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Vol. 67 Number 12

DECEMBER 2020

ANSWERS 16 | How modern simulation software addresses intralogistics challenges 20 | AMP upgrades to edge controllers 22 | Cybersecurity and the rise of IT-enabled OT systems

COVER: Tall storage and shuttle racks—with advanced lift and transport technology—make the most of available space in distribution and fulfillment centers. Serving as a digital twin, advanced simulation software can help fulfillment and distribution centers remain competitive, from design to operation. Courtesy: Siemens

INSIGHTS 6 | International: Flexible process control 8 | Technology Update: Cloud efficiency platform developed for databases 10 | Technology Update: Benefits of an alarm management philosophy

26 | Secure-by-design industrial products are increasingly important p.20 30 | How IT/OT convergence affects networking 41 | Developing a great sequence of operations: Additional answers

p.30

42 | What you need to know about cybersecurity Online learning: Plan to attend now www.controleng.com/webcasts

NEWS

12 | Control system best practices; wearable exoskeleton; Stretchable sensor gives robots, VR a human touch; Headlines online include Top 5 14 | Think Again: Data flow, alarms, simulation, cybersecurity, robotics

INSIDE MACHINES

M1 | Direct-drive advantages, part 1 M3 | How RFID improves machine performance M8 | The need for robotic offline programming in a COVID-19 world

CONTROL ENGINEERING (ISSN 0010-8049, Vol. 67, No. 12, 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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DECEMBER 2020

INNOVATIONS NEW PRODUCTS FOR ENGINEERS

43 | Integrated servo drives, Non-fusible

disconnect switches, Bluetooth dual-mode wireless modules, Advanced I/O system, Thermal mass flowmeter

44 | Review finalists and VOTE NOW!

www.controleng.com/articles/2021-engineers-choice-finalists-vote-now.

BACK TO BASICS

45 | Resiliency, security needed for digital automation future Manufacturing’s resilience has been strong during the COVID-19 pandemic, and cybersecurity needs to be stronger than ever as the nature of work changes.

NEWSLETTER: Industrial Networking • Maintenance automation: create a new recipe for data integration • How integrators can help IIoT applications • How raw data is made ready for applying analytics • Applying machine learning to making mechanical parts • How deep learning enables machine vision www.controleng.com/newsletters.

CFE Edu: Virtual Training Week On-Demand Did you miss the live event? You can still attend CFE Media and Technology’s Virtual Training Week on-demand to receive training on a variety of the latest industry trends. Register and receive full access to exclusive content offered by industry experts with live Q&A sessions! https://cfeedu.cfemedia.com/learning-paths/cfe-mediatechnology-virtual-training-week

Control Engineering eBook series: IIoT Cloud eBook Winter Edition Learn how the Industrial Internet of Things (IIoT) and the cloud are changing manufacturing in this helpful eBook. Featured articles include an overview of industrial IoT, from edge to cloud, harnessing efficiency to inspire innovation, Industrial Internet of Things vocabulary terms updated, and cloud efficiency platform developed for databases. Learn more and register to download at www.controleng.com/ebooks/. Global System Integrator Report December Control Engineering and Plant Engineering supplement Advice from automation and control system integrators with System Integrator of the Year for 2021, System Integrator Giants, case studies, advice and more. www.controleng.com/GSIR

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

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December 2020

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INSIGHTS

INTERNATIONAL: PROCESS CONTROL Ralf Jeske, ABB Automation

Flexible process control systems

An alternative modular automation approach to large-scale automation systems is emerging.

odularization breaks down systems, plants, processes, and unit operations into standard, modular components, much like those popular children’s building bricks that can be mixed and matched freely to make any number of different creations. The concept centers around the pre-fabrication of specific and complete operational packages, which include the automation to control them. The ease of assembly this brings has led to major reductions in on-site work time, complexity and a reduction in the possibility of error. As a concept, modular automation has been around for some time, with construction and shipping industries among early adoptors. Until recently, use was confined to a small number of examples in process industries, with no large rollouts. With advances in the automation technology that controls mechanical industrial equipment, modular automation has become easier to integrate into existing systems, widening adoption for use in industrial production lines. This is a big change from the large-scale plant-wide automation systems that have been at the heart of production line control for decades and are designed to supervise and control entire production plants. The aim is to modularize common unit operations into packages to allow customizing of both the products made and the production quantities, giving major competitive advantages in terms of flexibility and time to market. The concept KEYWORDS: process also allows rapid changes in deployment of control, process equipment production assets, to make specific product assembly types and volumes when and where needed. Modular automation has

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become easier to integrate into existing systems. Module type packages (MTP) for building modular automation capability into a process module can be integrated. Automation will be distributed where needed in the future rather than at a fixed location.

ONLINE More about scalability in greenfield and retrofit applications with this article at www.controleng.com.

CONSIDER THIS What do you see as the future for process control and process manufacturing?

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December 2020

NAMUR as a catalyst, MTP

Helping to move modular automation forward is done by NAMUR, an international user association based in Germany that focuses on automation technology and digitalization in process industries. NAMUR has led the fundamental efforts to develop standards which serve as a base for modular automation to be built upon in industrial plants. It sees increasing flexibility of production plants, using modularization, as a key tool to meet fast-changing market demands, especially for chemicals and pharmaceuticals. A few years ago, NAMUR introduced the module type packages (MTP) standard for building modular automation capability into a process module (or PEA, process equipment

control engineering

assembly). The PEA includes the combined mechanical equipment and controller, and uses an MTP interface, which contains a vendor-neutral and functional description of the process module automation and can be generated by the engineering tool of the module. Through a simple import of the MTP into the process control engineering of the production plant, the module can be integrated. This is described in the standard VDI-2658, developed in Germany and being adopted as IEC 63280 for automation engineering of modular systems in the process industry. Using PEAs takes less time and on-site work to deploy production lines and equipment. With automation already integrated into the mechanical production equipment, as MTPs within the PEA, deployment to get it running onsite is not difficult. Flexibility to meet rapid changes in market demand has been a major driver, especially for the pharma and biopharma sectors where it is becoming common to make very small batch quantities of highly specialized products and medications. For highly-targeted individual treatments, for cancer patients for example, the batch size can even be as small as one specific medication or formula.

Pilot trials at Bayer AG

Bayer AG, a life sciences company, successfully conducted a pilot study based on an MTP control sub systems and a modular configuration tool, running with a modular-enabled system for the orchestration. This is the world’s first commercial modular-enabled process automation solution, and Bayer has publicly stated that it sees it as a first step in moving from monolithic automation systems covering the complete production plant to a more flexible and market-oriented plug and produce solution. The modular automation sector now is using the term “numbering up” capacity instead of “scaling up,” reflecting the number of PEAs put into service to meet demand. The modular, flexible approach allows both regional redeployment as well as product-specific redeployment. This clearly offers much greater flexibility than would ever be possible using the large, fixed-plant infrastructure that most industrial processes are built upon today. ce

Ralf Jeske is global product manager for ABB Automation, Germany. This article originally appeared on Control Engineering Europe’s website. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com. www.controleng.com

Working late again? Tired of working nights and weekends on motion control projects? It’s time to contact an automation specialist at SEW-EURODRIVE for help. Using the latest innovation, we provide a complete package from start to finish, including expertise, project planning, software, components, commissioning, and worldwide support. Go home and relax . . . we got this!

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INSIGHTS

TECHNOLOGY UPDATE: CLOUD PLATFORM Chris Adam, Purdue University

Databases and cloud efficiency Cloud efficiency system targets data-intensive uses, like COVID-19 pandemic.

Purdue University data science and machine learning professor wants to help organizations and users get the most for their money when it comes to cloud-based databases. The technology, in addition to helping databases during the data-intensive COVID-19 pandemic, also may help self-driving vehicles operate more safely on the road when latency is the primary concern. Somali Chaterji, a Purdue assistant professor of agricultural and biological engineering, and her team created a technology called OPTIMUSCLOUD. The system is designed to help achieve cost and performance efficiency for cloud-hosted databases, rightsizing resources to benefit both the cloud vendors who do not have to aggressively over-provision their cloud-hosted servers for fail-safe operations and to the clients because the data center savings can be passed on them. “It also may help researchers who are KEYWORDS: cloud technology, crunching their research data on remote COVID-19 data centers, compounded by the remote OPTIMUSCLOUD was developed by Purdue University working conditions during the pandemic, researchers to help with cost and where throughput is the priority,” Chaterperformance efficiency for cloudji said. “This technology originated from hosted databases. a desire to increase the throughput of Uses include the IIoT, COVID-19 data pipelines to crunch microbiome or pandemic and self-driving vehicle metagenomics data.” safety. The Purdue technology works with ONLINE three cloud databases: Amazon’s AWS, Under topics, see virtualization Google Cloud, and Microsoft Azure. and cloud stories at Chaterji said, with some engineering, it www.controleng.com. would work with more specialized cloud CONSIDER THIS providers, such as Digital Ocean and What applications would FloydHub. benefit from data-intensive cloud It is benchmarked on Amazon’s AWS technology?

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cloud computing services with the NoSQL technologies Apache Cassandra and Redis. “Let’s help you get the most bang for your buck by optimizing how you use databases, whether onpremise or cloud-hosted,” Chaterji said. “It is no longer just about computational heavy lifting, but about efficient computation where you use what you need and pay for what you use.” Chaterji said cloud technologies using automated decision making often only work for short and repeat tasks and workloads. A more optimal configuration handles long-running, dynamic workloads, such as sensor networks in connected farms or high-performance computing workloads from scientific applications or the COVID-19 simulations. “Our right-sizing approach is increasingly important with the myriad applications running on the cloud with the diversity of the data and the algorithms required to draw insights from the data and the consequent need to have heterogeneous servers that drastically vary in costs to analyze the data flows,” Chaterji said. “The prices for ondemand instances on Amazon EC2 vary by more than a factor of five-thousand, depending on the virtual memory instance type you use.” Chaterji said the system has numerous applications for databases used in self-driving vehicles (where latency is a priority), health care repositories (where throughput is a priority), and Internet of Things (IoT) infrastructures in farms or factories. The software runs with the database server. It uses machine learning and data science principles to develop algorithms that help jointly optimize the virtual machine selection and the database management system options. Chaterji said, “Even the best data centers run at lower than 50% utilization; costs passed down to end-users are hugely inflated .... You don’t want to buy the whole car when you only need a tire.” ce

A Purdue team created a technology called OPTIMUSCLOUD – which is designed to help achieve cost and performance efficiency for cloud-hosted databases. Courtesy: Purdue University

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December 2020

control engineering

Chris Adam is with Purdue University. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com. www.controleng.com

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INSIGHTS

TECHNOLOGY UPDATE: ALARM MANAGEMENT Martyn Hilbers, PLC-Easy

Benefits of an alarm management philosophy Giving operators on the manufacturing floor a simple and clear-cut philosophy for alarm management with a simple and clear-cut system can help reduce downtime and improve overall automation and efficiency.

larm acknowledgement is a widely accepted industry practice, but the reason why we apply alarm acknowledgement is a question not often asked. During a recent meeting for a project with the purpose of developing an alarm management philosophy and implementing an alarm rationalization, the question “why we need alarm acknowledgement” arose. The essence of an alarm is to notify operators about a process is going or is out of bounds and requires intervention because the automation system is incapable to change the situation. Alarm acknowledgement is used to help the operator manage the active alarms. It allows the operator to distinguish which alarms have been addressed and which have not, providing the operator with a to-do list. From an alarm acknowledgement standpoint, this leads to an assumption it has KEYWORDS: Alarm been accepted the control system can genmanagement, alarm erate multiple concurrent alarms that affect acknowledgement the process. It is also acceptable that the Alarm management is automation is not capable to deal with many acknowledged as a need, but how it is managed is not situations and/or the automation is generatoften addressed. ing too many alarms.

