the data smarter. Courtesy: ABB

p.22

INSIGHTS 6 | Technology Update: Integrated design software lower costs, adds flexibility 8 | Technology Update: COVID-19 accelerates digital transformation 10 | Technology Update: Automation helps with COVID-19, energy efficiency, robotics, non-contact motion control, STEM NEWS

12 | COVID-19 developments and effects on engineers from the industry: Flexible and anlytical; reusable PPE; Students innovate pandemic solutions for workers; Headlines online 14 | Think Again: Hot topics in Control Engineering

p.M3

INSIDE MACHINES

M1 | Cost-effective position control boosts stepper motor performance M3 | Connect automation to the power of predictive maintenance M5 | Which IEC 61131-3 programming language is best? Part 2

CONTROL ENGINEERING (ISSN 0010-8049, Vol. 67, No. 8, GST #123397457) is published 12x per year, Monthly by CFE Media and Technology, 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 and Technology, LLC. All rights reserved. CONTROL ENGINEERING is a registered trademark of CFE Media and Technology, 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 and Technology, 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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August 2020

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input #4 at www.controleng.com/information

AUGUST 2020

INNOVATIONS NEW PRODUCTS FOR ENGINEERS

61 | Plant process management software;

Digital commissioning and turnover package; COVID-19 safety labels and signs; Customized LVDT position sensors; Inductive position sensor See more New Products for Engineers at www.controleng.com/NPE.

BACK TO BASICS

62 | Secure remote access to survive and thrive Secure remote access (SRA) is being used to help companies survive and thrive during the COVID-19 pandemic, but there are some new challenges that need to be considered. See 10 remote access best practices.

ONLINE EXCLUSIVES: Click on the headlines Extending TSN capabilities over 5G and other wireless networks

Time-sensitive networking (TSN) has gained more attention from manufacturers as capabilities like 5G become more accessible. Benefits include faster communications, better mobility and high reliability.

Dave Cavalcanti, Intel; Stephen Bush, GE; Alon Regev, Keysight Technologies

Control Engineering eBook series: Robotics eBook Summer Edition Robotics are one of the fastestgrowing industries and their impact can be felt on many manufacturing floors. There’s more to the robot, however, than what you see on the plant floor. This helpful eBook from Control Engineering and Universal Robots includes articles on robots fighting COVID-19, mitigating potential robot hazards and more. Learn more and register to download at www.controleng.com/ebooks/.

Robotic software improves robot health

Industrial robotic software, industrial networks and cloud-based technologies are helping to improve industrial robotic health, improve robotic uptime and better manage robotic assets. Mark T. Hoske, Control Engineering

NEWSLETTER: Safety & Cybersecurity • Separating process control and safety systems • Safety over EtherCAT conformance test benefits • Cybersecurity requires asset updates • Researchers develop method to recycle PPE using radiation • Phishing heads COVID-19 themed attacks. Keep up with emerging trends: subscribe. www.controleng.com/newsletters.

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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August 2020

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INSIGHTS

TECHNOLOGY UPDATE: PLM SOFTWARE Mark T. Hoske, Control Engineering

Integrated design software Product lifecycle management software (PLM) and service lifecycle management software enable digital twins, digitalization, automation design and plant design. See five digital twin attributes.

oftware can help with the collaboration of applications, Industrial Internet of Things (IIoT) and analytics, operations, manufacturing, simulation, electronics and mechanical aspects of design, according to Siemens Digital Industries Software. Product lifecycle management (PLM) software also improves the design process by inferring part relationships on the fly, improves design innovation during rapid-response development, speeds digital twin development and maintenance, uses artificial intelligence (AI) for generative material design to optimize component performance, helps with digital transformation electronic and digital designs.

M More INSIGHTS KEYWORDS: Product

lifecycle management PLM software helps integrate, eliminates waste and increases innovation. Digital twins simulate and model PLM.

CONSIDER THIS What benefits can you get by integrating PLM and digital twins?

ONLINE See more tips, images online.

PLM design collaboration

Collaborative PLM design software has been helping in a diversity of industries, including with COVID-19 vaccination development, said Tony Hemmelgarn, president and CEO of Siemens Digital Industries Software. Time to produce an experimental vaccine decreased from months or years to 42 days through use of a digital design architecture, he noted during the June Siemens Digital Industries Software’s virtual 2020 Media & Analyst Conference. Time savings result from development of a comprehensive and actionable digital twin that speed design iterations; personalized

adaptable and modern tools, and a flexible open collaborative ecosystem. Design software is helping to lower risk in restarting manufacturing with new laws and rules for a safe work environment. Stuart McCutcheon, global VP of global sales and customer success, Siemens Digital Industries Software, said digital twins create faster time to market, drive innovation, provide an adaptive response to demand as signals change, extract value from mountains of data and unite engineering disciplines from across the lifecycle driving to a common business goal. Digital twins also create the ability to be proactive to events while optimizing quality and productivity, and delivering new business models.

Five attributes of a digital twin

What is a digital twin? Beyond a virtual representation of a physical object that evolves with the lifecycle of physical objects, McCutcheon said, a digital twin also is: 1. A precise virtual representation of a physical product or process. 2. Used across its lifecycle to simulate, predict and optimize product and production systems. 3. Made of multiple representation of models for different aspects of physical behavior. 4. An evolving object with a lifecycle that needs to be managed from concept, development, verification, manufacturing, sales and support. 5. Closed-loop digital twin provides for bi-directional connectivity between the physical asset and the virtual representation.

Digitalization notes Integration of software tools are helping with the following. (See more details and benefits online.) 1. Electric-powered airplanes 2. Commercial supersonic aircraft 3. Wind power energy services 4. Rapid-start car company 5. Filling and packaging machinery manufacturer. ce Siemens Teamcenter and MindSphere and Xcelerator software products create a closed-loop digital twin across the lifecycle to correlate real-world behavior with the digital twin to optimize product design. Courtesy: Siemens Digital Industries Software

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August 2020

control engineering

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

The Plant Floor in Your Pocket Get an overview of your process at a glance. Control your SCADA with a swipe.

See the live demo now. Scan this QR code with your phone or visit demo.ia.io/engineering input #5 at www.controleng.com/information

INSIGHTS

TECHNOLOGY UPDATE Sean Callahan, Kepware

COVID-19, digital transformation Industrial organizations are realizing digital transformation value during the COVID-19 pandemic.

ow is COVID-19 affecting digital transformation? Control Engineering had questions for software connectivity company PTC about how the COVID-19 pandemic was changing digital transformation. Sean Callahan, senior director, strategic marketing for Kepware, part of PTC, provided answers about digital transformation value, enterprise-wide connectivity and Industrial Internet of Things (IIoT) proof of value.

QUESTION: How has COVID-19 impacted marketplaces, industries, and/or supply chains? Callahan: COVID-19 has been a catalyst for companies accelerating their digital transformation journeys. Industrial organizations have now seen firsthand the value that digital transformation brings when dealing with crisis situations, or when they need to rapidly make shifts in production, and are responding. Many organizations that did not undertake major digital transformation efforts ahead of the pandemic were more negatively impacted as a result. We have found that they are now evaluating and making plans to quickly implement transformative technologies in the future such as the Industrial IoT and augmented reality (AR). Demand for these technologies, as well as critical foundational technologies like enterprise-wide connectivity, continues to KEYWORDS: COVID-19, digital transformation, IIoT grow as organizations evaluate how Digital transformation and Industrial they’ll position themselves to thrive Internet of Things tools help industrial post-crisis.

M More INSIGHTS

connectivity during the COVID-19 pandemic. Two goals of digitalization are enabling remote work and remote service. Industrial connectivity tools can connect existing assets without replacing machines.

CONSIDER THIS If COVID-19 isn’t accelerating your digital transformation, what about your competitors?

ONLINE If reading from the digital edition, click on the headline for answers on the 1-3 year outlook, more details about growth, and a large graphic about connectivity and communications tools. www.controleng.com/magazine

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August 2020

Q: How will COVID-19 shape technologies, systems, people, training, processes and quality control? Callahan: The most tangible example of COVID-19 disrupting products, processes, and people is with training and digital work instructions. Facing rapid changes in demand, new social distancing measures, and the rise of remote work, industrial organizations needed new approaches to onboarding, training, upskilling, and reskilling that worked within the new normal they were facing. To maintain business continuity and help their employees navigate these challenges, manufactures are now leveraging AR to capture

control engineering

and transfer knowledge – to employees, customers, and other manufacturers. Q: How will engineering teams evolve in the coming months, using communications and productivity tools to drive efficiencies? Callahan: As organizations look to gain efficiencies, we are seeing teams from OT and IT [operational technology and information technology] groups work together more strategically, driving industrial IoT initiatives together to realize tangible business outcomes for both groups. We are also seeing a shift from a focus on “proof of concept” implementations to a focus on “proof of value.” Proof of concept implementations were typically deployed in an area of the shop floor that was less risky to test new technology on – but the problem was that with these low-risk, low-priority pilots, companies could not see the value that would be realized by scaling these to more impactful areas of the business. By shifting to a proof of value implementation, they are targeting the areas of the business where they can realize the largest impact and value. To do this successfully, they are looking for solutions they can get running quickly without disrupting the manufacturing process in the critical areas targeted for these high-value pilots. Industrial connectivity tools provide the ability to connect existing assets without replacing machines, enabling industrial organizations to demonstrate real proof of value without disrupting production on their most critical lines. Q: How will engineers help growth return? Callahan: We are seeing that manufacturing engineers are using this time to research, design, implement, and empower digital transformation strategies in their organizations. We are also seeing their organizations make commitments with global systems integrators and consultants to ensure they lock up the best resources for enabling digital transformation as soon as the economy reopens. In supporting the broader digital transformation economy, as well as strengthening their own businesses, manufacturers are leading the way to helping us return to a period of economic growth. Sean Callahan is senior director, strategic marketing for Kepware. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com. www.controleng.com

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INSIGHTS

TECHNOLOGY UPDATE Mark T. Hoske, Control Engineering

For 2020, Festo Bionic developed an autonomous flock of flying robotic birds using an indoor global positioning system to adjust as needed, said Karoline von Häfen, Festo head of bionic projects. Images courtesy: Festo

COVID-19, efficiency, robotics, non-contact motion control, STEM Automation innovation is helping with pandemic response, energy efficiency, robotics, non-contact motion control, training and science, technology, engineering and math (STEM) excitement.

lectric, pneumatic and process automation help interconnect engineering-related workers during the COVID-19 pandemic; Industry 4.0 and Industrial Internet of Things (IIoT) support and enable optimized automation architectures; bionics (robotics mimicking nature) inspire future engineers in science, technology, engineering, and math (STEM) and offer innovation to integrate into operations; training courses and automation modules help students and teachers; contactless motion control uses superconductivity. These were among innovations demonstrated by Festo in several online events in July leading up to a planned Festo North American online tradeshow Aug. 5 and 6, expected to be archived until Sept. 5 The pandemic cancelled Hannover Fair, IMTS and other shows and conferences, so Festo is sharing exhibits and trends online.

COVID-19, digitalization

Marcus Stemler, Festo product manager, digital pneumatics, said digital pneumatic valves can reduce related energy consumption up to 60% or more energy savings can result, for instance, in loading tires into a curing press, controlled by Festo Motion Terminal, said to be the first digitalized pneumatic valve terminal.

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August 2020

Dr. Frank Melzer, member of the Festo management board, product and technology management, said COVID-19 has brought many changes to private and professional lives globally. Melzer said Festo had a solid digital infrastructure and bolstered cybersecurity with installation of 6,000 virtual private network (VPN) nodes in one day. The company continued production especially for critical industries under sanitary conditions. Rapid engineering projects including face masks and emergency respirators in four weeks; parts are available to others. Festo is among companies on Germany’s Industrie 4.0 committee (with 150 companies and 600 participants), working on a future industrial framework. It’s important that systems can talk to each other to create efficiency with digital interoperability. Dr. Ansgar Kriwet, Festo member of the management board, sales, said the Hannover Fair theme this year

control engineering

would have been industrial transformation, and the coronavirus crisis shows the need for industrial transformation. This includes more home offices, higher data bandwidth and cybersecurity, safety distancing with high production efficiency and reliability. Better machine control with sensors enables more mobility. Dr. Hans Jörg Stotz, member of the management board of Festo Didactic SE, said industries need to bring digital competence to more applications with Industry 4.0 training covering technologies, business models and life-long learning. Applications include cyber-physical factories, module-based factories, and learning centers that do not disrupt production. Karoline von Häfen, Festo head of bionic projects, showed a soft robotic hand and a wrist for 12 degrees of freedom. The glove for the robotic hand has 113 tactile force sensors; a haptic glove can allow a human to feel what the robot feels, she said. At the wrist, a camera offers visual object recognition with artificial intelligence (AI) to improve learning; the robotic hand and wrist are mounted on a robot that balances and travels on a ball. For balance, a neural network system stabilizes while the robot rolls with an on-board energy supply. Humans and robots are changing to work together in workspaces, von Häfen said. Michael Schöttner, Festo head of SupraMotion, demonstrated commercialized Festo contactless motion control using superconductivity. The low-power system provides automated friction-free wireless movement, advantageous in many medical, biomedical, or pharmaceutical applications. It uses permanent magnets and superconductive cooling for precision movements. ce Mark T. Hoske is content manager, Control Engineering, CFE Media, mhoske@cfemedia.com.

M More INSIGHTS

KEYWORDS: Motion control, robotics, pneumatics COVID-19 has increased digitalization efforts. Automation, bionics (lifelike robotics) and education modules, can help STEM efforts. Non-contact motion control is commercialized. ONLINE: More photos and details with this web article. www.controleng.com

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INSIGHTS

NEWS

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

Manufacturers looking to be more flexible, analytical in wake of COVID-19

Relayr, a global Industrial Internet of Things (IIoT) company, surveyed more than 200 leaders in the U.S. and German manufacturing industries. Topics ranged from how the crisis affects their operations and how they’re dealing with challenges presented by the pandemic to their assessment of future economic development. Their six key findings from the survey were:

Reusable PPE for workers

study conducted by Georgia Tech researchers shows that ozone gas, a highly reactive chemical composed of three oxygen atoms, could provide a safe means for disinfecting certain types of personal protective equipment (PPE) that are in high demand for shielding healthcare personnel from COVID-19. The researchers, using two pathogens similar to the novel coronavirus, the study found that ozone can inactivate viruses on items such as Tyvek gowns, polycarbonate face shields, goggles, and respirator masks without damaging them — as long as they don’t include stapled-on elastic straps. The study found that the consistency and effectiveness of the ozone treatment depended on maintaining relative humidity of at least 50% in chambers used for disinfection. - John Toon, Georgia Institute for Technology

Health students use COVID-19 pandemic to innovate solutions

tudents and staff at Rice University, the Malawi University of Science and Technology (MUST) and the University of Malawi, The Polytechnic (Poly) gathered virtually for six weeks to iterate on creative devices that address the COVID-19 pandemic. Ideas had been prototyped by students in Africa at Rice 360˚’s partner design studios in Malawi and Tanzania earlier. Plans were revealed at the institute’s annual intern showcase July 16, a virtual event this year, with participants joining the Zoom session from around the world. Three of six proposals were presented at the showcase by 13 undergraduate interns and eight teaching assistants from Rice and Malawi. All were the focus of videos the multidisciplinary teams were required to produce. Presentations included a mask-disinfecting system, a walk-through decontamination unit and a “distancing” box for medical staff during patient intubation. - Mike Williams, Rice University

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control engineering

1. U.S. companies have been hit hard by the crisis: Two-thirds cited a negative impact on their business. 2. Investment behavior is curtailed: Half of the surveyed companies expected lower investments in 2020. 3. Flexibility is the new mantra: Almost 60% cited “increased flexibility” as the thing they want to improve most on. 4. Equipment-as-a-service (EaaS) models are becoming increasingly popular: This is beneficial for the supply and demand sides in the current crisis. 5. Predictive analytics, IIoT use is rising: U.S. companies are using predictive analytics more; German manufacturers are using a mix of IIoT and AI. 6. Easing of lockdown measures shows positive effects: Since some restrictions have lifted, demand has increased. ce - Edited from a relayr press release by CFE Media.

Headlines online Top five Control Engineering articles Articles about returning to the office after COVID-19, automation design software, cloud efficiency, learning ladder logic and more were Control Engineering’s five most clicked articles from July 13-19, 2020. Laser inversion enables multi-materials 3D printing Columbia university researchers develop technique enabling printing of circuit boards, electromechanical components and robots. Space-rate force/torque sensor developed for Mars 2020 Rover ATI Industrial Automation and NASA’s Jet Propulsion Laboratories (JPL) developed a custom force/torque sensor for Perseverance, the Mars 2020 Rover project. See video online. Graphene shield improves wastewater protection Rice University researchers found that a shield of graphene helps particles destroy superbugs in wastewater treatment plants. www.controleng.com

We see

plant operators ready for problems without ever experiencing one. Emerson introduces Mimic Train – a revolution in training simulation that gives plant operators dynamic, hands-on experience for unplanned events. Mimic Train is the most flexible operator training system available, customized to the needs of your plant and process. And it is cloud ready, scalable, and seamlessly integrates with DeltaV and other control systems. To see how Mimic Train can revolutionize your training, go to Emerson.com/WeSeeConfidentOperators

input #8 at www.controleng.com/information

INSIGHTS THINK AGAIN

Hot topics in Control Engineering

Research: For 2021, programmable logic controllers (PLCs), control system integration, instrumentation, industrial wireless, industrial PCs, industrial Ethernet and advanced process control are among hot topics; 18 topics are in the top 10; 62 are in the top 20.

readth of automation topical ranking follows, as engineering knowlrespondents stuffed 18 areas edge matters. Control of coverage into the top 10 and Engineering subscriban incredible 62 topics into the ers want to learn about an top 20. amazingly wide array of top18 top 10 Control ics in automation, controls, Engineering topics and instrumentation. To help prioritize Control EngineerMark T. Hoske, 1. Programmable logic ing’s 2021 editorial calendar, Content Manager controllers (PLCs) a survey asked subscribers 2. Control system to check off the most imporintegration tant topical areas of coverage. (Thanks 3. Instrumentation, industrial wireto those who participated.) The diverse less - tie 4. Industrial PCs, industrial Ethernet - tie 5. Proportional integral derivative and advanced process control KEYWORDS: Control Engineering 6. Loop control 2021 hot topics 7. Energy efficiency, drives, machine Top 5 contains seven topics. control, artificial intelligence/ Top 10 has 18 topics. machine learning (AI/ML) - tie Top 20 has 62 topics. 8. Process control, motors - tie CONSIDER THIS 9. Process sensors Contribute to industry knowledge and learn 10. Supervisory control and data from your peers at www.controleng.com. acquisition (SCADA), power supONLINE plies, COVID-19-related engineerSee some write-in comments with this ing topics - tie

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article online at www.controleng.com. Share your knowledge at: www.controleng.com/2020articles www.controleng.com/contribute

EXTRA THOUGHT The research demonstrates what I’ve heard consistently from subscribers in one form or another since I joined the team in 1994: Sometimes I don’t know what I need to know until I read it in Control Engineering. Write-in comments from the Control Engineering subscriber survey on 2021 editorial topics included: • All topics related to industrial automation. • I appreciate every topic you share. • Keep it up! • Try your best. Stay safe. Enjoy your life.

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August 2020

62 top 20 topics: Long tail of engineering interest

If you thought Control Engineering subscriber interests in automation, controls, and instrumentation might narrow after that, think again. Topics broadened considerably. To get through the top 20, when accounting for ties, subscribers ranked another 44 topics. The 2021 editorial calendar will be available soon, reflecting that wide breadth of interests, but before planning for 2021, please consider sharing your expertise with peers through 2020. Thank you to those who have. ce

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

Contributing Content Specialists Suzanne Gill, Control Engineering Europe suzanne.gill@imlgroup.co.uk Ekaterina Kosareva, Control Engineering Russia ekaterina.kosareva@fsmedia.ru Agata Abramczyk, Control Engineering Poland agata.abramczyk@trademedia.pl Lukáš Smelík, Control Engineering Czech Republic lukas.smelik@trademedia.cz Aileen Jin, Control Engineering China aileenjin@cechina.cn

Editorial Advisory Board

www.controleng.com/EAB Doug Bell, president, InterConnecting Automation, www.interconnectingautomation.com David Bishop, president and a founder Matrix Technologies, www.matrixti.com Daniel E. Capano, 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 and Technology 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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ANSWERS COVER STORY Christian Johansson, ABB

How edge computing will unleash IIoT potential Combining the potential of Industrial Internet of Things (IIoT) devices with the processing power of edge computing, automation solutions and analytics is giving manufacturing production data more value. See five ways to make edge IIoT deployment more effective.

he Internet of Things (IoT) is present as refrigerators order food deliveries and autonomous vehicles schedule their own service, examples of computing decisions on the edge of the process and internet. Manufacturing industries have taken a little longer to implement the Industrial Internet of Things (IIoT), but it is now making up for lost time, with significant technology developments, including edge computing. A major challenge industrial companies face is how to make the best use of the data gathered from IIoT-type devices and control systems in production processes. Unleashing data value can be hampered by a lack of the processing power needed to make the most of the industrial data and convert it into useable knowledge. Edge computing can move computing power and data storage closer to where needed, delivering benefits including faster processing, improved security and optimizing available bandwidth.

Manufacturer benefits

Edge computing and industrial analytics’ biggest benefit for manufacturers is the ability to use industrial data to optimize production processes. Companies have used edge computing and industrial analytics to help plants achieve accurate and efficient production – they are now looking at optimizing it through low cost sensing, data analytics and machine learning (ML) to add efficiencies. Putting computing power near to devices it serves produces enhances speed by reducing latency, the time needed Edge computing and the cloud are for data to travel from source valuable for manufacturers, but they to destination. Latency can be have different benefits. Edge comgreatly reduced by edge computing is better for real-time needs; puting compared to sending it cloud is better for long-term projto the cloud. ects. Images courtesy: ABB These gains depend on

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the use case – if an application is trying to control or interact with actuators and motors and the process, then real-time control is needed. If long-term process optimization based on the deep analysis of trends is needed, the cloud is the better alternative because it isn’t time critical. One major benefit of combining the cloud with edge computing is the ability to use the cloud to train models using data from IIoT devices. These models can then be executed at the edge, allowing devices to respond more appropriately to changes. Cloud connections can represent a security risk. Cybersecurity needs to be top of mind when selecting edge computers. Automation vendors can supply systems that incorporate end-to-end security built on application expertise. Edge computing also allows more scalability as the business grows and production plants expand. With a scalable range of computing devices, installations easily can expand for greater volumes of data and more applications.

Choose an edge computing use case

Many potential edge computing customers are exploring what’s possible and seeking the right use case that will help their operations. Many industrial users have increased efficiency with automation systems. To add extra percentages of efficiency, what’s added should not compromise what exists now. That difference can be found in IIoT and edge computing. Using the edge for computing and as a gateway to the cloud offers the potential to support many use cases of varied complexities, from a self-contained process to a set up involving multiple sites. A large mining company wanted to compare operational excellence, safety incidents and maintenance statistics across its mines, treating them as fleet assets. When operating multiple sites with the need to optimize operations in different ways or optimize the value chain across different factories or the transfer of goods between factories and sites, then look at the cloud. When it comes to artificial intelligence (AI) processing of IIoT data, some vendors are driving AI and ML technologies from the cloud, while others www.controleng.com

are building from the edge. In between is federated learning, a combination of smaller applications and the ability to learn and optimize by learning from a fleet of machines. The right choice depends on what the company is aiming for – edge and cloud are equally important depending on the use case. An integrated system benefits from digital technology data, edge computing’s fast processing and the cloud’s deep analysis and learning capabilities.

Improve edge IIoT in five ways

In the future, the most successful businesses will be those that deploy an effective site, edge and cloud strategy that can drive value by turning their collected data into useful information quickly, efficiently and cost effectively and share it across the enterprise wherever and whenever it is needed. Consider these five recommendations that can help to achieve these aims and ensure that expectations on return on investment are met. 1. Start with the edge computing use case When starting an edge deployment, consider where the industrial data comes from (such as intelligent devices and/or control systems), connectivity capabilities and how much processing will need to be done at the edge versus how much can be done through the cloud. This ensures applications using real-time control data are hosted near the source where data is processed quickly. This reduces latency and offering the best possible response times while other analytics are done in the cloud and easily shared between sites. 2. Keep edge computing simple The great thing with edge computing is its scalability, with elements such as new edge nodes or devices that can be added later down the line if necessary. Achieving this should be made as easy as possible by choosing solutions that allow easy connectivity between devices and systems and seamlessly bridge information technology (IT) and operations technology (OT) functions to give a greater insight into the data. Fast deployment of new value adding applications should also be easy. When it comes to selecting the appropriate technologies for an edge IIoT project, it pays to opt for solutions that are already pre-validated and proven to work together. Taking this approach will help ensure the edge IIoT solution can be deployed and/or scaled up quickly with a minimal risk of potential errors caused by untested or non-compatible technologies. 3. Difference between the edge and the cloud Both edge computing and the cloud serve different purposes, with neither being more dominant than the other. Consider the use case characteristics and how the data will be used to guide the choice. The key differences between edge and cloud include bandwidth, latency and network availability. The main reasons for choosing edge computing over cloud computing are performance related. Edge computing is ideal for real-time applications where a fast

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COVER: Edge computing has already been used by many manufacturers to become more efficient and productive, but the Industrial Internet of Things (IIoT) can help make the data smarter.

response is needed. The cloud better fits applications calling for centralized collection and analysis of complex data where time is less critical. 4. Consider security and integrity Data, which serves as a company’s collection of know-how, ideas and operations, is the most valuable asset and needs to be protected. In designing an edge IIoT solution, and choosing the right partner to help deliver it, cybersecurity and data privacy must be the top priority. Security should extend to all levels, providing robust protection from cyber infiltration and unauthorized access and ensuring plant integrity and confidentiality through inherent security features. The cybersecurity provider also should help maintain data confidentiality, providing full transparency on how it’s used and stored and ensuring nothing is disclosed to a third party without prior consent. Ensure the edge computing provider can guarantee continued protection against potential security issues by evolving soft- KEYWORDS: edge computing, ware and hardware so products keep pace Industrial Internet of Things, IIoT with cybersecurity standards. Edge computing and the cloud 5. Pick an edge computing partner can be combined to improve data Finding the right edge computing ven- speed and value. dor or partner can be key to determining Edge computing is better for the success of an edge IIoT deployment. applications where data is needed immediately; the cloud fits longLook for an established portfolio of prod- term applications. ucts and applications that can be integrat- Consider cybersecurity in edge ed. The vendor or partner also should be computing implementations. able to demonstrate a good track history ONLINE in deploying and supporting solutions in Read this article at industries and applications that are either www.controleng.com for more on the same or similar to yours. ce edge computing and the cloud.