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Too many alarms on the manufacturing floor can cause confusion for operators. The need for alarm management is tied into the level of automated and manual processes on the manufacturing floor.

ONLINE Go to www.controleng.com for additional stories about alarm management and safety.

CONSIDER THIS What challenges does your company face when dealing with alarms and how can they be overcome?

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December 2020

Fewer alarms are more effective

Can we avoid too many alarms? Consider the following: a valve limit switch has malfunctioned and on opening the valve provides a failed to open alarm. The valve is part of an equipment module and this too needs to provide an alarm of this event. The equipment module is part of a phase and the phase might be part of an operation and part of a procedure. In order to put the phase on hold and possibly the operation and perhaps even a procedure, an alarm condition must be propagated from the valve up through the hierarchy. It is important to provide the operator with a notification that explains the control engineering

reason of the hold of the phase (and possibly the operation and procedure), but it is important the operator is not overwhelmed with alarms.

Alarm rationalization, efficiencies

This requires identifying possible situations involving multiple pieces of equipment and implementing alarm masking schemes for these situation to give the operator one message conveying the reason of the hold. For large processes, this is where an alarm management philosophy and the implementation of an alarm rationalization becomes important. It will require an ongoing effort to keep the alarm rationalization and alarm-masking schemes up to date in order to provide the operator with effective alarms, however for many organizations this often falls by the wayside. The effects of neglecting alarm management are not immediately noticeable nor impactful. However the effects compound over time and lead to significant production inefficiencies. Circling back to why we need alarm acknowledgement, the answer to that question says something about the alarm efficiency and the level of automated operation vs. manual operation of the automation.

Raising the bar on alarm acknowledgement

When sitting down to discuss and design a new automation system, should the question “do we need alarm acknowledgement” be in the top 10 of our requirement list when selecting and/or developing an automation system? If this question is on top of the list and answered “No,” the implication is the system is expected to perform at a higher automated level, is applying alarm rationalization and requires less operator interaction. ce

Martyn Hilbers, principal engineer, PLC-Easy. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com. www.controleng.com

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NEWS

Researchers designing wearable The Occupational Safety and Health Administration (OSHA) said one in 10 construction site workers is injured every year, and 21% of worker fatalities are in construction. Aiming to improve worker safety and efficiency, LSU and Rutgers University researchers hope to develop an integrated, multidisciplinary approach to bring emerging robotic technologies, such as a wearable exoskeleton, to the construction industry to save lives and time. The researchers received a $150,000 planning grant from the National Science Foundation to develop an exoskeleton. The award gives LSU and Rutgers one year to create a team of researchers to compete for a $3 million research grant in March. So far, their project is ahead of the game since there are few, if any, construction companies that have actually adopted exoskeleton technology. Exoskeleton project goals: This FW-

HTF project has three goals – to develop lightweight, flexible, high-performance, personalized wearable exoskeletons for construction workers; develop machine learning-based human skill modeling and training in construction; and initiate new cross-disciplinary collaboration and foster engagement with industry partners and stakeholders. “Construction workers get hurt for three reasons,” said Fereydoun Aghazadeh, an LSU professor of engineering. “Number one, they are tired. Number two, the task is beyond their capacity. Number three, they are not properly trained. If they don’t have the capacity to do the physical work, how can we enhance their physical capability? We can give them more power. This project is all about that.” Wang, who serves as the project’s principal investigator, says there are a few exoskeleton products currently available on

the market, but they mainly target the industrial/manufacturing setting. The exoskeleton is still a new concept in construction because the construction site is more dynamic and complicated. “We’re seeing how we can explore personalized exoskeleton or robotics technology,” said Chao Wang, an assistant professor at LSU. “In a manufacturing facility, a worker probably does the same thing 1,000 times a day. It’s repetitive, which is perfect for an exoskeleton because they design it just for that one task. A construction site is a lot different. You must be able to climb stairs, walk, squat, and reach out to different levels depending on what trade you are in. “That makes it difficult to design an exoskeleton because you need something that can help with all of these tasks. We are investigating how to make the exoskeleton smart enough to recognize what

Stretchable sensor gives robots, VR a human touch RESEARCHERS at Cornell University have created a

complicated, combinational way, and there are a lot of

deformations happening at the same time,” Bai said. “We fiber-optic sensor that combines low-cost LEDs and dyes, wanted a sensor that could decouple these.” resulting in a stretchable “skin” that detects deformations Bai’s solution was to make a stretchable lightguide for such as pressure, bending and strain. This sensor could multimodal sensing (SLIMS). This long tube contains a pair give soft robotic systems – and anyone using augmented reality technology – the ability to feel the same rich, tactile of polyurethane elastomeric cores. One core is transparent; the other is filled with absorbsensations that mammals depend ing dyes at multiple locations and on to navigate the natural world. connects to an LED. Each core The sensor can detect The researchers are working is coupled with a red-green-blue to commercialize the technology pressure, bending or elongation sensor chip to register geometric for physical therapy and sports changes in the light’s path. medicine. A 2016 stretchable senby lighting up the dyes, which The dual-core design increases sor sent light through an optithe number of outputs by which cal waveguide, and a photodiode act as spatial encoders. the sensor can detect defordetected changes in the beam’s mations (pressure, bending or intensity to determine when the elongation) by lighting up the dyes, which act as spatial material was deformed. The lab also made sensors using encoders. Bai paired that technology with a mathematical optical lace and foams. model that can decouple different deformations and pinDoctoral student Hedan Bai drew inspiration from silicapoint locations and magnitudes. Sensors are wearable and based distributed fiber-optic sensors, which detect minor may boost virtual and augmented reality experiences. ce wavelength shifts as a way to identify multiple properties,

‘

’

such as changes in humidity, temperature and strain. Silica fibers aren’t compatible with soft and stretchable electronics. Intelligent soft systems present structural challenges. “We know that soft matters can be deformed in a very

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December 2020

control engineering

David Nutt, Cornell University. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.

www.controleng.com

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

exoskeleton task the construction worker is doing and adjust its power level and control strategy to more effectively assist with the work.” The researchers will study what tasks each construction crew member performs in order to develop and train an exoskeleton that fits different construction tasks. They will consider if the robotic exoskeleton should support the upper or lower body and how much power should be given. The team says its motivation for this project comes from the workforce shortage in the United States. There are plenty of construction jobs along the Gulf Coast but not enough workers. Wang said what caused the workforce shortage is construction workers aging or retiring due to an injury and a decrease in young people doing construction work. With an exoskeleton to alleviate risk of injury, more construction workers could

perform for more years and do so safely and efficiently. The team said it would also open the door to more women being able to do jobs that were once solely for men. There are some issues the team is trying to work out, such as the cost of the exoskeleton and how it could work safely in different weather conditions since it would be powered by battery. The team is collaborating with industry companies and trade schools who are not yet aware of this technology but will help them develop a better product. “It takes industry and society working together to make this happen,” Aghazadeh said. ce Libby Haydel, communications specialist, LSU College of Engineering. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.

Headlines online Top 5 Control Engineering articles Nov. 9-15 The most read articles covered SCADA, HMI and MES projects, the 2021 Engineers’ choice finalists [vote by end of December], top 5 VFD parameter changes, advanced process control changes and matching motors and drives. Lithium-metal batteries offer alternative for users Lithium metal solid-state batteries can provide a safer, more powerful alternative to the current standard. Squeeze-twist coupling material strengthens actuators University of Wisconsin-Madison engineers have made an asymmetric material that twists, which could help advance actuator technology.

Boeing updates 737 Max control system and its policies and procedures designed to strengthen training, safety, quality

n Nov. 18, the FAA approved Boeing’s request to resume Boeing 737 Max (737-8 and 737-9) operations. That news, summarized below, is posted at www.controleng.com as an update to a Nov. 13, 2019, “Think Again” Control Engineering commentary that noted: “Best practices matter when designing control systems.” Addressing design changes, Boeing said in an Oct. 25, 2019, statement: “Boeing has redesigned the way Angle of Attack (AoA) sensors work with a feature of the flight control software known as Maneuvering Characteristics Augmentation System (MCAS). Going forward, MCAS will compare information from both AoA sensors before activating, adding a new layer of protection. In addition, MCAS will now only turn on if both AoA sensors agree, will only activate once in response to erroneous AOA, and will always be subject to a maximum limit that can be overridden with the control column. These software changes will prevent the flight control conditions that occurred in this accident from ever happening again. In addition, Boeing is updating crew manuals and pilot training, designed to ensure every pilot has all of the information they need to fly the 737 MAX safely.”

www.controleng.com

Addressing changes to Boeing company policies, a Nov. 18, 2020, Boeing statement said: “In addition to changes made to the airplane and pilot training, Boeing has taken three important steps to strengthen its focus on safety and quality.

1. Organizational alignment: More than 50,000 engineers have been brought together in a single organization that includes a new Product & Services Safety unit, unifying safety responsibilities across the company.

2. Cultural focus: Engineers have been further empowered to improve safety and quality. The company is identifying, diagnosing and resolving issues with a higher level of transparency and immediacy.

3. Process enhancements: By adopting next-generation design processes, the company is enabling greater levels of first-time quality. For more information, visit www.Boeing.com/737-max-updates.” ce Mark T. Hoske is content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com.

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INSIGHTS THINK AGAIN

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Data flow, alarms, simulation, cybersecurity, robotics

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Control Engineering highlights automation, controls and instrumentation successes at www.controleng.com and in print.