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Christian Johansson, global product manager - digital for ABB Process Control Platform. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.

www.controleng.com/controlsystems/embedded-systemsedge-computing

CONSIDER THIS How can edge computing and cloud help your applications?

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HUMAN-MACHINE INTERFACES Bill Dehner, AutomationDirect

Embedded HMIs excel in automation applications Delivering the right human-machine interface (HMI) experience is critical whenever people need to interact with automation.

he ways we interact with our phones, vehicles, and automation systems have been generalized as human-machine interfaces (HMIs). Using a car, for example, HMIs have progressed over the years from mechanical (manual transmission stick shift), to electrical (headlight switch), to digital (touchscreen navigation controls). Digital systems appear to be the highest evolution of the HMI, and there are a few ways to implement these types of interfaces. For today’s industrial automation systems, users generally have two options for digital HMIs installed on the plant floor. They can select dedicated HMIs, also known as embedded HMIs, built for purpose. Or, they can choose standard or industrial PCs (IPCs) running more general operating systems (OSs) and IPC-based HMI applications. Because PCs are so common, many might think an IPC solution is the best choice because embedded HMIs were less capable than IPC-based HMIs. However, embedded HMIs can perform nearly all the same functions of an IPC HMI, with a lower net operating cost, smaller form factor and easier maintainability. Following are some points to consider when deciding between an embedded or an IPC-based HMI.

HMI evolution

The first automation HMIs were simple and physical pilot devices such as pushbuttons, switches, lights and needle gauges. These allowed operators to initiate inputs to automation systems

Figure 1: Digital HMIs, such as this AutomationDirect C-more embedded HMI, consume less installation space that physical pilot devices and provide a better developer and end-user interface experience. Courtesy: AutomationDirect

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and obtain output indications of status. Some devices, such as selector switches, provided input and output capability. Many users appreciated the immediate response and tactile feedback of these panel-mounted devices serving as human-machine interfaces. Digital HMIs were a great advance. Users could pack a far greater density of controls and indicators into one interface display, taking up only a modest footprint. The configuration could be updated via software and it was far easier than reworking and rewiring a physical control panel (Figure 1). Early digital HMIs were mission-specific embedded systems only capable of the specific and limited operations technology (OT) tasks they were designed to perform, making them highly efficient and lightweight from a computing standpoint. As PCs – and later IPCs and then mobile devices – became available with general-purpose information technology (IT) OSs, suppliers created HMI software to run on these systems. IPC-based HMIs quickly overtook embedded HMIs in performance, capabilities, and look-and-feel. However, these features came at a price.

Reasons to use IPC-based HMIs

PCs and their ruggedized IPC counterparts gained functionality and lowered costs due to mass commercial adoption. Major benefits of PCs employed as HMIs include: • Rapidly updated high-performance processors • Generous memory • Large storage • Numerous wired and wireless connectivity options • Repairable component-based designs • Capability to host higher-level functionality software, such as databases and analytics • OT personnel could choose from many HMI software packages • Improved integration with IT systems. So what is not to love about the comprehenwww.controleng.com

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ANSWERS

HUMAN-MACHINE INTERFACES Figure 2: Ready to work almost right out of the box, embedded HMIs are designed with robust and compact form factors, reducing overall costs. Courtesy: AutomationDirect

sive flexibility of an IPC-based HMI? In most cases, especially for mid-sized equipment or smaller machines, the overall lifecycle cost for using an IPC HMI exceeds an embedded HMI’s cost. In many situations, IPCs are too feature-rich for an industrial HMI’s job, driving up costs and complexity. Complications manifest themselves in hardware, OS and software management. PC-based hardware is modular and economical, but not well suited to the rigors of industrial use. IPCs are built for the target environment, but this specialization means the hardware is more expensive than office-grade PCs. Another part of the problem is the operating system, which users must carefully manage and update. Embedded HMIs are not immune from the need for performance and security updates, but PCbased platforms are more vulnerable and must get frequent cybersecurity updates. A benefit of IPC HMIs is users can choose KEYWORDS: Humanfrom dozens of HMI applications, suites and machine interface, HMI, related software products like historians, embedded PC reporting packages and more. Users can creIndustrial PCs (IPCs) are used by many on the plant ate their own custom-coded applications. The floor, but embedded HMIs diversity of software options places a burden on can do many of the same the end user to confirm interoperability, keep things. up on licensing costs and requirements and Embedded HMIs are seen update the software. An IPC can form the basis as the best technical choice for local displays out on the for an attractive HMI. It may run for years as factory floor; industrial PC it was installed, but it is more likely to require (IPC)-based HMIs may be ongoing support and updates. perceived as a better fit for Users also must consider their display larger applications. needs. Many IPCs are standalone boxes needONLINE ing a separate panel-mount display. While this See more articles means users can mix and match the exact parts from the author, a mobile they want, it creates more effort on the installaHMI photo, and more about tion side. Maintaining a consistent panel cutout remote connections. size for the display is a great concern for future www.controleng.com/ info-management/hmi-oi maintainability of any HMI. For these and other reasons, those considCONSIDER THIS ering an IPC HMI should look at embedded What benefits could HMI options. embedded HMIs bring?

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Embedded HMI functionality

The size of the application in terms of tag count and number of displays needed can be a major factor when determining the best type of HMI. For many types of equipment and processes that are mid-size and below, an embedded HMI offers the right level of functionality. While embedded HMIs may use some commercially-based computing elements, their hardware design is tailored for the role with accommodations for the temperature and other environmental factors associated with industrial applications. Instead of using a resource-hungry general-purpose OS, an embedded OS only needs to host the HMI functionality, which requires less processing power and memory. Embedded HMIs are often ready to work right out of the box. Their all-in-one touch screen form factor is easy to work with, presents fewer points of failure than an IPC-based HMI assembly, and lends itself to maintaining a spare on the shelf. They can be quickly deployed, whether for a new project or replacing a unit for an existing system (Figure 2). Embedded HMIs also can make good economic sense from several standpoints: • Dedicated, sometimes free, PC-based software development environments are easier to set up • Runtime software included • Complete product pricing typically less than an IPC plus software licensing • Compact and robust design is better for installation and maintenance • Standalone configurations are less likely to need system updates • Faster to replace an entire unit than for an IPC-based solution.

HMI platforms used to compete based on detailed feature sets. Maturity of today’s HMIs include a lot of crossover functionality between IPC-based and embedded HMIs. Both types can: • Communicate with many types of target devices • Support a variety of industrial protocols • Are configured with tags • Provide a rich variety of graphical objects • Offer animation options. In some cases, that maturity has led to simplification. Simplified high-performance HMI design principles have replaced excessive animation associated with older HMI designs. ce Bill Dehner, technical marketing manager, AutomationDirect. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media, cvavra@cfemedia.com. www.controleng.com

input #11 at www.controleng.com/information

ANSWERS

AUGMENTED REALITY Anna Velena and Vineesh Kapoor, Emerson

Augmented reality tools: A digital bridge for the skill gap Augmented reality (AR) is changing how manufacturers work in the field. See three benefits of augmented reality and three examples of how AR helps users.

s a new generation of technicians begins to step up, plant management can no longer rely on workers’ long-nurtured abilities to detect sights and sounds in the field. Those skills will come with time, but to accomplish continual improvements to safety, productivity and efficiency, organizations need to provide field technicians with tools such as augmented reality (AR) to bridge the gap and accelerate skill development. AR is already moving beyond the buzz and delivering value to organizations. The difference between flashy digital transformation technology and practical value to business is in the strategy. Prepare a strategy to get the most practical value from AR technology. Adopters should look for AR

solutions that integrate with existing plant and operations technology (OT) systems that provide three key benefits: situational awareness, IoT data integration and live remote assistance. Building a strategy around these elements helps organizations implement with ease and achieve fast return on investment (ROI) through practical AR applications to their operations. Two issues that vex new and incumbent workers in the field are knowing where to find devices and identify the correct assets when they have made it to the right location. Industrial sites can easily have thousands of devices scattered across large areas in the field. Further complicating asset identification, sometimes a facility can have similar devices adjacent to each other, making it possible for an inexperienced technician to disable the wrong device by accident. AR helps field workers build the situational awareness they need to quickly locate malfunctioning devices to resolve issues. Advanced AR technology includes functionality that helps operations and maintenance personnel visually map elements in the plant so that they can locate, identify and resolve problems. Navigation tools built into AR help users locate assets. Using their mobile devices, plant personnel can view assets in the field and see overlays that identify assets by name and provide an intuitive health status.

AR situational awareness, processing

One chemical manufacturer in North America has a large manufacturing site with numerous facilities – many of them adjacent to one another. Contracted instrumentation and engineering (I&E) technicians often don’t know the layout of the facility they are working in, so every time they visit, they are chaperoned by a plant employee to make sure they work on the correct equipment. To reduce the time personnel must spend chaperoning I&E technicians, the organization is implement-

Figure 1: AR tools provide new and incumbent field technicians with situational awareness, helping quickly locate needed assets and providing tools to work more efficiently once they arrive. Images courtesy: Emerson

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ANSWERS

AUGMENTED REALITY ing AR technology. This allows the I&E technicians to use AR technology to find a landmark such as a command center or a skid unit, and then quickly identify the right assets through an overlay on a mobile device.

AR IIoT data integration

For AR to deliver the most value to operations, the technology must be integrated with OT data systems such as an asset performance platform. However, manually engineering that integration can be expensive. Organizations should prioritize solutions with native integration that eases implementation. Otherwise, they risk spending more than the technology costs just to implement it. Integration provides field workers with instant IoT data relevant to a speKEYWORDS: augmented reality, cific asset. Using a mobile device, users Industrial IoT, skills gap can tap the asset to bring up its entire Augmented reality (AR) technology catalog of asset and process data, doccan help younger workers learn skills from older workers. umentation, and maintenance history. For AR to deliver the most value, With immediate access to relevant the technology must be integrated asset data, field operators and techniwith operations technology (OT) cians avoid the need to make multiple data systems such as an asset trips back and forth to the mainteperformance platform. nance staging area. Assets are fixed AR can cut costs and safety risks and efficiently, reducing outage lengths and improve collaboration and training. simplifying routine maintenance. ONLINE AR tools also help level the playing With this article online see field for less experienced technicians another photo and more text. by ensuring they have all tools needSearch “augmented reality” at www.controleng.com for more on ed for fast troubleshooting and mainaugmented reality. tenance – including history of work on the asset, notorious problems, and CONSIDER THIS notes left by previous technicians. What plant applications would benefit most from augmented reality? A natural gas organization in

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Figure 2: AR collaboration tools allow experts to see a field technician’s display, making it easier to remotely guide field technicians with step-by-step instructions and on-screen annotations.

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Asia has decades of plant knowledge stranded in the brains of an ever-diminishing number of experienced technicians and engineers. The reliability team wants to capture this knowledge to help upskill future generations of workers at the plant. To build the database necessary to preserve knowledge, the reliability team will capture the methods of experienced personnel in the AR system and tie them to the assets they impact. Newer technicians will have fast access to that knowledge directly from the field. The captured knowledge will serve as a powerful tool in the field as well as a learning platform to help improve the skillset of inexperienced personnel. AR also gives field technicians immediate access to a knowledge library containing tools they need to perform maintenance. Currently, technicians print manuals and loop diagrams to take to the site. If they arrive and discover they have the wrong materials, they need to go back. With AR, technicians know they always can access the right documentation – loop diagrams, datasheets, manuals, plant diagrams, and more – on the mobile device.

AR live remote assistance

Even when equipped with the right tools and resources, technicians can run into problems in the field they don’t know how to fix. When an assigned technician can’t figure out what is wrong, they often escalate the issue to more experienced personnel. experienced technicians and engineers are in high demand and waiting for them to travel to site often can cause extended delays. A more efficient solution is to remove the need for experts to travel to site. AR enables multiple technicians to work together from anywhere to resolve the problem more quickly. Experts can use AR tools to see what the field technician is seeing and share live onscreen annotations, provide voice and text assistance, and link to additional resources. When experts are available faster and have more tools to help fix problems in the field, asset downtime is reduced, leading to fast return on investment for the AR system. At the natural gas facility in Asia, technicians currently use a phone or a chat app to communicate with experts from the field. If a problem occurs late at night, this means waking up the expert on call and having them search the internet for a manual to provide guidance over the phone. With AR, experts can avoid site trips. The experts have remote assistance tools and documentation available in existing mobile devices to point a field technician in the right direction. ce

Anna Velena, product manager for software interfaces; Vineesh Kapoor, director of Plantweb product management, Emerson. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com. www.controleng.com

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Sell us your unwanted industrial automation product.