Kevin Parker, Senior Contributing Editor, IIoT, OGE 630-571-4070, x2228, KParker@CFEMedia.com

utomation, controls, and instru- itive with other companies and maintain mentations are critical, innova- the capacity to fill incoming orders, busitive, interesting and productive, nesses must increase fulfillment speeds. and Control Engineering offers Advanced simulation software addresses information on Boeing’s automation these and other issues by bringing togethadjustments to its 737 Max (News, prior er the software and live equipment worlds. page) and developments on data flow, This enables optimization of a warehouse alarm design, digital twins and simulation environment first in software – where creefficiency, cybersecurity and robotic pro- ating prototypes and modifying the process gramming, among others. is relatively inexpensive and simple – so the Data flow optimization – Technology resulting real-world deployment operates Update from Chris Adam, Purefficiently. Simulation demands due University: Current cloud time, money, and attention, the technologies using automatbenefits often outweigh costs. ed decision making often only IT helps OT – cybersecuwork for short and repeat tasks rity article from Larry O’Brien, and workloads. The team creatARC Advisory Group: Secureed an optimal configuration to by-design principles apply to handle long-running, dynamsoftware, devices and networks. ic workloads, whether it be Many commercially-available Mark T. Hoske, workloads from the ubiquitous Content Manager products and applications were sensor networks in connectnot developed using these princied farms or high-performance ples. Security by design does not computing workloads from scientific appli- absolve the end user from following good cations or the current COVID-19 simula- cybersecurity practice, project implementions from different parts of the world in a tation or operations work processes. Other rush to find the cure against the virus. strategies include supply chain cybersecuriAlarm design and management – ty, provenance (determining where system Technology Update from Martyn Hilbers, computing components like chipsets come PLC-Easy: When discussing and designing from and their inherent levels of security) a new automation system, should the ques- and other issues. tion “do we need alarm acknowledgement” Robotic programming article from be in the top 10 of our requirement list Michael Castor, Yaskawa Motoman Robotwhen selecting and/or developing an auto- ics Division: Flexibility provided by offline mation system? If this question is on top of programming software for robotics offers the list and answered “No,” the implications many perks and enables a higher mix of is that the system is expected to perform at jobs with a simple transition from one job a higher automated level, is actively apply- to the next. Larger companies with multiing alarm rationalization and ultimately ple locations and/or workcells may be able requires less operator interaction. to reduce programming time and inconsisDigital twins and simulation cost tencies by distributing the programmed job savings – cover story from Colm Gavin, from a central, controlled source. ImproveSiemens Digital Industries Software: ments in sensor technology for tasks such Successful fulfillment center operation as robotic welding have come a long way requires increasing application of digitali- recently, providing considerable advantages zation and efficient automation concepts, for end users spanning diverse industries. especially focused on removing costs and Think again about what automation, reducing risks when installing new materi- controls and instrumentation innovation al handling equipment. To remain compet- can do to advance your world. ce

Amanda Pelliccione, Director of Research 978-302-3463, APelliccione@CFEMedia.com

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Emily Guenther, Director of Interactive Media 630-571-4070, x2229, eguenther@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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years in business

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COVER STORY: DIGITAL TWIN SIMULATION SOFTWARE Colm Gavin, Siemens Digital Industries Software

How modern simulation software addresses intralogistics challenges Advanced simulation software provides optimization insight, enabling distribution and fulfillment centers to address issues and optimize efficiency.

he end of the year is notorious for causing sudden onsets of panic as the weight of the holidays hits, and the realization of purchasing gifts sinks in. Every pressure experienced by the general public around this time of year, however, is multiplied by an order of magnitude for distribution and fulfillment center managers.

These managers and their personnel are faced with difficult tasks, with internal production expectations from the corporate level and external delivery expectations from customers adding to the heat. Fortunately, digitalization is continuously providing new methods for intelligent and efficient operation in warehouse settings. Thanks to advanced simulation software, taking care of intralogistics – the management and optimization of internal production and distribution processes – is constantly evolving and improving. As anyone who has set foot in a modern fulfillment center knows, its managers must be resilient, and be able to adapt and scale intralogistics processes. It takes thoughtful warehouse design and preparedness to address these issues, and advanced simulation software can help fulfillment and distribution centers remain competitive, from design to operation.

Intralogistics issues for simulation software

Though increased consumer demand creates lucrative business opportunities, the challenges to overcome in the world of distribution and fulfillment centers are great. In addition, the COVID-19 pandemic has created new workplace safety needs, increasing the need for low-touch and no-touch processes. The finite size of fulfillment centers requires intelligent use of technology to make more effi-

COVER: Figure 1: Tall storage and shuttle racks— with advanced lift and transport technology— make the most of available space in distribution and fulfillment centers. Serving as a digital twin, advanced simulation software can help fulfillment and distribution centers remain competitive, from design to operation. All images courtesy: Siemens

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Systems need to generate insights in digestible formats, reducing complexity for interaction among humans, auto-

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mation and information.

cient use of limited space (Figure 1). It also requires effectively planning the layout, strategically placing products and improving material flow availability, along with maintainability and performance. Growing global ecological awareness and rising energy prices are motivating many companies to work towards carbon neutrality, impacting how work is done in a warehouse. To support these efforts, methods must be put in place to monitor energy consumption and provide insights on ways to further increase energy efficiency. Transparency initiatives also often require this data to be made publicly available. Adding to these technology-related difficulties, there are often not enough IT staff available to keep up with advancements in automated technology – too much data, not enough information processors. To overcome this obstacle, warehouse staff need systems that generate insights and present them in digestible formats, reducing complexity for interaction among humans, automation and information. Overcoming these hurdles to successful fulfillment center operation requires increasing application of digitalization and efficient automation concepts, especially focused on removing costs and reducing risks when installing new material handling equipment. Furthermore, to remain competitive with other companies and maintain the capacity to fill incoming orders, businesses must increase fulfillment speeds. Though the challenges abound, there is a way to optimize efficiency and meet the many needs of modern fulfillment centers.

Digital twin for design optimization

Advanced simulation software addresses these and other issues by bringing together the software and live equipment worlds. This enables optimization of a warehouse environment first in software – where creating prototypes and modifying the process is relatively inexpensive and simple – so the resulting real-world deployment operates efficiently. Though simulation demands time, money and attention, the benefits often outweigh the costs. An advanced simulation software suite helps warehouse managers digitalize the value chain at the time of conceptual design and during commissioning on the warehouse floor, and also after deployment for review and analysis of methods to

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Figure 2: The Siemens Plant Simulation Tool can be used to create a digital twin for optimizing design of a new facility, or for experimenting with methods for improving operations in an existing warehouse.

Figure 3: Ergonomics analysis helps identify optimal positioning of pick-and-place machines, platforms, and other mechanisms.

improve operational effectiveness. A facility simulation tool provides a virtual view into warehouse operations. At design time, software engineers can create a multi-dimensional warehouse environment in conjunction with the facility designers, enabling a three-dimensional simulation of how the warehouse will perform. Users are provided with the ability to simulate the distribution center layout, visualize material flow, monitor programmable logic controllers (PLCs), configure intelligent industrial devices and apply advanced statistical tools to analyze processes. Engineers can run these processes and monitor each in real time, model production data and optimize the facility configuration to determine a more efficient design (Figure 2). Monitoring includes the ability to visualize real-time PLC input/output updates in accordance with the program logic.

Analyzing logistics applications with software

For material handling applications, the software provides the capability to access working conditions. It also includes built-in ergonomics analysis for optimal positioning of pick-and-place control engineering

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COVER STORY: DIGITAL TWIN SIMULATION SOFTWARE Figure 4: An ultramodern sorting and conveyance system implemented by a global shipping company at one of its international airport locations.

machines, platforms, and other mechanisms to provide mechanical advantages for manual human motions (Figure 3). By using advanced software through iterations of simulations, robots can learn optimal paths and movements, and trackless automated guided vehicles (AGVs) can determine best routing. The software runs thousands of possible movement schemes, taking into consideration all proposed equipment and its location on the warehouse floor, and provides the most efficient robot movements and AGV routes.

Motors, drives, other automation

Physics calculations – including gravity, friction, and torque – are built into the software, increasing the simulation’s realism and building confidence in the mechatronic models. A mechanical engineer can be tasked with confirming the kinematic components are optimally configured, and once mechanical components and statistics are known, designers can properly size motors, drives, and other equipment. From this software suite of tools, users can automate multi-domain engineering, enabling collaboration with consistent data among the various engineering disciplines. The software can automatically generate electrical drawings and PLC projects, which provides a head start on the engineering effort and reduces overall design time. Once this basic code is generated, programmers can make adjustments impacting later simulations, and they can drill down as deep with code updates as required. This enables users to view a full model of the future warehouse floor – complete with conveyors,

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automated lifts and scanners, stack lights, AGVs, and material flows – all operating in sync.

Nine ways simulation software can help Many other equipment types can be staged in the simulation workspace: 1. High-density storage and retrieval systems for food, hard items, and consumer-packaged goods 2. Functional safety devices 3. Advanced optical identification devices for product movement tracing 4. Scalable and flexible shuttle systems 5. Control components for advanced shuttle vehicles, onboard and non-onboard 6. Real-time, fail-safe communication with industrial wireless local area networks for reliable, high-speed, and cyber-secure connection among devices in the warehouse 7. Industrial radio frequency identification (RFID) systems for product index tracking 8. Edge computing devices 9. Compact and mobile controllers embedded in other equipment. While a simulated view of plant floor processes plays out, users can simultaneously monwww.controleng.com

itor human-machine interface (HMI) displays and PLC ladder logic operation within the simulation software to help virtually commission the machines. These virtualized simulations are digitalized plans for warehouses and distribution centers, helping ensure the physical deployments will operate as intended. Modeling underwent a transformation from 2D sheets to 3D virtual renderings a short while ago, and now, real-time feedback and motion also is attainable. Software simulation allows designers to model and visualize how a facility will operate in advance of real commissioning. As a result, multidisciplinary design teams can adjust early in the game, yielding positive productivity.

Simulation software results

A large-scale manufacturer of home care products was able to consolidate four distribution centers into one facility to simplify operations and reduce overhead cost. Using an advanced simulation software suite, this manufacturer effectively modeled and implemented a facility only half the size of its previous facilities’ combined areas while increasing processing capacity. It increased its product storage density by 50%, and now utilizes around 90% of its volumetric storage capacity. Furthermore, it requires 20% less transport within the facility than it did prior to the consolidation. Greater efficiency, made possible through advanced simulation and cutting-edge intralogistics technology, provided the manufacturer with higher profit margins and a reduced carbon footprint. In another example, a global shipping company recently implemented an ultramodern sorting and conveyance system at one of its international airport locations (Figure 4). Using components, which included PLCs and drives, it was able to achieve a sorter transport speed of eight feet per second and peak performance of 9,000 parcels of various size per hour.

Simulation software system diagnostics for runtime

Once a facility is up and running, simulation maintains its value as a tool for experimenting with process or program adjustments, while system diagnostic software capabilities add value to optimization efforts. Diagnostic tools enable predictive maintenance by alerting personnel of issues detected in the facility in advance of equipment failure. In some system diagnostic configurations, certain events, like broken wire or low voltage, are embedded in the PLC for communication with an accompanying HMI. In such a case, maintenance technicians can troubleshoot common issues right from the

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Figure 5: Siemens ProDiag feature, embedded in its Simatic WinCC HMIs, enables operators to jump from an alarm directly to the PLC code from where it was triggered, enhancing troubleshooting capabilities and facilitating quicker recovery.

HMI screen, with no need to pull out a laptop and plug in to the PLC (Figure 5). Furthermore, these same configurations gather and store real-time data and provide operators with the ability to play back previous data on the HMI, helping them to determine what triggered the alarm condition. These tools, accessible on the warehouse floor, help reduce downtime and increase throughput.

Simulation software helps moving, sorting, picking, packing

As society becomes increasingly connected, warehouse technology is advancing. Customer and corporate expectations also are increasing, as well. Left to outdated tools and methods, distribution and fulfillment centers cannot keep up. But by using advanced simulation software and modern technology for moving, sorting, picking and packing – warehouses can overcome these challenges. While simulation requires additional initial costs and efforts, future time and effiKEYWORDS: Simulation software, ciency savings typically far outweigh warehouse manufacturing the costs. Simulation software helps improve Through simulation in projects’ the management and optimization of internal production and early stages, system designers can simdistribution processes. plify scope, reduce total time and effort Digitalization provides new required to implement, and help ensure methods for intelligent and efficient more efficient fulfillment center operaoperation in warehouse settings. tion. When the rubber meets the road, Advanced simulation software this can make the difference between a brings the software and live equipment worlds together. happy delivery recipient and a livid customer whose order got lost in the wareONLINE house. ce See additional stories about

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Colm Gavin is the portfolio development manager for Siemens Digital Industries Software. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com. control engineering

simulation software at www.controleng.com.

CONSIDER THIS What immediate benefits could your facility gain from advanced simulation software?

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EMBEDDED CONTROLLERS Josh Eastburn, Opto 22

AMP upgrades to edge controllers Largest U.S. rotary heat-treating facility modernizes controls and automation with tight database integration.

utomation upgrades were needed to ensure reliable operations at American Metal Processing (AMP), which specializes in rotary heat treatment for deep case carburizing, carbonitriding, and neutral hardening processes. However, with control system components dating back to the late 1990s, some experiencing regular failures, others approaching end-of-life, and no automation staff on-site to support them, “We knew we were on borrowed time,” said Grant Pinkos, president of AMP. Realizing the need to modernize, Pinkos also saw an opportunity to make the system better than before. “We wanted it to be more than a control system,” he said. “We wanted it to be intelligent.” For AMP, this meant addressing the need for automated interlocking and alarm notification as well as integrating their backend structured

query language (SQL) database, which served as the repository for material tracking and process recipes.

Controls upgrade: Sensors, controls, drives

Given the scope of its controls upgrade — including computerized weighing, burner control, and drive control — along with these other opportunistic improvements, AMP knew it would require a custom solution. After researching the state of the art, they decided an edge programmable industrial controller would offer the most value and versatility. Even without controls expertise in-house, Pinkos was confident taking on the task. “I could see the pieces coming together... When I realized I could do data logging with [an edge controller], that checked another box for me. Once we found a

Figure 1: One of AMP’s seven upgraded furnace lines takes advantage of modern, flexible controller architecture with Opto 22’s groov EPIC (edge programmable industrial controller). Images courtesy: Opto 22

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Figure 3: Opto 22’s groov EPIC provides an ecosystem of embedded applications for visualization, device integration, connectivity and data processing.

Figure 2: The new operator interface, built using the Opto 22’s groov EPIC embedded HMI server, incorporates data from many sources, including an IP camera feed and work order database.

way for our lot tracking database to use REST calls to extract data from the [controller], then we had a complete solution.” In just a few months, and at a fraction of the cost of traditional solutions, AMP had a design that was ready to deploy when one of its existing programmable logic controllers (PLCs) finally died.

Five-stage design with controls for each

Each of AMP’s seven furnace lines consisted of five stages (feeding, washing, heating, quenching, and conveying), each run by separate control devices. Pinkos’s design incorporated many of these control elements into one program. Then, using the controller’s embedded human-machine interface (HMI) server, he created a unified operator interface incorporating additional data sources: IP camera feeds, process trends, and alarm notifications. Then, in addition to signaling process alarms with light and sound beacons around the furnace perimeter, AMP connected the edge controller to the company PA system. They used the controller’s embedded IoT engine to query the company’s operations database for alarm occurrences, generate a string representation of each (for example, “Temper furnace 204 overtemp alarm”), and send the string through a text-to-speech (TTS) function, creating unique audio announcements that directed

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operators to the specific piece of equipment needing attention.

Controls enable integrated recipe management

With the furnace line’s controller connected to the company database, Pinkos was able to put the final piece of the puzzle in place by integrating recipe management and work order tracking into the control program and HMI. Instead of requiring operators to manually copy recipe parameters from a separate computer, the controller queries the database for the appropriate process values (feed rate, retort speed, temperature, oscillation period, and more) and feeds them to the control program. Work order information entered by the operators is then recorded back into the database along with process data captured from the run. Many of AMP’s customers are Tier 1 and 2 suppliers to original equipment KEYWORDS: Industrial controllers, manufacturers (OEMs) in the automoedge controllers tive industry, so AMP knew investing in See how an upgrade includes tight integration would be important in sensors, controls and drives. the long run. These changes also helped Recognize a five-stage design reduce operator error, streamline 24/7 with controllers for each. process monitoring and improve cusLearn how controls enable tomer confidence. “The new system is integrated recipe management as easy to understand and even easier to part of the design. visualize,” Pinkos said, “which builds CONSIDER THIS confidence with existing customers and Beyond reliability, what capabilities helps attract new ones.” ce are your applications missing

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Josh Eastburn is director of technical marketing, Opto 22. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com. control engineering

without an automation upgrade?

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

December 2020

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IT FOR OT AUTOMATION Steven Seiden, Leighton Johnson, Dr. Tony Barber, Acquired Data Solutions; Djenana Campara, KDM Analytics.

Cybersecurity, IT and OT Information technology strategies can help combat new cybersecurity vulnerabilities and deploy a solid cybersecurity program for operational technology use for industrial control systems, RTUs and SCADA, as IIoT deployments increase.

xploitation of resources has been a concern to mission operations since the dawn of the industrial age. Cybersecurity concerns have increased, as well. With advancement of information technology (IT), opportunities to compromise, corrupt, and disable networks and systems has exponentially grown, creating new development of malicious mechanisms. Although the first cybersecurity patent was registered in the early 1980s, the enablement of business needs and protecting mission operations are increasing priorities for national security and intelligence agencies. Cybersecurity within IT has seen exponential growth over the last three decades, but security of traditionally standalone, non-connected systems in the operational technology (OT) space continue to lag behind due to the independent nature of their functionality. OT systems include KEYWORDS: Industrial industrial control systems (ICSs) such as supercybersecurity, IT/OT visory control and data acquisition (SCADA) convergence systems, distributed control systems (DCSs), Understand the summer remote terminal units (RTUs), and program2020 cybersecurity advisory, mable logic controllers (PLCs). With the onset risks, infrastructure of the Internet of Things (IoT) as applied to See cybersecurity risks OT, the Industrial IoT (IIoT), more attention and rewards of integrated IT

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and OT. Review risk management modeling, automation, tools

has been given to cybersecurity. During the past decade, there has been a major increase in the demand for connected OT utilization with multiple deployments of advanced technologies requiring connectivity for operations and equipment maintenance. Using IT-enabled OT systems and components increases vulnerabilities, due to the convergence of IT and OT, have exposed new opportunities for cyber-attacks.

Summer 2020 cybersecurity advisory

In July 2020, the National Security Agency (NSA) and the Cybersecurity and Infrastructure Security Agency (CISA) of the Department of Homeland Security (DHS) alerted U.S. corporations to take immediate actions to reduce vulnerabilities and exposure across all OT and ICSs. The advisory, “NSA and CISA Recommend Immediate Actions to Reduce Exposure Across all Operational Technologies and Control Systems,” (U/OO/154383-20 | PP-20-0622 | July 2020 Rev 1.0), stated: “Over recent months, cyber actors have demonstrated their continued willingness to conduct malicious cyber activity against Critical Infrastructure (CI) by exploiting Internet- accessible OT

CONSIDER THIS Has your IT/ OT cybersecurity risk management advanced to meet the needs of advanced automation and IIoT?

ONLINE If reading from the digital edition, click on the headline for more resources. www.controleng.com/ magazine www.controleng. com/networkingand-security/ cybersecurity

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Figure 1: The standard approach to modeling risk within operational technology (OT), according to NIST, which defines risk as “risk is a function of the likelihood of a threat event’s occurrence and potential adverse impact should the event occur.” Courtesy: NIST via Acquired Data Solutions and KDM Analytics

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assets. Due to the increase in adversary capabilities and activity, the criticality to U.S. national security and way of life, and the vulnerability of OT systems, civilian infrastructure makes attractive targets for foreign powers attempting to do harm to US interests or retaliate for perceived U.S. aggression.” This critical warning establishes a call to action for U.S.-based utility companies that do not adhere to federally-regulated security guidance leaving much of their CI potentially compromised. The implementation of cybersecurity approaches and the prevention of vulnerability exploitation is one of the largest concerns for most CI manufacturers, policy developers, and federal leadership.

Connectivity, critical infrastructure, risk

Imagine a CI manufacturer or a utility supplier without a clear understanding of the security implication on critical services, such as energy, water, and/or food. Imagine unintentionally, or intentionally, propagating a virus on a large-scale complex system that supports U.S. transportation communications, and/or emergency services infrastructures and not knowing or understanding the multiple vulnerabilities opportunistic hackers can exploit on U.S. operational network through the U.S. defense industrial base (DIB). This is why applying the maturity and automation of cybersecurity to CI could provide comprehensive identification and assessments of vulnerabilities while employing a security and risk culture among federal, state and local decision makers. This includes protection from inappropriate accesses to CI systems and reduction of data disclosure, compromise, and/or loss through the optimization of these assessment via automation.