Radwell.com - 800.884.5500 - sellto@radwell.com input #13 at www.controleng.com/information Radwell_Asset_7x10_2020.indd 1

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ANSWERS

WIRELESS

Ford Cheeseman, Siemens

What industrial wireless network should I use? Are your industrial wireless local area networks up to date? Industrial communications are taking another leap forward with IEEE 802.11ax and 5G wireless technologies. Evaluate industrial wireless LAN (iWLAN) technologies.

he steady evolution of fast, deterministic and reliable wireless networks in industrial environments has been a critical driver behind the realization of Industry 4.0 and Industrial Internet of Things (IIoT) concepts over the past decade. Industrial communications are taking another leap forward with IEEE 802.11ax and 5G wireless technologies available for industrial environments. That’s why it’s a good time to evaluate the status of industrial wireless LAN (iWLAN) technologies supporting production plants and their associated logistics and warehouse facilities. [LAN stands for local area network.] Industrial engineers working in operations technology (OT) environments should work together with their enterprise information technology (IT) counterparts to develop wireless modernization roadmaps to ensure maximum performance, reliability, and security in coming years. The collaboraKEYWORDS tion between OT and IT teams is critical Industrial wireless, 5G, IEEE because data can be used differently in 802.11 wireless industrial environments than enterprise Closing wireless latency gaps ones. This primer on industrial wireless can achieve real-time wireless communications. communications intends to help OT and Industrial wireless is more than IT professionals better collaborate on hotspots. those roadmaps. IEEE 802.11ax and 5G boost It’s been more than 20 years since future network communication the IEEE first ratified the original IEEE options. 802.11 wireless standard, with IEEE CONSIDER THIS 802.11a,b, and g versions quickly folWhere do you need reallowing, all mostly designed for office time industrial wireless and home applications under the “Wicommunications? Fi” trade name. Although some plant ONLINE engineers may have trialed these verIf reading from the digital sions in industrial applications – mostedition, click on the headline for ly with hopes of reducing cabling costs more resources. and gaining floorplan configuration www.controleng.com/magazine flexibility – the deterministic inadewww.controleng.com/ quacies of these early Wi-Fi versions networking-and-security/ became apparent in OT networks. wireless/

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Closing wireless latency gaps, real-time

The biggest shortcoming was data transmission latency – mostly from data collisions within the iWLAN’s shared medium that require data to be retransmitted. Too many retransmissions of the same message can cause an expiration of watchdog timers that monitor the response time of control and safety data traffic between sensors and programmable logic controllers (PLCs), leading to nuisance faults that can disrupt production. It can be especially problematic when roaming is involved. That’s because the moving client is transitioning its wireless communications from one access point (AP) to the next. The time required to re-associate to the new AP, which can be even longer if it must go through an AP controller, can also lead to communication faults that compromise the effectiveness of control and safety systems. These delays may even influence controls engineers to increase their watchdog timers to accommodate the longer latency, sacrificing their control and safety standards to keep production running. The introduction of IEEE 802.11n in 2009 and IEEE 802.11ac in 2014 helped changed this. Transmission speeds of each increase by orders of magnitude over their previous standards and specific technology developments helped ensure greater determinism for OT applications—with latencies as low as 17 milliseconds. Such technology reduces, fixes and distributes even the polling cycles among clients enough to minimize latencies and allow for much faster roaming times. A variation of this protocol was developed especially for continuously moving nodes like those aboard automated guided vehicles (AGVs) and cranes, to further boost performance and reduce roaming times to under 50 ms.

Industrial WLANs are not just hotspots

Establishing iWLANs takes more tech-savvy than setting up Wi-Fi in a home, office or café. Hotels, airports and municipalities may be more complex underwww.controleng.com

input #14 at www.controleng.com/information

ANSWERS

WIRELESS

takings because of their scale, but in a production plant wireless connectivity must meet much more rigorous demands. Here are two other differences: • Fail-safe reliability: Data loss or corruption during transmission in non-industrial environments isn’t always critical since the data can often be retransmitted without any detectable impact by the recipient. In industrial environments, however, failed data transmissions can compromise process and safety controls, leading to plant downtime, quality issues and injuries. • Radio interference, attenuation, and reflection: Non-industrial environments tend to lack the different sources of radio frequency (RF) interference, reflective objects, and attenuation that industrial environments have: large, odd-shaped metal machinery, ductwork, metal decking, and aluminum rolling doors can reflect RF waves; thick concrete walls or materials stored in warehouse racks that can block them; and a range of other sources of radio signaling – RFID, neighboring industrial WLANs and office WLANs, to name a few.

IEEE 802.11ax and 5G options

Given the growth in IoT and IIoT device numbers and density, IEEE 802.11ax shifts the Wi-Fi paradigm from theoretical peak data speeds to overall network capacity. To be sure, IEEE 802.11ax increases speeds from IEEE 802.11ac up to 10 Gbps, a 37% boost. Using an orthogonal frequency-division multiple access (OFDMA), which was borrowed from 4G LTE technology, the IEEE 802.11ax standard improves spectral efficiencies enough to support the communications of a million devices per square kilometer. Industrial 5G is another animal

Wireless connections are ideal for applications where it would be too complex or even impossible to lay cables. The Siemens Scalance W line provides flexibility and fail-safe communications without a wired connection. Courtesy: Siemens

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entirely. It opens the door to the comprehensive, wireless networking of all kinds of new applications in production, maintenance, and logistics. High data rates, reliable and powerful broadband transmission, and ultra-short latencies will boost efficiency and flexibility in industrial value creation, although all of these benefits will not be available simultaneously. Industrial 5G raises a lot of questions on how the new communication standard can be best implemented. Some automation companies have 5G research teams working with standards bodies to bring customers 5G when it’s ready for full deployment in industrial environments. In the meantime, sticking with IEEE 802.11 Wi-Fi standards, particularly IEEE 802.11n, ac and ax, is recommended, depending on the wireless industrial application.

Time to update industrial WLANs?

Many iWLANs in use today may have been deployed with IEEE 802.11a, b, g or n technology that is in some cases now a decade old. Plant engineers should consider evaluating their current networks for modernization – or at least a modernization roadmap – in concert with industrial networking experts and their enterprise IT counterparts. While 5G and IEEE 802.11ax are the future directions of wireless, IEEE 802.11ac and IEEE 802.11n are capable today of providing the fast throughput and low latencies industrial applications require. For example, IEEE 802.11ac can provide the throughput needed for video applications, while IEEE 802.11n is valuable for industrial MIMO (multiple input, multiple output) applications. The latter can support mobile automated guide vehicles and overhead cranes by helping to deal with ever-changing RF reflections as one moves through a plant. In addition, where deterministic communications such as control traffic and safety must be prioritized, iWLANs can be optimized using technology that adds determinism to industrial wireless communications. Low latencies can improve edge computing performance, workers assisted by virtual and augmented reality (VR/AR) technologies, provide greater mobility in plant equipment, machines, autonomous machines and logistics. Of course, the greater sophistication of these applications will require more sophisticated RF engineering, making careful site surveys and other best practices critical to successful deployments. ce

Ford Cheeseman is automation networking consultant, Siemens. 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

ANSWERS

5G WIRELESS

Daniel Quant, MultiTech Systems Inc.

Six answers about 5G wireless

Industrial communications is adding 5G to wireless protocols to use. ndustrial applications will benefit from 5G 2. What are 5G’s main benefits?

wireless technologies. See answers about 5G wireless from Daniel Quant, vice president, strategic development, MultiTech Systems Inc.

1. What’s 5G’s rollout status?

Quant: More than 50 operators in more than 30 countries have launched one or more 3GPP 5G commercial service, about 8 to 10% of 4G-LTE network operators. Initial focus was on consumers and commercial enterprises requiring faster and lower latency wireless connectivity, mobile to smartphones or fixed to commercial and residential buildings (3GPP 5G-NR [New Radio] Release 15 – Enhanced Mobile broadband). [3GPP is the 3rd Generation Partnership Project.] More than 10 million handsets have shipped globally, with a few million more customer premise equipment (CPE) devices connecting outside or inside of buildings to 5G fixed wireless access services. South Korea, USA and China lead new service deployments.

Quant: Enhanced broadband data speeds, estimated at well over 1 Gbps, lower latencies – for most at less than 10 ms and targeted at sub 1 ms with ultra-reliable connectivity for industrial mission critical assets (3GPP release 16, released in June 2020). Far higher density of low power lower bit rate machine connections, many running on batteries for years, often referred to as massive machine connectivity (3GPP release 17 expected by 2022)

3. What will be the top 5G applications?

Quant: I think industrial transformation (well behind the digital transformation of most smartphone consumers) is the 5G game changer. Connecting machines and workers for greater process efficiency and improved data-driven decision making. Much of this will be privately deployed by industrial enterprises, such as oil and gas, utilities, real estate owners, transportation and other industries for improved net-

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More agile business models and network architectures enable enterprises to capitalize a converged wireless private 5G network with edge intelligence for improved security, greater performance, faster decision making along with reduced bandwidth, cloud compute and storage costs. 5G wireless standards efforts are helping. QAM is quadrature amplitude modulation. MIMO is multiple input and multiple output. Courtesy: MultiTech Systems Inc.

work performance targeting sub-millisecond ultrareliable connectivity for mission-critical assets and services vs. large scale deployments of low-power-constrained devices, such as sensors and actuators.

milli-wave spectrum are being rolled out, improving access to more spectrum bandwidth and increasing data performance.

4. What are 5G adoption challenges?

Quant: 3GPP 5G new radio is a standards-driven process and will be for years. Industrial enterprises have the most 5G benefits to gain and are joining 3GPP stake holders with data transformation needs for upcoming releases and work items. ce

Quant: Thousands of sensors require low bit rate long battery life often in difficult to reach places sharing 5G-NR resources with enhanced broadband and sub-millisecond latency time-series networks for mission-critical control automation. Who will manage these new networks?

5. What 5G developments are near?

Quant: Improved data speed and reduced latency target consumers. Early 5G-NR networks gain maturity. Dynamic spectrum sharing and mid-band and

6. What else can you add?

Daniel Quant is vice president, strategic development, MultiTech Systems Inc. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com.

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KEYWORDS: Industrial wireless, 5G for industry Industry will use 5G wireless technologies. 5G wireless services are ramping up, and applications offer industry benefits. CONSIDER THIS Are you developing or using 5G industrial wireless applications?

ONLINE Click on the headline for more on each point and related links.

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ANSWERS

SYSTEM INTEGRATION PRIORITIES Ryan Courtney, MEM, PMP, Matrix Technologies Inc.

How to build a system integration business case for automation, controls When starting any system integration project, consider four fundamental components to business case development: business needs, situational analysis, recommendation and evaluation to create due diligence for project management.

roblems are the driving force behind automation and operational technology engineering projects. Company leadership recognizes this need and relies heavily upon cross-functional teams to study feasibility and determine if a business case can be developed for system integration projects as part of effective project management. Management uses a business case to quantitatively and qualitatively determine the economic feasibility of a system integration effort currently lacking in definition. The business case is a key input to the project charter and will be a living document throughout the life of the system integration project that serves as a litmus test against the engineering project objectives. Within the initiation phase of any system integration project, four fundamental components to business case development need to be considered: business needs, situational analysis, recommendation and evaluation on the way to creating due diligence.

1. Determine business needs for a system integration project

Determining business needs is an important first step in the process of developing a solid business case for an industrial system integration project. Accomplish this by assessing needs, identifying stakeholders and identifying scope. A needs assessment is a data collection process that identifies business needs versus wants and corresponds to the gaps between the current situation and the desired outcome. This manner of data collection involves understanding regulatory requirements, surveying stakeholders and analyzing historical data, as well as an important component

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Don’t press your luck by starting a major system integration project without considering business needs, situational analysis, recommendation, and evaluation, according to Ryan Courtney, MEM, PMP, project manager, Matrix Technologies Inc. Courtesy: Mark T. Hoske, CFE Media and Technology

of listening to the customers involved in the project. Stakeholder identification is a process of engaging all key decision-making personnel to collaborate on determining the business need. Stakeholders often represent operations, maintenance, engineering, procurement, and environmental health and safety, in addition to a representative or champion from the steering committee or leadership. The challenge in stakeholder identification is ensuring all key personnel are appropriately represented and engaged early on in the system integration engineering project. Failing to involve all the proper stakeholders early on in initiation can lead to oversights and misalignments later in the project effort. Identify scope by determining what work is required to achieve the desired business outcome www.controleng.com

or objective for the system integration project. Scope identification relies upon stakeholder identification to make certain there is early alignment with the business functions the project effort will impact.

tion. This statement and supporting information outline how you will measure the long- and shortterm benefits of the project deliverables.

2. Analyze the situation for the

By following the steps identified above, a team can ensure it has performed due diligence in developing the business case for a system integration, operational technology project. Moreover, company leadership can be assured the business case is objective in nature, watertight and aligns with organizational goals, objectives and strategies.

industrial system integration project

Situational analysis is important for an organization to recognize their objectives, goals and strategies. Determine root causes of the problem or the conditions to leverage in the case of an opportunity. Consider conducting a gap analysis on the identified business need versus the current organizational capabilities. Discuss and capture the known risks, which, at this point in the process, may be at a high level and highlight factors that are critical to success of the effort, especially those quick wins and low-hanging fruits. Determine the decision-making criteria you will use to assess the course of action through the life of the system integration project effort. Through situational analysis, classify identified components as being required, desired or optional. This further qualifies needs versus wants and is essential to the business case’s objectivity. Take the time and identify options during situational analysis. This ensures the business leadership you have considered and vetted all avenues to determine the best course of action relative to an investment. Further classify options as doing nothing, doing the minimum or going beyond the minimum to address the problem or opportunity.