DHS: Three infrastructure areas

The Department of Homeland Security divides infrastructure into three areas. 1. Physical infrastructure: Cable fiber, dams/ reservoirs/treatment plants, corporate institutions, delivery sites, farms/food processing plants, government facilities, hospitals, nuclear power plants, power plants/production sites, railroad/highway bridges/pipelines/ports. 2. Critical infrastructure/key resource: Agriculture and food, banking/finance, chemical, commercial facilities, communications, dams, defense industrial base, emergency services, energy, government, information technology, monuments/icons, nuclear, postal and shipping, public health, transportation, water. 3. Cyber infrastructure: Control systems, hardware, information services, software.

Integrated cybersecurity risks, rewards

Because everything is connected, unpatched vulnerabilities, misconfiguration or application weakness can subvert connected systems and put all at risk. The linking between IT and OT systems expands daily as new technologies are introduced; organiza-

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tions extend their customer bases and the CI grows. The energy production sector is among many CI areas experiencing this cross-over of IT and OT inter-mixtures of technologies, hardware and software combinations to benefit organizations, companies, agencies, and corporations that use these connected components and systems. Converging safety, security and dependability requirements shows the immense need for a holistic approach for CI and the various control systems contained across the domains for risk understanding. This multi-faceted view is needed in all CI sectors. As IT is being used to support OT operations, the merging of these two technologies brings new risk factors into the operations and maintenance of each area. The IT employee now has machine-level communications and connections with OT-based data. Its IT security components are not designed to sense and

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Figure 2: This is the scientific lens that all risks, explicitly cybersecurity risk, should be viewed, according to NIST Special Publication 800-30, rev.1 (2018), page 12. Courtesy: NIST via Acquired Data Solutions and KDM Analytics

As IT supports OT areas, the merging of technologies brings new risk factors into the

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operations and maintenance of each area. monitor, using networking protocols not familiar to the monitoring activities, with the attendant risks being transmitted and received on a daily basis. This can, and often does, lead to unidentified vulnerabilities in the IT devices and applications which result in breaches, failures and unexpected negative results.

IT data structure impact on OT

OT systems are being installed, implemented and deployed with connections and monitoring from the IT side. IT inputs to OT systems are not designed or configured to handle these new and different data types and structures. IT and OT differences cause OT to react in unknown and unexpected ways, causing the OT to operate less than optimally. This can negatively impact services that affect our way of life, such as energy delivery, water delivery and other areas. To produce and support the converged OT with the IT, we need to understand and work with the areas of concern these systems perform. There are risks to our operations, products, services and activities. Risk is developed when a threat, taking advantage of a weakness or discrepancy within the control engineering

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IT FOR OT AUTOMATION system, produces an adverse impact on the system, activity, or organizational process. These issues can cause loss of revenue, loss of data (resulting in loss of profits due to regulatory fines), loss of customers, loss of reputation, even possible loss of market share; all of which affect the organization as a whole, not “just” IT or the cybersecurity teams.

Risk management applicability to OT/CI

To address cybersecurity concerns in OT/CI, the following question should be addressed: • What are components relevant in OT and CI? • How are they connected? • What data is stored and/or in transit between each component and any external entities? • What are the risks, threats, and vulnerabilities within the system? • Where do you find them? • How are they uncovered? The system analysis and curiosity begin the process of “risk modeling.” Figure 1 outlines the standard approach to modeling risk within OT, according to National Institute of Standards and Technology (NIST), which defines risk as “risk is a function of the likelihood of a threat event’s occurrence and potential adverse impact should the event occur.” Unique to OT cybersecurity, there are multiple approaches that can aid cybersecurity professionals with analyzing risk to comprehensively develop the appropriate response(s). These include:

Figure 3: KDM Analytics’ (KDMA) Blade RiskManager (BRM) takes the model-based systems engineering (MBSE) approach and extends the analysis capabilities to assess cybersecurity postures based on components, elements, information exchanges, and data flows. Courtesy: Acquired Data Solutions and KDM Analytics

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1. Performing risk modeling 2. Isolating and containerization of components

3. Defining OT attack patterns 4. Establishing and implementing a secure supply chain.

These techniques help the organization determine the high areas of risk, as well as what needs to be protected and monitored to prioritize the security efforts for the OT under consideration. Figure 2 provides the scientific lens that all risks, explicitly cybersecurity risk, should be viewed, according to NIST Special Publication 800-30, rev.1 (2018), page 12. This process produces quantifiable risk calculations for each area and allows the organization to produce areas of prioritized risk for mitigation and to drive decision-making actions.

OT risk management, automation

This type of tool can take the model-based systems engineering (MBSE) approach and extends the analysis capabilities to assess cybersecurity postures based on components, elements, information exchanges, and data flows. Automated risk accelerators were developed based on the unified architecture framework (UAF) to widen breadth and depth of analysis to address evidence-based cybersecurity and risk assessment. Such a tool provides a comprehensive view of current, relevant cybersecurity guidance from international and national standards organizations, such as NIST. The second approach, isolation and containerization of components, allows for OT components isolation that blocks exposure to the outside risks present in the OT operating environment. In the third approach, the automated risk modeling tool graphically displays a schematic diagram of the attack patterns/paths that are assessed by the tool. In the fourth approach, secure supply chain produces an operating activity that is secure throughout the environment, which provides a reduced risk arena for the OT and connected IT to work. This provides the organization to reduce and manage risks which provide secure OT based actions and activities. Such techniques offer critical insight and cybersecurity analysis results in the proactive protection of OT components for the system of interest to costeffectively and efficiently manage cybersecurity. ce

Steven Seiden is the president of Acquired Data Solutions. Leighton Johnson, CISSP, CISM, CMMC-AB Provisional Assessor L-3, is a senior cybersecurity engineer at Acquired Data Solutions. Dr. Tony Barber, CSEP, RMP, is a system engineering executive at Acquired Data Solutions. Djenana Campara is president of KDM Analytics. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com. www.controleng.com

The digital challenge Dr.-Ing. Hans Egermeier | Lenze

With the digital transformation already in full swing, is your company prepared for the fundamental changes facing our entire industry? Industry 4.0, the Industrial Internet of Things (IIoT), big data – common everyday terms for actions and innovations that are already transforming the machine-building business. Due to the acceleration effects of digital technologies, the change will be exponential – so there’s no time to lose. Learn the steps you should take to master digitalization – you’ll get basic technical information, clarification on how various issues are connected, tips on overcoming obstacles, and suggestions for further reading. Download the paper at: https://bit.ly/2Bzr7Lv

+1 800 217-9100 • info.us@ Lenze.com www.lenze.com

input #9 at www.controleng.com/information

ANSWERS

IT ADVICE FOR OT AUTOMATION Larry O’Brien, ARC Advisory Group

Secure-by-design industrial products are increasingly important Cybersecurity often is the catalyst for control system modernization, and industrial and critical infrastructure sector projects increasingly specify automation products and systems that are designed as cybersecure.

hose in the industrial and critical infrastructure sectors increasingly seek products and solutions that are inherently cybersecure. In many cases, cybersecurity provides the catalyst for control system modernization projects. This is especially true in cases where users discover they can no longer support an installed base that requires an increasing amount of time and resources to make it cyber-secure. Much of the cybersecurity focus for industry and infrastructure to date has focused on providing layers of cybersecurity on top of existing infrastructure, rather than procuring products and applications that provide a level of inherent cybersecurity. Inherent cybersecurity is often achieved through some combination of product design features and a secure development lifecycle process. From the supply chain perspective, many end users also are looking to source inherently secure components, microprocessors and embedded systems.

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Using cybersecurity certifications to help pre-qualify potential products can save asset

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owners considerable time and effort.

In addition to closer supplier scrutiny during the selection process, the built-in, secure-by-design approach also requires secure implementation, installation and maintenance approaches throughout the system or product’s lifecycle. Two separate but related lifecycles are at play here: One for product development and one for implementation and support. Looking for products certified to a cybersecurity standard, like the ISA/IEC 62443 series of

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industrial control system cybersecurity standards (formerly ISA-99), also can be a challenge since many users are unfamiliar with the various certification and standards bodies. While even products not certified to a published standard can sometimes provide acceptable cybersecurity, this requires closer scrutiny of vendor offerings and their associated development and sourcing practices. Using certifications to help pre-qualify potential products can save asset owners considerable time and effort.

Industrial products require security by design

Most operational technology (OT)-level products and applications in industry and critical infrastructure worlds aren’t designed from the ground up to incorporate cybersecurity. Until recently, features, functions and open network connectivity have received more attention. The drive toward “openness” in the 1990s and early 2000s resulted in a cybersecurity mindset focused on adding layers of cybersecurity in OT-level systems to address potential vulnerabilities. While this mindset is still required for effective cybersecurity, many end users are finding it is much easier and less expensive investing in products designed from the ground up to incorporate security rather than increase investments to lock down products that are not secure. Security by design should go beyond the products themselves and how they are designed to incorporate secure development lifecycle practices for applications. The same principles apply to the processes used in control system engineering, installation and startup. End users also are taking a closer look at the security of the supply chain, specifically in how systems are developed and manufactured, and if the systems utilize secure components and embedded systems. www.controleng.com

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Many ICS end users have not developed good selection criteria for systems and applications; industry and infrastructure systems may not consider cybersecurity at all. Industrial IoT increases need for cybersecurity

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The new wave of products for Industrial Internet of Things (IIoT), such as edge computing devices; cloud computing platforms; and smart, connected sensors provides an additional level of complexity for end users from a cybersecurity perspective. While many of these “industrial edge” offerings incorporate good cybersecurity, such as “zero trust” architectures, others do not. Since many of these offerings are making their way from the information technology (IT) world into the OT world, they must be more closely scrutinized to evaluate cybersecurity risk.

Cybersecurity as a catalyst for system modernization

Control systems in industrial and critical infrastructure environments typically have extremely long lifecycles. Many distributed control systems (DCSs) and programmable logic controllers (PLCs) have been in service for 20 years or more. Many end users are finding the older installed base is too complex, costly, and risk-prone to continue to support from a cybersecurity perspective. This often provides the impetus for a control system migration or modernization project.

Security by design, cybersecurity standards

The ISA/IEC 62443 series of standards are the key cybersecurity standards for manufacturing and critical infrastructure. The series is recognized internationally and the product of decades of work by end users and suppliers. While the initial focus of the standards was on describing reference architectures and fundamental concepts like defense-indepth, the IEC 62443 standards today encompass all aspects of industrial cybersecurity, from product and application development through the complete lifecycle. The IEC 62443-4-1 standard specifies process requirements for the secure development of products used in industrial control systems (ICS). It defines a secure development lifecycle (SDL) for developing and maintaining secure products. This lifecycle includes the following practices:

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Figure 1: Average lifecycle of process automation system components shows that automation isn’t supported indefinitely and older systems may require replacement due to increased cyber risk. Workstations and consoles may require attention in less than 5 years and controllers in less than 15 years. Courtesy: ARC Advisory Group

• Security management • Specification of security requirements • Secure by design • Secure implementation • Security validation and verification testing • Management of security-related issues • Security update management • Security guidelines.

Driving cybersecurity into the ICS procurement process

Selecting secure-by-design products and applications can be challenging for many ICS end users. Many have not developed good selection criteria for systems and applications. Many systems used in industry and infrastructure are obscure and may not consider cybersecurity at all. At the same time, many of these offerings are becoming more IoTenabled, which compounds the risk. While most major DCS suppliers offer controllers and other system components that are ISASecure-certified, many suppliers that offer lesser known types of systems, such as terminal automation systems, RTU-based SCADA systems, boiler controls and compressor controls may not incorporate secure-by-design principles. Having a good selection and procurement process also means different stakeholders within the end user organization must also be involved. The normative requirements described in the IEC 62443 standards provide a solid foundation for such a process. control engineering

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ANSWERS

IT ADVICE FOR OT AUTOMATION Security by design means a better return on investment

Many end users have achieved better return on investment (ROI) and lower lifecycle costs by investing in secure-by-design technologies. Many end users have dwindling resources for managing cybersecurity issues. In addition to adding cost to prevent threats during day-to day operations, the cybersecurity dimension of systems design and engineering can add to the cost and time required to complete a project. Incorporating security by design can reduce engineering costs and overall project costs as well as operational and maintenance costs.

Examples of security by design in products and systems

Many products for industrial and critical infrastructure applications provide some security by design that can help end users reduce lifecycle costs and improve cybersecurity. Some products offer security by design in their inherent design or physical properties. These include things like data diodes or unidirectional gateways, which provide secure unidirectional or even bidirectional communications. Data diodes can incorporate enhanced security into the inherent design of the product or through layers of secure software and network design. One data diode provider, for example, offers a data diode that incorporates physical send-only and receive-only circuits with KEYWORDS: Cybersecurity fiber optic communications. lifecycle, process automation Other data diode suppliers use COTS upgrades components to build their data diodes, Design cybersecurity into but incorporate specialized content automation and systems, including Industrial Internet of inspection engines and other softwareThings upgrades. based methodologies to ensure secure Consider cybersecurity as a unidirectional communication. catalyst for system modernization Many other products incorpoand use of cybersecurity rate secure-by-design principles into standards. automation and control systems or Drive cybersecurity into instrumentation. the industrial control system procurement process. These could include unique backplane designs, port locking features, or CONSIDER THIS other features. A smaller, but innovative Like automation safety, automation supplier, for example, may cybersecurity requires more than attention to product design. offers inherent secure-by-design principles into several of its systems comONLINE ponents, including backplane, power If reading from the digital supply, and others. Ask an automation edition, click on the headline for more resources. supplier or industrial cybersecurity supwww.controleng.com/magazine plier about secure-by-design features are www.controleng.com/ integrated into products. networking-and-security/ The other dimension to look for with cybersecurity security by design is system and netSee related New Products work implementation. Some suppliers for Engineers under the can offer tested and verified reference cybersecurity product category at www.controleng.com/NPE architectures for system and network

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design that incorporate the highest degree of inherent security. This is often the result of partnerships between specialist networking suppliers and automation suppliers. Other automation suppliers offer design features in process safety systems to prevent unauthorized user access devices. All system suppliers are incorporating these or similar features. New features are being rolled out continuously, which means users should evaluate what existing and potential suppliers have to offer.

Cybersecurity product testing and certification

Other products provide security by design by undergoing a certification or registration process where they are tested against a cybersecurity standard. One example is the ISASecure family of certified products, which are tested against the ISA/IEC 62443 cybersecurity standard. ISASecure offers certifi-cations for both physical products such as controllers, PLCs, gateways and routers. This also goes for systems, which includes process automation systems and process safety systems. It also offers secure software development lifecycle certifications for systems and applications developed by certified suppliers.

Beyond cybersecurity layers of protection

Layers of protection are necessary. But it is perhaps even more important to incorporate secureby-design principles into products and applications to ensure a certain level of security right “out of the box.” Ensuring devices are secure by design is the goal of many cybersecurity efforts, such as ANSI/ CAN/UL 2900 Standard for Software Cybersecurity for Network-Connectable Products and ISASecure. Secure-by-design principles apply to software, devices and networks. Many of today’s commercially-available products and applications were not developed using these principles. While important, security by design is not a panacea. It does not absolve the end user from following good cybersecurity practice, project implementation or operations work processes. Incorporating security by design is one aspect of a well-rounded and competent cybersecurity organization and strategy. Other aspects of security in the system design process are also becoming more crucial. These include supply chain cybersecurity, provenance (determining where system computing components like chipsets come from and their inherent levels of security) and other issues. ce

Larry O’Brien is vice president, ARC Advisory Group. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com. www.controleng.com

input #10 at www.controleng.com/information

ANSWERS

AUTOMATION ADVICE FROM IT Mark Mullins, Fluke Networks

How IT/OT convergence affects networking

Information technology and operational technology can integrate, but needs differ. Industrial visibility, interconnections, scalability, wireless mobility, remote data collection and data analytics are among 7 benefits of IT/OT data flow.

oT/IIoT and IT/OT convergence continues to draw attention for the potential benefits they bring. IoT (Internet of Things) and IT (information technology) are associated with datacentric networks; the IIoT (Industrial Internet of Things) and OT (operational technology) are associated with industrial networks like supervisory control and data acquisition (SCADA) systems used for monitoring and control industrial devices. IT and OT networks were once distinctly different departments with their own architectures, protocols, standards, cabling and connectivity. Many on the OT side tended to be proprietary and vendor controlled. With the proliferation of industrial Ethernet applications, such as Modbus TCP/IP, EtherCAT, EtherNet/ IP and Profinet and network-based smart IIoT sen-

sors that can collect and transmit vital manufacturing information for real-time analysis from anywhere, the IT and OT worlds are merging into one.

7 benefits of IT/OT data flow

While OT networks are still going to carry out functions like monitoring and controlling industrial machines and field devices at the I/O level such as relays, electronic flow meters, remote telemetry units (RTUs) and programmable logic controllers (PLCs), the implementation of Ethernet and smart sensors shifts these systems away from proprietary environments to one of open standards and protocols. This allows data to move more freely, all the way from the field sensor to the factory backbone and on to the IT network and eventually the internet service provider (ISP) network and the cloud. This exchange of data is the foundation of IT/OT convergence that enables: 1. Real-time visibility of industrial information from any location 2. Interconnecting of multiple sites and facilities 3. Scalability to reach to more environments 4. Wireless communications for mobility on the factory floor 5. Data collection from remote sites via 4G/5G cellular technology 6. Data analysis via more devices and back-end system applications 7. Standardization and rapid deployment for faster time to market

Figure 1: MICE environmental classifications help with design of industrial cable and network components. MICE stands for mechanical, ingress, climatic/chemical and electromagnetic. Images courtesy: Fluke Networks

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These capabilities pave the way for enhanced planning and decision making, improved efficiency, less downtime, reduced maintenance and better productivity, which lowers costs and maximizes profitability. To leverage IT/OT convergence, IT and OT departments within a manufacturing company need to come together to ensure both networks are designed and deployed in a way that makes data accessible, meaningful and secure. A key factor is understanding that because the data is now in a common format that can traverse IT and OT networks and the interwww.controleng.com

Figure 2: Fluke Networks’ DSX CableAnalyzer M12 channel adapters for M12D (4 position) and M12X (8 position) allow for testing and certifying installed channel links to ensure reliable Ethernet transmission in the demanding MICE environment of industrial network applications.

net, the cabling and connectivity that comprises these networks, as well as the environments in which they reside and testing considerations, are not the same.

Diverse industrial cables, connectors

The cabling plant that comprises the OT network is subject to harsher conditions. Out on the factory floor or within a processing facility, cables and connectors used to connect the industrial field devices and equipment must be robust enough to withstand a variety of elements including vibration, extreme temperature, liquids, dust, chemicals and interference. ANSI/TIA-1005 and ISO/IEC 11801 industry standards use mechanical, ingress, climatic/chemical, electromagnetic (MICE) specifications to classify components based on factors such as vibration, force and impact (mechanical); protection against dust and liquids (ingress); temperature, radiation and pollutants (climatic/chemicals) and noise interference (electromagnetic). The parameters determine various degree of environmental conditions and an associated MICE level, with MICE 1 defining a typical office environment, MICE 2 defining a slightly harsher environment and MICE 3 defining heavy industrial. MICE 2 and MICE 3 environments that comprise the OT network require different Ethernet connectors compared to those used in MICE 1 IT networks. Unlike common commercial-grade RJ45 connectors used for connecting computers and devices in the office, industrial-grade RJ45 connectors often include features such as chemical-resistant thermoplastic housing and IP67-rated seals for ingress protection. OT networks also use M12 locking connectors for I/O connections on industrial equipment because they are far more durable and better designed to handle the ongoing vibration since they are locked into place.

Industrial Ethernet cable benefits

Industrial Ethernet cables are no different than commercial-grade Ethernet cables in terms of data transmission capabilities, but shielded cabling construction is more common for copper cables in OT networks due to electromagnetic interference from switching relays, AC drives and other noise sources. Industrial Ethernet cables may also have different temperature ratings and jacket material depending on the environment where deployed. Fluorinated ethylene polypropylene (FEP), thermoplastic elastomer (TPE) and polyurethane (PUR)

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Figure 3: Fluke Networks’ DSX CableAnalyzer tests for different end-to-end cable configurations including E1, E2, and E3 limits per industry standards.

jacket materials have a far greater temperature range, flexibility, and chemical and abrasion resistance than polyvinyl chloride (PVC) used for commercial-grade cables. Applications where cables are exposed to frequent bending, flexing and twisting (think robotics and other repeated motion applications) may require high-flex cables that contain higher strand counts per conductor. IT and OT managers need to be on the same page when it comes to testing. This includes proper training and outfitting technicians with quality testers capable of connecting to both RJ45 and M12 connectors and testing for continuity, length, crosstalk and shield integrity. ce Mark Mullins is product manager at Fluke Networks. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com. control engineering

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KEYWORDS: IT/OT convergence,

industrial networks Examine how IT/OT data flow provides at least seven benefits. Fit environmental specifications to the industrial network application.

CONSIDER THIS Is your industrial network enabling or constricting data flow and information development?