3. Recommend options with risks, assumptions, constraints, and interdependencies

The recommendation section of the business case is often synonymous with the conclusion. It states to the business the most feasible option to progress with. A recommendation of an option includes a summary of the results compiled in addition to the risks, assumptions, constraints and interdependencies associated with the chosen option. The recommendation should highlight the success criteria used to measure the outcome of the option pursued. Depending upon the nature of the business case and organizational requirements, consider including high level milestone schedule as well as a RACI (Responsible/Accountable/Consulted/ Informed) chart accentuating roles and responsibilities as part of the recommendation.

4. Evaluate the success of the system integration project

Finally, consider the evaluation part of the business case. The evaluation section determines the measure of success during the course of the project effort, handoff between project and operations and the operational impacts beyond implementa-

www.controleng.com

Justifying a system integration project with due diligence

‘

Failing to involve all the proper stakeholders early in system integration project initiation can lead to oversights and misalignments

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later in the project.

The more objective, concise and data-driven the business case is for the system integration project, the more efficient the process will be to determining the payback of an investment, whether it be return on investment, net present value or other financial efficiency metric. The culmination of these components in a solid business case will allow for leadership to render a “go/no-go” decision effective. ce Ryan Courtney, MEM, PMP, is project manager, Matrix Technologies Inc. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technologies, mhoske@cfemedia.com. This was adapted with permission from a Matrix Technologies blog post on building a business case.

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KEYWORDS: System integration project management Justifying an industrial system integration project requires due diligence. Develop a business case as part of the system integration project. System integration project management should begin with considering business needs, situational analysis, recommendation and evaluation. CONSIDER THIS As you prioritize for 2021, will you incorporate system integration project management into planning?

ONLINE If reading from the digital edition, click on the headline for more resources. www.controleng.com/magazine www.controleng.com/Global-SI-Database control engineering

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ANSWERS

INSIDE MACHINES Jim Stevens, Posital Inc.

Cost-effective position control for stepper motors Kit-based absolute encoders (position sensors) can make stepper motors a lower-cost option to servo motors for motion control applications.

ow-cost stepper motors are an attractive alternative to high-end servomotors for many motion control applications in industrial machines. This has been made possible by a new generation of kit encoders (modular position sensors) that can be added to standard motors, providing accurate and reliable closed-loop position control. As well as providing absolute position measurements, these new sensors offer self-powered, maintenance-free multi-turn functionality. Stepper motors are simple brushless dc motors used in a wide range of applications, such as small tools, appliances, printers and vehicles. In the industrial arena, they KEYWORDS: Position control, have been used for positioning tasks in encoders, motion control machines or high-speed pick-and-place Stepper motors and encoders processes. provide closed-loop control. Compared to servomotors, which Absolute encoders provide are designed for precision motion conreliable position capabilities to stepper motors. trol, stepper motors are simpler devices. They also are much less expensive, averCONSIDER THIS aging one tenth the cost of servomotors. Where could you use lower cost With stepper motors, control is achieved rotational position control? through incremental rotation of the elecONLINE tromagnetic field generated by the motor’s See: Kit encoders with magnet stator coils. With each controller pulse, absolute encoders.

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Stepper kit exploded view shows how magnetic kit encoders can be mounted on a stepper motor’s housing, with a rotating magnet assembly attached to the shaft. Courtesy: Posital Inc.

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the rotor moves forward by a clearly defined step or angular offset. Up to 200 steps per revolution are common, although motors with 400 or more steps also are available. A resolution of less than 0.1 degrees can be achieved by micro-step operation. The step accuracy is usually in the range of a few percent.

Position sensor closes the control loop

Basic stepper motors operate as part of an openloop control system. If a motor fails to move as requested (due to unexpected mechanical resistance), there will be a discrepancy between what the control system “thinks” is the position of a mechanical component and the actual position, resulting in a loss of accuracy. This shortcoming can be overcome by adding an encoder (rotation sensor) that can confirm if each step motion has been completed. Incremental encoders provide simple pulse signals with each completed rotation step and are ideal for speed control. However, absolute encoders can be a better choice for position control tasks. With incremental encoders, if the control system needs to determine the absolute rotary position of the motor’s shaft, it must keep an accurate count of the number of steps that have been completed. If this count is lost or corrupted – such as from to a power interruption – position knowledge is lost. In this case, it is often necessary to “re-home” the system by returning the machinery to a known starting position and re-starting the step count. By contrast, absolute encoders measure rotation angles directly and can report complete position data, including the number of complete rotations. This information can be retrieved by the controller at any time so production can resume immediately with minimal loss of time and materials. Stepper motors with built-in position sensors are a useful alternative option for positioning tasks in manufacturing equipment, packaging machinery, robots and other applications where a reliable, cost-efficient drive mechanism is needed. ce

Jim Stevens is product specialist, Posital Inc. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com. www.controleng.com

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ANSWERS

INSIDE MACHINES, DISTRIBUTION CENTERS Eric Rice, Honeywell Intelligrated

Connect automation to predictive maintenance Leveraging operational data already in control systems can drive distribution center (DC) performance and maintenance improvements.

ndustry 4.0, Industrial Internet of Things (IIoT) and digital transformation efforts are helping material handling companies recognize the need to make a fundamental shift in how distribution and fulfillment (D&F) operations are run. In fact, 70% of material handling executives consider Industry 4.0 a top priority. While the potential benefits of IIoT technologies are well-known in other industries, the D&F sector has relatively slow adoption rates. A recent study said only 2% of executives identified supply chain performance as a focus of their digital strategies. This trend suggests IIoT’s importance may be misunderstood and/or its potential benefits difficult to measure. In the energy sector, IIoT’s transformative operational impacts were proven a decade ago. A 2010 Department of Energy study of operations, maintenance and energy professionals revealed the average savings from an IIoT-driven predictive maintenance operation delivered a 1,000% return on investment (ROI), including the following key performance indicators (KPIs):

Figure 1: When it comes to maintenance operations, limiting the duration of downtime is a top priority. Market growth paired with a declining technician workforce will dictate the need for more predictive automation. As a result, enterprise and DC operators will need the insights to implement smarter processes and achieve more reliable equipment operation. Images courtesy: Honeywell Intelligrated

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• 25 to 30% reduction in maintenance costs • 70 to 75% elimination of equipment breakdowns • 35 to 40% decrease in downtime • 20 to 25% increase in production. The building automation sector has been deploying IIoT best practices for more than a decade. Other industrial sectors, like the oil and gas industry, also have willingly embraced the power of operational data to help predictive maintenance. Despite the differences between these sectors and D&F, they share similar business objectives and KPIs – and the same potentially transformative benefits.

Automated devices and systems

The D&F industry has unique complexities, barriers to adoption and opportunity costs for automation devices and systems. Because no two operations are alike, it can be difficult to approach implementation from a “standard” perspective. The ever-present risk of disrupting operations in a hyper-competitive, e-commerce fulfillment sector also may be a deterrent. The proliferation of warehouse software, management systems and automation technologies can present compatibility challenges when integrating existing assets into a connected infrastructure. For most companies, the absence of a viable change management strategy prevents them from achieving fundamental progress and affecting the required organizational shift needed to embrace a data-driven enterprise. The risks of doing nothing and not making a digital transformation, may be greater, given the acceleration automation can provide. Increasing digitization of operations, business transactions and customer interactions say IIoT infrastructures can: • Address e-commerce pressures • Ensure customer service level agreements (SLAs) are met • Shorten order cycle times and delivery windows. In a world where reliable, consistent uptime is a differentiator, skilled service technicians for automation, devices and systems are vital to an operation’s success. But as a generation of service veterans nears www.controleng.com

retirement, there are few qualified technicians poised to replace them. This trend is creating a significant knowledge and service gap that presents a long-term threat to many operations. DC operators are now in a race to improve training processes, recruit new candidates and get them up to speed on increasingly integrated automated systems.

Effective digital transformation

The most common barriers to successful IIoT adoption can be traced to three primary causes: 1. Lack of understanding of the technology landscape and its effects on your business 2. Lack of adequate talent to effectively implement and use the technology 3. Lack of a clear business case to justify the investment.

3 steps for smart digital transformation 1. Create a strong business case for digital transformation. IIoT adoption leaders were 75% more likely than IIoT laggards to cite the preparation of a strong business case or clearly articulated vision for value creation as key factors in their IIoT programs’ success. 2. Start small and clearly define the scope for digital transformation. • Digital transformation is an iterative process. • Choose a key area of operations for many stakeholders and establish time-bound parameters. • Create an actionable business plan with goals for achieving a specific financial outcome. 3. Build a competent and capable IIoT innovation team for digital transformation. • Visionary: Establishes the vision and provides clear direction • Motivator: Engages the team with a common goal and coaches others along the way • Executor: Brings necessary resources and capabilities to drive change through an organization.

Cost of facility downtime

Up to 80% of businesses are unable to accurately estimate downtime rates. Many underestimate downtime costs by 200 to 300%. The following factors are often ignored when calculating downtime: • Lost production • Recovery costs • Wasted labor/productivity • Missed customer SLAs • Depleted inventories • Mechanical equipment/system stress • Disruption to innovation • Loss of brand loyalty/customer trust.

Use control system data

For those who are new to using their data, a good place to start is tapping into the vast amounts of

www.controleng.com

Figure 2: New technologies can give service teams remote eyes in the field, allowing diagnoses of problems that staff may not have the knowledge or expertise to address.

available data from their machine control systems. It’s estimated there are hundreds of thousands of data points that can be accessed from a control system, but this data is often underused. Some operators pull data from programmable logic controllers (PLCs) periodically throughout a day or shift. However, PLCs are only capable of storing limited amounts of data, which means this information alone is transient and offers no trending information or insights for predictive maintenance. About a quarter of the extracted data has value. To extract value from control system data, operators need software and analytKEYWORDS: Digital ics tools to make sense of it. By continutransformation, predictive ally aggregating and interpreting this data, maintenance, automation these tools filter out the noise to deliver U.S. Department of Energy said IIoT-driven predictive historical trends and actionable insights maintenance operation delivered that provide operational value. Analya 1,000% ROI. sis of conveyor run statuses can help DC Automation help distribution and operators evaluate KPIs such as read rates, fulfillment. throughput, flow balance through merges Smart glasses allow a and conveyor jams. Armed with this data, technician to share live audio/ video with OEM experts. operators can address a variety of issues that impact performance. CONSIDER THIS By connecting control system data to How’s your digital transformation software with alarm management capagoing? Better than competitors? bilities, operators see real-time dashboards ONLINE and receive needed notifications. ce

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Eric Rice is principal product marketing manager, Honeywell Intelligrated. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com.

Read this online for: - Augmented reality photo - Condition systems, motors - Integrate predictive capabilities into maintenance - Prepare for a more connected automation future.

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INSIDE MACHINES: PROGRAMMING Gary L. Pratt, P.E., ControlSphere Engineering

Which IEC 61131-3 programming language is best? Part 2 With many programmable logic controller (PLC) programming languages and standards from which to choose, select the best language for specific automation and controls applications. Part 2 focuses on function block diagram (FBD), continuous function chart (CFC) and structured text (ST).

any programming language choices exist for programmable logic controllers (PLCs), and the IEC 61131-3 Programming Languages standard has several options. It’s more efficient and effective to use the strength of each rather than learn the tricks and workarounds required to force-fit one language to all applications. The programmer should select the best language for the application.

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

“Which IEC 61131-3 programming language is best? Part 1” discussed the strengths and best applications for each language, has a graphic showing all five languages, and provides details on ladder diagram (LD) and sequential function chart (SFC).

“Which IEC 61131-3 programming language is best? Part 2” (this article) discusses function block diagram (FBD), continuous function chart (CFC), structured text (ST) and how they can be mixed and matched for optimal results.

Function block diagram (FBD) and continuous function chart (CFC)

Function block diagram (FBD) is a graphical language which appeals to engineers’ affinity for graphical information. The Codesys integrated development environment (IDE), from Codesys GmbH (previously called 3S-Smart Software Solutions), offers two flavors of FBD, the traditional IEC 61131-3 FBD and the similar but more flexible continuous function chart (CFC) which is not formally part of IEC 61131-3. CFC is a super-set of FBD and has two areas of strength:

Figure 1: An example of a block-based programming design is show in Codesys continuous function chart language programing from Codesys GmbH. Courtesy: ControlSphere Engineering.

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www.controleng.com

Figure 2: Structure pins enhance readability of diagrams by reducing unnecessary detail and clutter. Courtesy: ControlSphere Engineering.

1. Block-based functional programming (performing Boolean and mathematical operations)

2. Keeps the block size small so that the overall flow of information can be viewed on one page

2. Hierarchical designs (calling other functions and function blocks).

3. Allows information to flow upstream and downstream (to further reduce the unnecessary detail).

Block-based programming with CFC

Block-based designs consist of assemblies of predefined functionality which are wired together to carryout Boolean logic, mathematical calculations, or a combination of the two as shown in Figure 1. CFC block programming is excellent when the outputs are strictly a function of the current inputs (in other words, when there are no state variables such as Boolean feedback, set/reset coils, or flags). When there is a combination of state-less and state-based functionality, use a combination of CFC and SFC. Because connectivity is represented with lines between the function blocks, it is easy to understand the flow of information and how the information is modified along its path. If the functionality begins to become complex, it should be split into smaller, more manageable sub-blocks as described in hierarchical designs below. If there are a significant number of connections between blocks, the lines can be consolidated into pins that are declared as a data structure type as shown in Figure 2.