ONLINE If reading from the digital edition, click on the headline for “Industrial cabling problems.” www.controleng.com/magazine www.controleng.com/ networking-and-security

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INSIDE MACHINES: MOTORS & DRIVES Dakota Miller and Bryan Knight, Yaskawa America

Direct drive vs. geared rotary servomotor: A quantification of design advantage: Part 1 A geared servomotor can be useful for rotary motion technology, but there are challenges and limitations users need to know.

or decades, geared servomotors have been one of the most common tools in the industrial automation toolbox. Geared sevromotors offer positioning, velocity matching, electronic camming, winding, tensioning, tightening applications and efficiently match the power of a servomotor to the load. This raises the question: is a geared servomotor the best option for rotary motion technology, or is there a better solution? In a perfect world, a rotary servo system would have torque and speed ratings that match the application so the motor is neither over-sized nor under-sized. The combination of motor, transmission elements, and load should have infinite torsional stiffness and zero backlash. Unfortunately, real world rotary servo systems fall short of this ideal to varying degrees. In a typical servo system, backlash is defined as the loss of motion between KEYWORDS: servomotors, the motor and the load caused by the direct-drive motors mechanical tolerances of the transmisReal-world rotary servo sion elements; this includes any motion systems fall short of the ideal performance due to technical loss throughout gearboxes, belts, limitations. chains, and couplings. When a machine Several types of rotary is initially powered on, the load will servomotors can provide benefits float somewhere in the middle of the for users, but each has a specific mechanical tolerances (Figure 1A). challenge or limitation. Before the load itself may be moved Direct drive rotary servomotors offer the best performance, but by the motor, the motor must rotate to they’re more expensive than take up all slack existing in the transgearmotors. mission elements (Figure 1B). When the ONLINE motor begins to decelerate at the end of See more motors and drives a move, the load position may actually articles at overtake the motor position as momenwww.controleng.com/motors-drives. tum carries the load beyond the motor position. CONSIDER THIS The motor must again take up the What do you look for when selecting a servomotor? slack in the opposite direction before

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applying torque to the load to decelerate it (Figure 1C). This loss of motion is called backlash, and is typically measured in arc-minutes, equal to 1/60th of a degree. Gearboxes designed for use with servos in industrial applications often have backlash specifications ranging from 3 to 9 arc-minutes. Torsional stiffness is the resistance to twisting of the motor shaft, transmission elements, and the load in response to the application of torque. An infinitely stiff system would transmit torque to the load with no angular deflection about the axis of rotation; however, even a solid steel shaft will twist slightly under heavy load. The magnitude of deflection varies with the torque applied, the material of the transmission elements, and their shape; intuitively, long, thin parts will twist more than short, fat ones. This resistance to twisting is what makes coil springs work, as compressing the spring twists each turn of the wire slightly; fatter wire makes a stiffer spring. Anything less than infinite torsional stiffness causes the system to act as a spring, meaning potential energy will be stored in the system as the load resists rotation. When combined together, finite torsional stiffness and backlash can significantly degrade the performance of a servo system. Backlash can introduce uncertainty, as the motor encoder indicates the position of the motor’s shaft, not where the backlash has allowed the load to settle. Backlash also introduces tuning issues as the load couples and uncouples from the motor briefly when the load and motor reverse relative direction. In addition to backlash, finite torsional stiffness stores energy by converting some of the kinetic energy of the motor and load into potential energy, releasing it later. This delayed energy release causes load oscillation, induces resonance, reduces maximum usable tuning gains and negatively impacts the responsiveness and settling time of the www.controleng.com

load to the motor. Whereas the gearmotor configuration uses a coupling to a relatively small diameter shaft, the direct drive system bolts the load directly to a much larger rotor flange. This configuration eliminates backlash and greatly increases torsional stiffness. The higher pole count and high torque windings of direct drive motors match the torque and speed characteristics of a gearmotor with a ratio of 10:1 or higher.

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A direct drive rotary servomotor offers the best performance and lowest system complexity, but at higher cost than a

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gearmotor.

Figure 1: In a typical servo system, backlash, rotation and slack are all elements that are part of the drive process. Images courtesy: Yaskawa America

servo system. In all cases, reducing backlash and increasing the stiffness of a system will increase servo performance and simplify tuning.

Rotary axis servomotor configurations

The most common rotary axis configuration is a rotary servomotor with a built-in encoder for position feedback and a gearbox to match the available torque and speed of the motor to the required torque and speed of the load. The gearbox is a constant power device that is the mechanical analog of a transformer for load matching. An improved hardware configuration uses a direct drive rotary servomotor, which eliminates the transmission elements by directly coupling the

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The least common and most complicated configuration is a fully closed-loop system, whereby a regular rotary servomotor and gearbox or other transmission elements is combined with a second encoder used to measure the position of the load, masking, but not eliminating the effects of backlash. This adds significant cost and complexity of a second encoder, additional machining and mounting hardware, additional cabling, and added maintenance. Of these three system designs, the direct drive rotary servomotor offers the best performance and lowest system complexity, but at a higher cost than the gearmotor solution. Attempting to quantify the performance advantage through manufacturer manuals and catalogs is impossible though, as the motors seem remarkably similar in terms of specification. In part 2 of this article, the performance of a gearmotor and direct drive servomotor (Figure 2) are tested by mounting each to a common load that simulates a high inertia rotary indexing table. Using a 30-bit ring encoder on the load, the motion of the load is recorded, and compared to each motor. Performance metrics including positioning accuracy, backlash, settling time and total motion cycle time are evaluated and weighed against the cost and complexity of each system. ce Dakota Miller is automation product specialist, Yaskawa America; Bryan Knight is product marketing manager, Yaskawa America. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com. control engineeering

Figure 2: The performance of a gearmotor and direct drive servomotor are tested by mounting each to a common load that simulates a high inertia rotary indexing table.

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ANSWERS

INSIDE MACHINES: RADIO FREQUENCY IDENTIFICATION Linda Htay, Idec Corp.

How RFID improves machine performance, safety RFID authentication devices on original equipment manufacturer (OEM) machinery ensure the proper users are taking permitted actions, providing performance benefits and improved safety. See five methods for security for industrial machinery.

utomated equipment and machinery can incorporate many ways for users to monitor and control operation, such as with buttons, switches, and touchscreens. When original equipment manufacturers (OEMs) design and build machinery, they want to deliver easy-to-use functionality. However, they must balance this desire with the need to verify authorized users are at the controls and making acceptable selections. Several authentication methods are possible, ranging in the security levels, user convenience, and features they provide. The simplest schemes may not offer enough protection, while the most complex are usually expensive and limiting. Balanced solutions provide strong security and audit logs – and they are simple to implement, cost-effective to maintain, and easy for end users to work with, which is where radio-frequency identification (RFID) can play a role.

Authentication drivers for industrial machinery

Figure 1: Unlike common commercial-grade RFID readers, industrial-rated readers are available to fit common 22 mm panel-mount knockout holes while resisting harsh environments. Images courtesy: IDEC Corp.

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It is possible to design machinery void of authentication methods, just as a car could be built with an on/off switch instead of an ignition key, or a house with no locks on its doors. Just as there are logical reasons to implement authentication solutions on cars and houses, there are motivations for doing so on industrial machinery, such as achieving operation restriction, traceability or both. Sometimes these motivations are driven by technical initiatives, but often they are mandated by regulatory requirements. Operation restriction can sound negative, so operation permission may be a better term. OEMs and end user manufacturing companies incorporate authentication methods to ensure proper perwww.controleng.com

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Traceability drivers involve gathering data, and manufacturers can use authentication to log which users operated a machine and the

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sonnel are accessing machinery controls, but they don’t want to limit authorization to a binary yes or no. Authentication extends into defining groups of personnel and even individuals, with granular selection of what machinery information they can view and adjust.

Industrial machine traceability: Who did what, when, why

Some companies may add permissions to better ensure safe and proper equipment operation. In other cases, compliance with industry safety standards such as ISO16090 (for machine tools) or ISO10218-1 (for industrial robots) can lead to adopting authentication methods. Traceability drivers involve gathering data, and manufacturers can use authentication to log which users operated a machine and the actions performed. This history may be used for informational purposes, which a company can analyze with the goal of improving performance. Or, the data trail may be stored to satisfy an industry requirement, such as FSSC22000 for food safety, which calls for traceability in the manufacturing process.

Five methods for security for industrial machinery

Several levels of security are possible, each with a range of benefits, disadvantages, and costs. The following methods are suitable for adapting into industrial machinery use, and are familiar to most consumers: • Physical/mechanical keys • Magnetic strip cards / swipe cards • Passwords • Biometrics • RFID.

Physical keys are the oldest and most familiar of the authentication methods. They are simple and low cost, but easy to copy or lend. OEMs can implement a basic key switch into their machine, but it provides a binary or limited selection by any user who gains access to the key. Magnetic strip cards are an improved version of physical keys, which add some digital capability. However, they may not be convenient to carry and protect at industrial sites. www.controleng.com

Common use of automation authentication

Modern digital devices used for industrial machine automation – including PCs, human-machine interfaces (HMIs), and mobile devices Figure 2: RFID tags – have made passwords a common authentication method. Passwords can provide a limitless can be traditional number of authentication levels per user, and are cards, but the key inexpensive to manage. Unfortunately, they can be fob style shown forgotten or leaked, and can be difficult to use in here is especially many industrial settings where gloves are used or suitable for industriwhere a full keyboard or touchscreen may not be al-rated smart RFID readers like the available. Biometrics such as fingerprint and face scan- Idec KW2D series, ners are common in consumer electronics and which can include a some commercial applications. Because they use bracket to hold the personal and non-transmittable information, they tag in place. are relatively secure, do not require operators to carry or remember anything and often cannot be duplicated or lent out. Unfortunately, biometric techniques are expensive to implement and manage. They don’t work well around machinery where gloves, helmets, masks and safety glasses may impede their function, either. This brings up RFID, which occupies a sweet spot within industrial machinery authentication. RFID tags are familiar to most anyone who has KEYWORDS: Radio frequency used a parking lot or building access identification, RFID, original system. They are simple and relativeequipment manufacturer ly inexpensive to manage, and they are (OEM) not easily duplicated. Although they are Review methods for controlling easy to lend, authentication is easy to and monitoring how machines operate and who controls them. modify because they are digitally manSee how radio frequency aged. As a physical token, RFID tags identification (RFID) is a passive and sensors are readily implemented for tag system, but it can be used in industrial applications. many industries and applications.