Three advantages of structured pins Structure pins have three advantages:

1. They remove unnecessary detail from this level of the design hierarchy so that the forest isn’t lost in the trees (to paraphrase the saying). www.controleng.com

For PLC programmers who have used LD to perform block-based or hierarchical functionality, CFC provides a more concise and flexible approach. CFC is quicker to develop and much more understandable for future engineers who will be called to maintain or enhance the code. See the online version of this article for a graphic showing the implementation of structured pins.

Hierarchical designs with CFC

Hierarchical design is the practice of creating a design from building blocks, which are built from simpler building block, which are built from simpler building blocks and so on. Small building blocks have many advantages over the traditional large flat designs, including being easier to: 1. Specify 2. Create 3. Test and perfect 4. Understand and maintain 5. Be much more likely to be reused.

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KEYWORDS: IEC 61131-3

Programming Languages, FBD, CFC and ST Function block diagram (FBD) is a graphical language. Continuous function chart (CFC) programming, a super-set of FBD, is a similar but more flexible extension to IEC 61131-3. Structured text (ST) is based on the Pascal programming language and is similar to Visual Basic.

CONSIDER THIS Use the right IEC 61131-3 programming language for the application.

ONLINE If reading from the digital edition, click on the headline 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 Codesys GmbH, used for examples in this article can be downloaded at no charge, including a softwarebased PLC that will run for 2 hours between resets.

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INSIDE MACHINES: PROGRAMMING

Figure 3: Hierarchical design is implemented here in continuous function chart (CFC) graphical programming. Courtesy: Marine Hydraulic Consultancy.

The building block technique is easier to design and understand because it enables and encourages the practice of maintaining a consistent level of detail at each level of the hierarchy. In this way, upper levels of the design are not cluttered with confusing and unnecessary detail that is important at the lower levels of the design. The analogy is an automobile engine which has a starter, which has an armature, which is wound with copper wire, which is extruded from copper, which is mined throughout the world. The automobile designer doesn’t need to be an expert or be concerned with how the copper in the engine is mined. This level of detail is left to the lowest levels of the design, where that detail is important. Hierarchical CFC designs should be designed with a consistent level of detail on each level of the hierarchy.

Two downfalls of using LD as a building-block language

This reveals the downfall of the traditional method of using LD as a building-block language. Specifically: 1. The low density of information requires LD designs to be spread-out over dozens of pages, making it difficult or impossible to see and understand the big picture. 2. High-level details and low-level details are intermingled on the same level leading to clutter, which makes the design difficult to understand and maintain.

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Hierarchical design in CFC using structure-pins solves both of these problems, while maintaining the graphical nature of LD. It’s a no-compromise solution with the best of both worlds.

Benefits of using CFC and hierarchical design

Hierarchical design is a key feature of objectoriented industrial programming (OOIP). Figure 3 shows an OOIP design of a control system for a racing sailboat. The top-level of the design shows the boat control consists of inputs and outputs (I/O), services, winches, cylinders, and hydraulics. Double-clicking any of those blocks reveals the next level of detail such as the overview of the cylinders and the hydraulic system. Further double-clicking on any blocks in those reveal progressively further levels of details, each implemented in the best language for the job. Notice the careful attention to keeping the CFCs one page and of consistent levels of detail so the functionality is easily understood at each level. These objects are then configured with a .CSV file as shown in the OOIP article and video referenced in the “More Answers” box on the prior page. With the ability to place and configure userdefined blocks, CFC programming begins to closely resemble programming/configuring for a distributed control system (DCS), except with IEC 61131-3, the programmer is in control of the underlying blocks. If a block needs a minor enhancement, the programmer has the power to do this without the expense and time required to involve the DCS vendor. www.controleng.com

A complete hierarchical PLC design can be thought of as a tree with hierarchical CFC making up the trunk and branches (the block diagram); and block-based CFC, SFC, LD, and ST filling in the detailed functional design at the leaves of the tree. Together, the IEC 61131-3 language forms a team that is more powerful than any of its individual parts.

What operations should be programmed with structured text?

While LD, SFC, and FBD/CFC are great tools for their purposes, there are some operations that do not lend themselves to graphical languages. Some operations that favor use of ST programming include: 1. Iterative operations such as For, While, and Repeat

effective industrial controls programs, it 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 their effective use. Use the tips on LD, SFC, FBD, CFC and ST in this two-part series to 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

KNOW THIS FEELING? Then stop using complicated controllers for precision motion. You shouldn’t need a master’s in digital signal processing (DSP) controls to program your controller. With Automation1, you can now reduce your set up time — in many cases, from days down to minutes — thanks to a user-friendly, intuitive interface and machine setup wizard. Automation1 is the easiest, fastest and most precise motion controller available.

2. Complex conditionals and selections such as IF-THEN, and CASE 3. Bit manipulations such as bitwiseAND, Shift, Rotate 4. Text string manipulation 5. State machines with unusual requirements or complexity 6. Pure object-oriented programming (calling methods, setting properties, etc.) There are many good tutorials available for engineers transitioning from other text-based languages to ST. A Visual Basic tutorial is a good starting point for those completely new to text-based languages. While structured text is based on the Pascal programming language, it has enough similarities to VB to make use of the more widely available VB tutorials.

Know programming vocabulary for best results

To be able to communicate effectively in the English language it’s important to have the right vocabulary and to know how to use that vocabulary effectively. Similarly, to be able to create August 2020

•

See how we make your motion easier.

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AT0520A-CSG

Education and personal development are vital to the advancement of the engineering community. We invite you to explore and utilize the educational efforts of the following companies participating in our annual Educating Engineers program:

ABB Motors and Mechanical

EZ Automation

Acromag

Hammond Manufacturing

AutomationDirect

HELUKABEL USA, Inc.

Beckhoff Automation

Lenze Americas

Cimon

Radwell

Contemporary Controls

SEW Eurodrive Inc.

Dataforth

Siemens Digital Factory

Digi-Key Electronics

Stratus Technologies

Emerson

WAGO Corporation

EPRI

n this 2020 ABB webinar series, our experts are providing practical solutions to everyday challenges faced by operators and facility owners alike.

On-Demand Now Do your bearings or gear reducers tell you how they are feeling? If not, learn how they can in “Condition monitoring for mechanical power transmission,” an on-demand webinar available now. Changes in temperature and vibration can indicate potential problems in mounted bearings and gear reducers, yet if the health of these products is overlooked, problems are unnoticed until failure occurs. Listen as we discuss “traditional” equipment maintenance and how the installation of smart sensors will increase plant safety and productivity while decreasing maintenance and unplanned downtime. By the end of the session, you will understand how safe your data is and how it can make your operation safer, more predictive and efficient. You will also have a better understanding of the products that can be monitored with this technology. Watch on August 10 As variable frequency drives (VFDs) are being adopted in more and more industrial applications, something to consider is that the motors they are driving need to be carefully selected. The improper selection of motors can lead to unsatisfactory reliability and longevity. The August 10 session titled “Tips to extend motor life when driven by variable frequency drives” will provide tips for proper motor selection to ensure reliability when powered by a VFD. After the session, you should understand the importance of shaft current mitigation, insulation systems, Corona prevention, speed turndowns, and effective heat dissipation.

baldor.abb.com 479.646.4711 input #21 at www.controleng.com/information

utomationDirect provides free online

PLC training to anyone and everyone with no purchase necessary.

As the world around us becomes more and more automated, an understanding of electrical control systems becomes more and more vital. Because of this, the demand for training in industrial controls has grown exponentially over the years. Luckily, AutomationDirect has decided to meet this growing demand head-on by offering absolutely FREE online PLC training – no purchase necessary! This online video training course encompasses various levels of training from entry level programming to advanced PLC functions, and is available 24/7/365 so you can learn at your pace and at your convenience. Some of the general topics covered include: • • • • • •

Logic circuits Basic switches Sinking and sourcing PLC scan time I/O fundamentals PLC memory addressing

A wide variety of free training videos can be found at automationdirect.com.

Also available are over 200 training videos specifically covering AutomationDirect PLCs and include topics on how to use their rung editors, logic instructions, internal control relays, subroutines, communication, data view windows and many other functions. • CLICK PLC Family Video Library (64 videos) • Do-more\BRX PLC Family Video Library (115 videos) • Productivity PLC Family Video Library (62 videos) This training is provided by AutomationDirect’s education and its training partner Interconnecting Automation who has been training automation professionals for more than 20 years. Interconnecting Automation’s instructors pride themselves on providing a “no hype”, “no sales pitch” type of instruction and aim to thoroughly help others learn about PLC products so they are ready to use these products to their fullest potential. To get unlimited access to the FREE online PLC training or to learn more about what is provided, we invite you to head on over to www.automationdirect.com/plc-training.

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echnical resources you need from an

automation vendor you can depend on The Beckhoff team works hard to design and deliver the most advanced automation and controls technologies available. Of course, that is only half the battle as offering best-in-class education and training is also crucially important. A wide range of online resources are available 24/7/365 from Beckhoff for engineers:

E-Learning Portal - Beckhoff USA is pleased to announce the launch of an e-learning portal with a range of presentations on topics related to industrial automation – and you’re invited to join! These useful educational resources are free and open to engineers located in the U.S. Multiple classes are available, including topics from all Beckhoff product families: automation software, industrial PCs, I/O and drive technology. Each presentation is followed by a quiz to reinforce the topics covered and gauge what you’ve learned. No Beckhoff hardware is required to participate, but there are modules that permit students to use their own Beckhoff equipment during the training. Register for an account at learn.beckhoffus.com and start learning today!

Educational Webinars - Pressed for time? Beckhoff offers many webinars throughout the year on a wide range of interesting topics, particularly automation and controls programming, industrial Ethernet applications, tips for designing world-class motion control architectures and much more. Visit www.beckhoff.com/webinar to learn more. Don’t forget to visit the webinar archive to view the complete history of Beckhoff webinars anytime.

TwinCAT Engineering Environment - Programmers and engineers can download the base engineering module of TwinCAT 3, the leading PC-based automation software at no charge from Beckhoff (TE1000). Visit www.beckhoff.com/twincat3 to quickly download and install TwinCAT 3 on your programming and development PC today! For more information: www.beckhoffautomation.com input #23 at www.controleng.com/information

he Future of Automation Starts

with CIMON

In the Industry 4.0 era, automation is evolving at a rapid pace. As the demand for automation grows, so does the competition. CIMON offers free and unlimited resources for learning and advancing with the latest automation technology.

CIMON will soon be offering free hands-on training with their hardware.

Free HMI, PLC, and SCADA Software

Webinars

All of CIMON’s product software is absolutely free to download. Simply create an account on the CIMON website and visit https://www.cimon.com/customersupport/download/ to download the HMI, PLC, and SCADA software. Updates are free, as well, and so is CIMON customer support.

If you can’t make it for a live training session, there are also free webinars for your convenience. Visit www.cimon.com/videos-webinars-tutorials/ to become familiar with CIMON hardware and software.

Online Training CIMON offers an array of free online training courses dealing with all of their products and software. Reserve your spot for a live training session by visiting www.cimon.com/book-your-cimon-training/ and selecting a date that works for you. Some common training topics include the following:

In-person Training CIMON’s in-person training is still being set up at their newest U.S. location, but when it is complete, they will be offering free hands-on training with their hardware. Experience PID control, servo operation, and HMI communications with the CIMON PLC CM1 and CM3 series. For more information about CIMON products and training, get in touch with their support staff!

• Tags and database • Switches and lamps • Scripting and Syntax • Trend graphs and reporting • Data logging • Security • Troubleshooting • Free simulator setup +1 800 300 9916 • support@cimoninc.com www.cimon.com input #24 at www.controleng.com/information

igi-Key Electronics offers automation

and control products and solutions to meet the manufacturing demands of today and requirements for the future.

From robotics and safety to controls and relays, Digi-Key enables engineers to design easier and operators to work smarter. Robots can reduce human error, increase productivity, and improve the overall automation process. Digi-Key’s educational robotics kits and industrial robotics include a variety of robotics and accessories for a host of applications. Machine safety and the use of safeguarding equipment protects a company’s most important asset - its people. From the production line to shipping and pumping to drilling, each type of machine creates unique hazards in the workplace. Learn more about area scanners and light curtains that protect personnel from getting too close and door interlocks that prevent unauthorized entry into hazardous areas. Turn information into action with controls and relays that manipulate values to ensure your automated cell works exactly as you intended. PLCs and smart relays monitor your devices for ease of mind and improve efficiency by observing patterns and modifying accordingly.

Digi-Key offers a wide variety of online resources to empower your success, including: • Design & Integration Services - Access a network of experienced system integrators to develop automation solutions from concept to commissioning, testing, and beyond • Interactive Product Selectors – Use the visual product selectors to navigate to the automation products you need • Blogs – Learn something new today! • Articles & White Papers – Discover the latest technology news, product information, and supplier updates • 3D CAD Models, Datasheets, & Technical Manuals – Take your design to the next level

sales@digikey.com • 1-800-344-4539 • www.digikey.com input #25 at www.controleng.com/information

ultivate a “future proof” workforce that

can sustain profitability in any market. As automation technology continues to revolutionize the industry, organizations risk falling behind if they don’t adapt to the changes. When personnel are overwhelmed with data, and their work processes haven’t evolved along with the technology, it can be difficult for them to turn investments into real, quantifiable results. Emerson’s Educational Services offer innovative, scalable, and customizable training solutions that enable you to use workforce development as a strategic lever for sustaining growth in highly competitive industries. With hundreds of available courses and a range of content delivery methods, from on-site and hands-on to virtual and self-paced, you’ll be able to accommodate different learning styles and find solutions that match your training budget.

Learn online and bring the experts to you. Working alongside Emerson trainers, provide your team with full access to software and control systems without the need to travel. Choose an online option that works best for your business needs. Emerson offers online self-led eCourses, and virtual instructor-led courses through our virtual classroom. The virtual classroom platform allows students the ability to engage with peers and industry experts at a place and time that work for them. In addition to hands-on demo sessions, the virtual classroom offers theoretical training in several courses and webinars covering field instrumentation, measurement, final control, process control, safety systems, reliability, digital solutions, and more. Emerson’s Educational Services can help you develop the strategies to arm your workers with the practical knowledge and skills they need and to provide your business with a strong foundation of expertise. Emerson Automation Solutions is accredited by the International Association for Continuing Education and Training (IACET) and is accredited to issue the IACET CEU.

To learn more or to find training, visit Emerson.com/education input #26 at www.controleng.com/information

nterested in a quick way to improve

process productivity? Squash Your Power Quality Downtime!

Lightning, storms, fallen trees or tree limbs, animals—these and more cause power quality issues—and process downtime. But we can help you keep your “Uptime Up!” EPRI’s Power Quality Services Team specializes in helping industrial and commercial enterprises make their important processes more resilient in the face of common power quality (PQ) phenomena, especially as more sophisticated control systems appear in their manufacturing systems. With more than 300 PQ Site Assessments completed to date, plus thousands of laboratory tests and years of applied R&D, our team can quickly identify the unique issues and solutions for your individual facility. Our team can prescribe the most cost-effective and relevant mitigation and control system design techniques to reduce process and

machine sensitivity to PQ events, often without requiring batterybased solutions. EPRI’s PQ Services include: • Industrial facility assessments, testing, design consulting, training in power quality, process control sensitivity to PQ, and mitigation methods—all turbo charged by our unique Power Quality Investigator (PQI) expert tool. • Direct engagement with plant management, engineers, maintenance, and process operators to understand shutdown issues and their relation to PQ at the facility as revealed by available PQ event data at the site.

PQServices@epri.com • MyPQ.epri.com input #27 at www.controleng.com/information

• Expert analysis of available shutdown logs and process control drawings identifying specific component sensitivities as well as mitigation options. • Testing of control component, machine or process PQ susceptibility, or compliance to standards, such as SEMI F47 and IEEE 1668, including verification of mitigation strategies. • Comprehensive PQ recommendations including economic analysis. Put our decades of experience investigating and solving industrial PQ issues to work for you. Learn more about EPRI’s capabilities and how we can help your organization keep your “Uptime Up!”

ot every HMI/PLC Programming Software is the same! Read below: 10 minute screen design, on-line edit, drag-n-drop PLC software. Most suppliers of HMIs and PLCs claim that their software is easy to learn and easy to use. The real test comes in when you actually get to do it. We introduced EZTouch in 2001 with a simple aim for a new user to learn the software from scratch in less than an hour and create a fairly complex screen in 10 minutes or less. No going to a school like Rockwell requires, nor spending endless hours reading manuals. We created a simple design interface to add pre-built objects to a screen. You have a quick selection on which EZTouch panel, what PLC protocol among hundreds including DH+/RIO, and you start placing the objects on the screen. There is an extensive symbol library to pick objects from. You can also simulate your HMI screens on the computer itself! A recent study of plant users of HMIs found that a typical user makes changes to the HMI screens at least 6 times during the first three months. EZTouch patented on-line edit allows screen modification without shutting the machine down. Changes are made on the fly. This feature is enhanced by our new miniWIFI, allowing you to program up to 50 feet away and with no cables. EZPLC offers a similar free-flowing drag-n-drop programming software. No restrictions, just draw the ladder. Try inserting an e-stop contact in an existing rung in any other PLC programming software and you will quickly find out that not every programming software is the same. In addition, our integrated software with no annual fees with free life time upgrades, is common to all our HMIs, PLCs and EZTouchPLCs. Order your FREE KTD (Knowledge Treasure Drive) to see live examples. www.ezautomation.com.

sales@ezautomation.net • 1-877-774-3279 • www.EZAutomation.net input #28 at www.controleng.com/information

nclosure Quality Supported by

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

Polycarbonate Watertight Enclosures Hammond Manufacturing offers several series of watertight polycarbonate and ABS plastic enclosures available from stock. Ideally suited for mounting printed circuit boards or DIN rail mounted components, with several series offering optional subpanels. Gasketed lids with two piece “tongue & groove” construction provide protection against access of oil, dust and water. Polycarbonate versions are cUL and UL508A listed and are designed to meet NEMA Type 4, 4X, 6, 6P, 12 & 13 ratings – exceeding IP ratings up to and including IP68. Replaceable gasket is one piece made from high temperature, U.L. listed silicone. Optional mounting accessories include external feet, as well as pole mounting brackets. There are

sales@hammfg.com • 716-630-7030 www.hammondmfg.com input #29 at www.controleng.com/information

Quickly find the right enclosure at hammondmfg.com

modifications also available to customize any enclosure with holes, cutouts and screen printing. For CAD files and detailed specifications visit: hammfg.com/electronics/small-case/industrial.

Is Finding the Right Enclosure a Challenge? With a variety of materials as well as hundreds of sizes, how can you quickly find the right enclosure for your need? Hammond Manufacturing’s web site – www.hammfg.com/electrical provides the tools needed to help. Hammond’s site has a built in search function which quickly allows for a search by size. Once size has been specified, additional criteria like material, NEMA Rating and specific features can further refine the list of options. No more poking through page after page based on generic descriptions or pictures — the site is extremely intuitive and user-friendly.

ELUKABEL Introduces ISOBUS

Hybrid Cable for Agriculture Industry HELUKABEL, one of the leading global manufacturers and suppliers of cable, wires and accessories, has introduced the ISOBUS PUR hybrid power and data cable for use in the agriculture industry. This cable connects tractors, combines, sprayers and other farm vehicles to their implements at the front or rear of the machine. The ISOBUS PUR is built to the worldwide ISO 11783 standard that governs the communication between agriculture machinery, mainly tractors and implements. ISOBUS areas of application include: wheel sensors, auto steer and turnaround, GPS navigation, row guidance, equipment monitoring and sensors, video input, as well as fleet management to name a few. The PUR-jacketed hybrid cable can operate in environments ranging in temperature from -40°F to +185°F (-40°C to +85°C), application dependent. Additionally, the ISOBUS PUR’s rugged outer jacket can withstand oil, abrasion, UV rays, microbes, and is flame retardant. HELUKABEL currently offers three configurations for agriculture OEMs, but can also provide additional custom constructions upon request. The three standard configurations are: • PN: 17001249 – 2xAWG10 + 2xAWG14 + 1x4xAWG20 (2x6 mm2 + 2x2.5 mm2 + 1x4x0.5 mm2) • PN: 17001250 – 2xAWG8 + 2xAWG14 + 1x4xAWG20 (2x10 mm2 + 2x2.5 mm2 + 1x4x0.5 mm2) • PN: 17001251 – 2xAWG6 + 2xAWG14 + 1x4xAWG20 (2x16 mm2 + 2x2.5 mm2 + 1x4x0.5 mm2) Visit www.helukabel.com/us/products/data-network-bus-technology/isobus-pur.html to learn more about the ISOBUS PUR.

(847) 930-5118 • sales@helukabel.com • www.helukabel.com input #30 at www.controleng.com/information

he best machines and production facilities around the world use Lenze

Lenze offers a comprehensive, future-proof portfolio that covers the control level, the field level, and the electromechanics, and ensures standardized data communication right up to the cloud level. Our solutions enable you to meet all your machine development requirements easily and efficiently, with the greatest possible flexibility. You can rely on: • Scalable hardware in a comprehensive and open automation platform • Modular software for efficient software engineering • Open networking thanks to the use of market standards • Solutions that meet the requirements of digitalization • A thorough understanding of your machine from experienced experts in your sector

Our newest portfolio additions: The i950 Servo Inverter is a match for any operational scenario thanks to three different modes of operation. It can be freely programmed or serve as an actuating drive under a CiA402 motion control, but the most common mode of operation is via parameterization using preconfigured technology applications. Lenze’s X4 Remote, offers an integrated and readyto-use solution for cloud-based remote services. Easily

set up and configured, machine manufacturers can confidently offer reduced downtime and increased productivity, making their machine fit for the future. Our new i550 protec Frequency Inverter, well-protected with IP66 (NEMA 4X), conquers a wide range of decentralized drive tasks. It is an exceptionally compact device with a design that ensures maximum protection against adverse environmental conditions such as high temperatures, dust, dirt or water jets during cleaning operations. The Lenze Smart Motor works without contactor or starter, fixed speeds can be set at will, and there are many integrated functions for material handling applications. It meets the strictest energy efficiency requirements and can be operated very conveniently using a smartphone.

info.us@lenze.com 800-217-9100, 508-278-9100 www.Lenze.com

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eed to Liquidate your Inventory Quickly

and Professionally?

Radwell International’s Asset Recovery program is an exceptional resource for your company. We offer cash for parts and products you don’t need. In many cases, selling your excess inventory to Radwell gives you the opportunity of adding dollars to your bottom line. With extensive knowledge, Radwell stocks and sells new and certified preowned industrial automation, MRO, pneumatic, motion, electronic, hydraulic, HVAC, and electrical control equipment for plant floor and facilities maintenance machinery. The process is easy. Gather all your inventory, box it, and then call Radwell for free pick-up. Need more information? Radwell has highly trained and

experienced asset recovery and surplus team members ready to help. It is important to note that any equipment being sold to or sourced by Radwell International must meet the highest standards of functionality and use. However, not all equipment sold to Radwell via the Asset Recovery program has to be brand-new. Radwell has a team of in-house engineers and technicians who can refurbish equipment to a like-new state, granting it the Radwell Certified PreOwned stamp of approval, which comes with Radwell’s Two-year warranty.

Radwell has highly trained and experienced asset recovery and surplus team members ready to help you make your business thrive.

The types of equipment Radwell most often purchases and upcycles include industrial automation equipment, PLCs, drives, motors, electronic parts, circuit boards, meters, ensors, and all types of industrial controls. However, if your company has other types of surplus inventory that you’re looking to offload, please feel free to contact us at 800-884-5500 ext. 824.

To learn more about Radwell International’s Asset Recovery Program visit https://info.radwell.com/en/asset-recovery-program

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ant to learn about engineering topics

pertaining to gearmotors? We have the information at your fingertips! Tired of looking up multiple sources for answers to common engineering questions about gear units or gearmotors? We have the solution. SEW-EURODRIVE’s online Technical Notes can be a real life-saver when you need answers. Technical Notes provide quick access to many engineering topics such as how to properly mount a torque arm, how to determine and design for inertia, or how to properly design your machine to use a hollow shaft gear unit. Need answers on how the speed, mounting position, environment, and duty cycle can affect the thermal rating of a gear unit and how to protect against too much heat? That’s one of many in-depth documents you can find by visiting www.seweurodrive.com and clicking Technical Notes.

Whitepaper Our technical white paper, Maximizing Gearmotor Speed Range shows you how to operate VFDs above 60Hz to widen speed range, improve stability and reduce cost. In this white paper, you’ll learn why it can be a good idea to operate gearmotors above 60Hz. Through a common example, we will show you how to select the proper gearmotor that will significantly enhance performance in the following ways: • Increase stability by reducing inertia mismatch • Widen the available speed range • Eliminate a costly ventilator fan at low speed • Eliminate motor overheating at low speed • Enable the use of a smaller motor Visit www.sewwhitepapers.com/vfd to download the PDF.

mktg@seweurodrive.com 864-439-7537 www.seweurodrive.com input #33 at www.controleng.com/information

aker of prefab pharmaceutical clean rooms (POD) standardizes on Siemens technologies with huge cost, time and space savings

By standardizing on Siemens automation, controls, and building management system components, G-CON Manufacturing cut its prefab cleanrooms’ component costs by as much as 75 percent, programming time by 80 percent, and mechanical space requirements by 30 percent — all while ensuring greater lab reliability, availability and utilization for its customers. When Patrick Dorman, G-CON’s automation and electrical engineering manager, joined the company in 2018, he saw lots of opportunities to improve the PODs, especially the automation and controls for each one’s building management system (BMS) and environmental monitoring system (EMS). These are the most important systems in a POD and contained in each POD’s mechanical space. With G-CON management’s support, Dorman made the strategic decision to bring the design and

engineering of the BMS/EMS automation and controls in-house and combine them to manage both systems. In addition, he chose to standardize on the Siemens SIMATIC Totally Integrated Automation (TIA) portfolio of highly integrated components, programming them all using the SIMATIC TIA Portal, a common software engineering and programming framework with point-and-click ease-of-use. Both decisions would greatly simplify procurement, fabrication, support, and service, saving G-CON weeks, if not months, rework by a third-party, and associated costs. The combination of Siemens TIA components and the TIA Portal enhances interoperability and scalability, both big benefits of standardization. G-CON’s PODs

fa.marketing.us@siemens.com • 1-800-241-4453 usa.siemens.com/automation input #34 at www.controleng.com/information

provide easy traceability and audit trails of their BMS/EMS systems for Title 21 CFR Part 11 compliance and similar regulations in the EU and other world regions. This saves customers time and labor by not having to log system data manually. For G-CON customers, the company’s standardization on Siemens components means greater reliability and availability as well as asset utilization. Reliability and availability of G-CON PODs to a customer’s process is critical both in terms of cost and life-or-death outcomes, according to Backstrom. Lowering cost was a primary objective for G-CON and Siemens delivered.

ecome an Edge Computing Expert with Stratus Educational Services

Whether you are a Stratus customer or partner, or simply looking to gain expertise in Edge Computing, we can help. Stratus offers a variety of learning opportunities to enable you to become an expert in configuring your Edge Computing environment to prevent downtime of critical systems and applications. With 40 years’ experience across numerous industries, we are ready to pass along our expertise and help you make the best of your resources.

Stratus offers instructorled courses as well as online self-paced classes.

Stratus offers instructor-led courses as well as online self-paced classes. In-person classes offer an opportunity for face-to-face discussion and Q and A, while our self-paced classes have been created in a format to allow more flexibility on the part of the students. They have also been created in a modular fashion to provide the ability for the students to upgrade their knowledge without having to review or retake materials they have already learned. We also offer the Stratus Always-On Certified Professionals Program, a global certification program designed to help you maintain 99.999% availability. Successful completion of the program validates technical knowledge in implementing and supporting continuously available Stratus ftServer®-based solutions. The objective of the program is to effectively set and validate high standards of excellence in the support of Stratus solutions by using certification testing to measure skills, experience, and the degree of specialized knowledge candidates have gained. The requirements for certification are consistent worldwide. For more information on the Stratus Education Services currently available, and information on registration and costs, please visit https://stratus.com/education/.

Stratus Technologies 5 Mill and Main, Maynard, MA 01754 978-461-7000 • www.stratus.com input #35 at www.controleng.com/information

AGO is adapting to New Training Methods in 2020 During this unprecedented time, we are currently unable to provide the quality face-to-face learning opportunities you have come to expect from our expert training team. Currently we are not offering free training classes at WAGO. Go to www.wago.com/us/learning-opportunities to see when they may become available again. To help fill this void, we have expanded our online training options to include a series of free webinars that may be accessed entirely remotely (in addition to our eLearning modules and YouTube channel). Read more details below:

WAGO’s Free webinars may be remotely accessed at any time for your convenience

Our experts will teach you how to use specific products for certain applications through hands-on demonstrations. Also, watch for upcoming live webinars each month to further broaden your skillset. See the complete list of topics to start watching right away: www.wago.com/us/ondemand-webinars.

eLearning Modules On Demand Webinars for Instant Learning If you are interested in learning new automation skills, check out our on demand webinar portal — available now. Learn at your own pace and choose from a multitude of topics like:

· · · · · ·

Cybersecurity Advanced power supply features IIoT: Node Red and Linux Electronic circuit breakers IIoT: Edge computing And more!

Customers can improve their understanding of our product solutions through eLearning modules available online (www.wago.us/elearning) covering topics such as Ethernet, power measurement, Bluetooth, and more.

YouTube The WAGO YouTube channel covers a wide variety of how to videos, product demonstration videos, and product overview videos. Visit our YouTube channel at www.youtube.com/wagocorp.

WAGO Corporation Info.us@wago.com 1-800-DIN-RAIL (346-7245) www.wago.us input #36 at www.controleng.com/information

Acromag Supports Engineers from the Beginning of their Education through their Career Acromag has been designing and manufacturing industrial I/O for over 60 years. Acromag’s founder believed in helping the next generation of engineers and bestowed to the University of Michigan a scholarship. This scholarship is awarded on the basis of academic merit to students pursuing engineering degrees. Engineers are encouraged to visit our website to download industry related application notes and white papers. Technical support is available from the factory from a team of experienced application engineers to help you find the best solution or to troubleshoot your system.

sales@acromag.com • 877-295-7057 www.acromag.com

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EIGR-C3 Gigabit Cellular Router Available The Contemporary Controls EIGR Series IP routers allow you to create subnets to separate your IT and OT infrastructure. VPN models allow remote access to devices at the job site for easy troubleshooting and commissioning. The EIGR Gigabit routers allows for higher speeds and data throughput while supporting OpenVPN client/server functionality for worry-free communications. The EIGR line is being expanded with the introduction of a 4G LTE cellular router that has been certified and approved for use on Verizon networks. We are now shipping the EIGR-C3 VPN Router which allows for cellular, secure VPN connection to remote sites where wired connection is not an option. Multiple cellular data service options are available for purchase from us for convenient and quick device commissioning.

info@ccontrols.com • Tel: +1 630 963 7070 www.ccontrols.com

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Dataforth: The Industry Leader in Signal Conditioning, Data Acquisition & Control Founded in 1984, Dataforth’s ongoing commitment has been to incorporate leading-edge technology into the design, development, and manufacture of top quality, affordable Industrial Electronics. Today, Dataforth’s 2,000+ made-in-the-USA products all ensure rugged signal and data integrity, wide spectrum accuracy, and unrivaled reliability for wide-ranging applications. Key Dataforth signal conditioning modules and data acquisition systems

Unmatched Isolated Signal Conditioning

Exceptional Data Acquisition & Control

• SCM5B Analog Modules

• MAQ®20

• SCM7B Process Control Modules

• 8B isoLynx® SLX300

• Miniature SensorLex 8B Analog Modules

• SCM5B isoLynx® SLX200

• DSCA DIN Modules

• DAQ System Builder

Other product lines include dedicated DAQ software; isolated digital I/O modules, loop isolators and transmitters, and data communication drivers and converters.

Dataforth’s online library includes Application Notes, Tech Notes, and User Manuals, along with real-time demos, a MAQ20 webinar, and the Full-Line Product Catalog.

sales@dataforth.com • 800-444-7644 • dataforth.com

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PRODUCT & LITERATURE SHOWCASE

The Unlimited SCADA Platform of the Future is Here

• Unlimited high-performance tags • Instant web-deployment • Build pure-web applications

Ignition 8 will revolutionize the way you control your industrial processes. Input #100 at www.controleng.com/information

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Discover more at: inductiveautomation.com/ignition Input #101 at controlengineering.hotims.com

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August 2020

control engineering

INNOVATIONS

NEW PRODUCTS FOR ENGINEERS

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

Plant process management software for shift handover Shiftconnector software from Eschbach is plant process management software that tracks and manages all important information that is needed at the time of the shift handover. It has a 360°-overview of all events and change. All information known is captured, stored and auditable and makes shift changes easy and efficient. The data in Shiftconnector can be analyzed to find optimization potential and sources of error, leading to improved business processes. It provides visual presentation of data and performance figures, filters and search functions that highlight errors and faults. It also can communicate, control and determine the benefit of improvement initiatives. Eschbach, www.eschbach.com

Input #200 at www.controleng.com/information

Digital commissioning and turnover package

Endress+Hauser expands end users’ digital experience on instrument projects with their digital commissioning application and Netilion projects digital turnover package. These capabilities are designed to empower the plant startup team by mitigating project risks and tracking progress in real time. Users can see project work progress across the field devices startup phases in real-time and can flag any potential issues on the commissioning app. The web-based application workflow is tailor built to field technician and project manager user’s needs for greater productivity. Netilion Library helps users organize asset records, drawings, pictures, files, and turnover package documents. It is a file-sharing and data management service for the complete life cycle of an instrument. This saves significant time when carrying out maintenance or engineering activities since the often-tedious search for information is eliminated. Endress+Hauser, www.us.endress.com

Input #201 at www.controleng.com/information

Inductive position sensor has stray field immunity

Renesas Electronics Corp.’s magnet-free IPS2200 inductive position sensor features high accuracy and speed, total stray field immunity and efficient motor integration in a thin and lightweight form factor. The sensor is ideal for use as an absolute position sensor in a wide range of industrial, medical, and robot applications. The sensor allows customers to cost-effectively tailor sensor design for their applications and maximize the performance of the sensor’s accuracy. It is designed around the motor, allowing customers to match the number of sectors to pole pairs of the motor to maximize accuracy, accommodating both off-axis (through shaft and side shaft) and on-axis positioning. Renesas Electric Corp., www.renesas.com Input #202 at www.controleng.com/information

COVID-19 safety labels and signs

Clarion Safety Systems has expanded its safety product line to offer a full portfolio of COVID-19 safety products. These visual safety solutions are designed to help businesses to keep employees, visitors and customers safe by supporting social distancing policies, reminding of hygiene protocols and reinforcing personal protective equipment (PPE) requirements. The COVID-19 safety label and sign products include signs on washing your hands, virus pretention tips, virus symptom awareness, social distancing notices, and floor markers to tell workers where to stand. These are signs with complaint with OSHA regulations and also use the latest American National Standards Institute (ANSI) and International Organization for Standardization (ISO) warnings technology to more effectively create awareness and explain hazards specific to the issue at hand. Clarion Safety Systems www.clarionsafety.com Input #203 at www.controleng.com/information

Customized LVDT position sensors fit many applications

NewTek Sensor Solution is providing custom LVDT position sensors in short timelines in meeting unique and demanding position measurement requirements for applications in a range of industries including oil and gas, packaging, manufacturing and power generation. The most popular sensor modifications include custom mounting brackets, specific electrical output requirements, ratiometric (difference/sum) output, high stroke to length ratios, high temperature exposure, radiation and submersion resistance as well as custom signal conditioning. These sensors can be used for many different applications as users deal with supply chain issues due to the COVID-19 pandemic. NewTek Sensor Solutions, www.newteksensors.com Input #204 at www.controleng.com/information

www.controleng.com

control engineering

August 2020

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INNOVATIONS

BACK TO BASICS: REMOTE ACCESS John Almlof, Nozomi Networks

Secure remote access to thrive Secure remote access (SRA) helps companies survive and thrive during the COVID-19 pandemic. Some new challenges need to be considered. See 10 remote access best practices.

s the world sorts itself out during and post-pandemic, one thing is certain – remote working is here to stay. Fortunately, technology can provide the visibility needed to secure operational access, whether employees are working from the office or at home. While this level of flexibility hasn’t been so readily embraced in the past, secure remote access (SRA) is now being widely used to help companies survive and thrive. For example, a 70-year old plant engineer was considered high risk due to a medical condition, and needed to self-isolate. The company he worked for had to provide secure remote access for him, so he could get “inside” their facility to manage their critical assets. The challenge was by enabling remote access to critical operations assets, the company significantly expanded its attack surface. According to research from NordVPN, 62% of employees are now vulnerable to cyberattacks, thanks to the use of personal computers for remote work during the COVID-19 pandemic. Another survey found COVID-19-related phishing emails are on the rise, with many embedding different malware strains as attachments. AgentTesla (45%), NetWire (30%), and LokiBot (8%) were the most actively exploited malware families, said researchers at Singapore-based MORE INNOVATIONS: Keywords: Group-IB’s Computer Emergenremote networks, remote security, cy Response Team’s (CERT-GIB). COVID-19 With some minor differences, the The COVID-19 pandemic is forcing goal of all these malware sammore workers to operate remotely, ples is to harvest user credentials which brings new challenges for from browsers, mail clients and file companies. transfer protocol (FTP) clients, as Cybersecurity, in particular, is playing a larger role as more people work from well as capture screenshots, and home. secretly track user behavior and Remote access should be protected send it to cybercriminals’ comwith firewalls and companies and mand and control centers. employees need to follow standard Security was always thought best practices. of as a collection of people, proONLINE cesses and technology, but the latRead more articles about wireless ter is now playing a bigger role in networks in the “wireless” sub-channel allowing businesses to operate via page under networking and security at www.controleng.com. remote access. “I’ve found that people were CONSIDER THIS often the inhibitor to technoloWhat challenges does your company gy, in that they simply didn’t want face with remote networks and how are you overcoming them? to allow technology to be acces-

M More INNOVATIONS

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August 2020

control engineering

sible remotely,” Bill Johnson said. “Historically, SCADA technologies and OT technologies haven’t been connected to a network that could be remotely accessed. So, consequently, some organizations default to ‘security by obscurity.’ But the COVID19 pandemic has forced companies to re-think both people and processes.” While it might be preferable for employees to be physically present, secure remote access technology allows organizations to manage remote access to critical systems in a responsible, secure way, providing situational awareness and auditability to see who is touching the business infrastructure.

10 secure remote access tips

To help ensure secure operating practices, Bill Johnson and Pam Johnson listed best practices that companies and employees could follow: Companies should: 1. Protect everything with firewalls, VPNs and two-factor authentication (basically zero trust) 2. Monitor remote access connections to see how remote systems interact with the network 3. Ensure standards and policies in place include rules for secure servers, and server settings 4. Consistently make sure settings haven’t changed 5. Evaluate how those servers are configured, what software is on them and what version it is, and all automation behind the scenes 6. Apply patches remotely if it is possible to do so securely 7. Incorporate a regular password update process, through automation 8. Keep a log of configuration or firmware changes, what was done and by whom.

Employees should: 1. During remote access, double check the location you’re going to visit before going there 2. Don’t click on unknown links and files. ce John Almlof is director strategic alliances and business development – Americas at Nozomi Networks. This article originally appeared on ISSSource’s website. ISSSource is a CFE Media content partner. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com. www.controleng.com

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