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Industrial-specific RFID devices

RFID is a preferred technology for many applications because the user’s tag is lightweight and does not require batteries. Reader devices, typically installed in a fixed location, generate a radio signal, causing a passive tag in range responds with a unique signal. Consumer-grade RFID readers commonly found in commercial applicontrol engineeering

Learn how many RFID scanners are designed to work in harsh environmental conditions.

ONLINE Read additional stories about RFID systems at www.controleng.com.

CONSIDER THIS What do you use RFID systems for and what benefits have they provided?

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INSIDE MACHINES: RFID

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RFID tag at a machine access or safety cage location may be used in conjunction with unlock solenoids to allow the door to open for permitted personnel.

Figure 3: Smart RFID readers can communicate tag information over an industrial communication protocol like Modbus TCP/IP, and each tag carries a unique ID which is associated with a user or group and can be assigned specific functionalities.

cations are often robust, but they usually are not built to withstand the temperature, vibration, and washdown/chemical environments associated with many machines. Most readers are designed to use rectangular cutouts, which are not convenient for many control panel designs. However, some industrial-grade RFID readers are explicitly designed to fit industrial-friendly common control panel form factors, such as the 22-mm knockout hole (Figure 1). These devices also are available with IP67 ratings, meaning they are protected from dust, low-pressure water jets and even immersion situations sometimes found with industrial installations. Industrial-rated RFID readers can take functionality a step further with LED multi-state and color indicator lights on the face, which can be activated to identify conditions such as standby, success or error. Some also can generate an audible signal to give users operational feedback.

RFID standards for cards, tags, fobs

Not all RFID tags are created equal, though. There are global RFID standards such as ISO14443A, ISO15693, and ISO18092 that apply to credit-card style configurations. While cards can be useful for industrial applications, there are also key fob styles which may be more suitable for

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carrying and using in production environments (Figure 2). Each tag carries a unique ID, which can be registered and associated with a user or a worker category. Users may present tags at a reader for an intermittent acknowledgement, but sometimes an application requires the user to place the tag in constant contact with the reader during certain operations. In such a scenario, some industrial RFID readers include a mechanism to hold the tag. RFID readers are intelligent devices. On the front end, they must interpret IDs from physical tags; on the back end, they must communicate with supervisory systems. This is usually performed with an industrial communication protocol such as Modbus TCP/IP (Figure 3), through which the reader can send complex tag IDs or simple authorization levels to the supervisory system, as well as receive commands to operate its light indicators and buzzer.

RFID applications and advanced RFID benefits

Industrial RFID readers are often integrated with the programmable logic controllers (PLCs) which control machinery such as machine tools and injection molding equipment. Consider one of these machines, which may have a few types of users: • New or temporary staff • Trained operators • Technical leads • Maintenance personnel. When the new staff applies their RFID tags, machine operation can be limited to their skill level and operating authority. Trained operators may be able to access normal operation monitoring and control functions; technical leads are authorized to adjust advanced settings and make special production runs. Maintenance personnel may be restricted from running the system norwww.controleng.com

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INSIDE MACHINES: RFID

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Machines and equipment of all types can benefit from applying industrial-rated RFID readers and tags. The ability to manage and track user authority can be used to ensure basic access control and improve overall safety. Advanced features include paperless traceability and database connectivity.

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mally, but they may be allowed to jog motors and manually actuate devices.

RFID for access, machine procedures

For traceability, preceding users and their actions can be logged by the PLC and HMI. If the RFID tag is at a machine access or safety cage location, it may be used in conjunction with unlock

solenoids to allow the door to open for permitted personnel. Workers who inspect parts could confirm their review by scanning a tag. RFID tags can be incorporated into maintenance procedures to confirm personnel are working in the right areas, enhancing safety. Engineering teams also can review logged user activity to analyze machine operation and determine more efficient ways to run. All actions can be stored and retrieved in a database environment to facilitate analytics and avoid inefficient paper logs. Machines and equipment of all types can benefit from applying industrial-rated RFID readers and tags. The ability to manage and track user authority can be used to ensure basic access control and improve overall safety. More advanced functions, such as paperless traceability and database connectivity, can help OEMs and manufacturers cost-effectively meet regulatory requirements and optimize machine performance. ce Linda Htay, product marketing specialist, IDEC Corporation. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.

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

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input #12 at www.controleng.com/information

AT0520A-CSG

ANSWERS

INSIDE MACHINES: ROBOTIC PROGRAMMING Michael Castor, Yaskawa Motoman Robotics Division

Robotic offline programming in a COVID-19 world Offline robot programming platforms are increasingly being used during the COVID-19 pandemic. See four scenarios and programming features.

has workers striving to complete high-mix, lowvolume runs at a record pace. To deal with the changeover required, a greater focus has been given to smart technologies, such as OLP software, to reduce programming downtime and optimize overall equipment efficiency (OEE).

Four scenarios for robotic offline programming

SCENARIO 4: Testing a new approach Loosening government restrictions have businesses reopening, which results in a new sense of urgency for revitalizing production. As a result, company leaders have decided to tackle tough challenges through creative and collaborative approaches to robotic automation. Either current robots are being redeployed or new robots are being purchased. Quite possibly, robotic automation is being introduced to the factory for the first time. Regardless of the

obotic automation and other advanced technologies have proven vital for businesses in recent months for sustaining and improving productivity in a demanding, yet uncertain, markets affected by the pandemic. From welding to coating, robots with feature-rich technologies can help businesses achieve greater accuracy and higher quality with increased efficiency. While robotic automation can accelerate production output, it also can cause significant downtime if a solid robot programming plan is not in place. To facilitate robot uptime – especially for manufacturing companies that cannot afford to interrupt production while a robot program is being written point by point from a teach pendant – offline robot programming platforms increasingly are being used to accommodate complex system layouts.

Using a 3D representation of a robotic workcell that visually demonstrates how a robot moves along a programmed path, offline programming (OLP) can be accomplished through original equipment manufacturer (OEM) -specific software platforms or third-party options. OLP also gives experienced and novice robot programmers the ability to create, test and adjust a robot program or job from the convenience of a PC-based virtual programming environment before it is implemented on the factory floor. Due to events surrounding the COVID-19 pandemic, many manufacturers are finding themselves in one, or more, of the four following situations: SCENARIO 1: Restricted access on the floor The whirlwind of new health concerns and regulations has prompted businesses to implement social distancing, along with work from home (WFH) policies. This has caused restricted access to robots on the factory floor, making it difficult to program/re-program jobs. SCENARIO 2: Adapting to changing demand An uptick in demand for general use products

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SCENARIO 3: Adding automation quickly Similar to scenario two, the increase in demand for products, especially those important to battling the pandemic, companies need to integrate new robots or redeploy old ones. Either way, to facilitate a smoother transition to the manufacturing of these essential products, using OLP software has been suggested.

Figure 1: Offline programming (OLP) can be accomplished through original equipment manufacturer (OEM)-specific software platforms or third-party options. Images courtesy: Yaskawa Motoman control engineeering

December 2020

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ANSWERS

INSIDE MACHINES: ROBOTIC PROGRAMMING ticular fashion to weld a specific part?”and other considerations.

Four robotic offline programming benefits for manufacturers

Aside from addressing the previously mentioned scenarios, the proper and effective use of OLP software can help manufacturers achieve various production goals including:

Figure 2: OLP can help manufacturers execute faster integration, quick changeovers and more.

approach, a viable method for setting up new, more complex, robot jobs with offline programming.

Four key features of robotic offline programming

While OLP software is not limited to the following, most users seek offline programming platforms that have an extensive model library and offer these four key features:

1. Robot collision detection If several robots are working in close proximity, it is vital they are programmed to work as a team. During the offline programming process, the collision detection feature signals potential interference hazards, allowing the programmer to make costsaving adjustments before the program is introduced to the factory floor. 2. Robot path planning While a robot is programmed to move from point to point, it is imperative to plan around specific items like fixtures for KEYWORDS: offline robotic holding parts. With path planning, proprogramming, COVID-19 gramming a robot to maneuver around Offline robot programming fixed points is made easier, as it actiplatforms are increasingly being vates collision detection to help avoid used to accommodate complex interference. system layouts. 3. Robot conveyor tracking The COVID-19 pandemic is When parts are in different positions, forcing many manufacturers to use offline robot programming conveyor tracking can help the robot because of workplace align those parts, as needed. restrictions. 4. Robot cam path Offline robot programming, If performing a welding application, when used properly, helps dispensing application or other complex manufacturers address current market challenges. task, the cam path feature can help automate the process. Instead of manually ONLINE teaching points to the robot, cam path See additional stories about provide these points automatically. robotics and COVID-19 at www.controleng.com. These features and more work together to help conceptualize possiCONSIDER THIS ble robot scenarios such as, “How fast What benefits would your robots can a robot go with a particular appliand manufacturing facility gain from offline robot programming? cation?” or “Can a robot move in a par-

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December 2020

control engineering

1. Execute fast integration with robots Offline programming provides a way of creating a robot job while a workcell is still in the construction phase. This process speeds up integration time, as data files can be transferred once the workcell is complete and installed on the shop floor. While minimal touch-up may be required, having a robot job prepared beforehand is a huge timesaver. 2. Perform quick changeover of robots If a robot is being used to process multiple parts, offline programming enables the ability to program the robot for “part B” while “part A” is being run. Once “part A” is complete, the programmed files can be downloaded to the robot controller to run “part B.” 3. Set up functional safety for robots OLP allows for items like arm interference, speed limits and safety zones to be established. This includes the ability to graphically overlay the safety zones (robot range limits) during simulation, allowing visual confirmation and testing with motion in the simulation. 4. Achieve quick cycle times for robots When extremely fast cycle times are required, OLP platforms can help users monitor the duty cycle of a robot so the life of the motor can be monitored. The flexibility provided by OLP software offers many perks and enables a higher mix of jobs with a simple transition from one job to the next. Similarly, larger companies with multiple locations and/or workcells may be able to reduce programming time and inconsistencies by distributing the programmed job from a central, controlled source. Furthermore, improvements in sensor technology for tasks such as robotic welding have come a long way in the recent past, providing considerable advantages for end users spanning diverse industries. Once implemented and properly used, the collective use of software – along with feature-rich sensors –can help manufacturers address current market challenges and the growing needs of a highmix low-volume production environment. Michael Castor is product manager, material handling at Yaskawa America Inc. – Motoman Robotics Division. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com. www.controleng.com

ANSWERS

TECHNOLOGY UPDATE Zach Goldsworthy, LEED AP BD&C, Siemens Industry Inc.

A great sequence of operations Applications, repairs and risk reduction, failure modes, retrofits, documentation and project scope are ways to develop a critical power sequence of operation.

mergency parallel switchgear is vital to a building’s resiliency or for processes inside, and the sequence of operation (SoO) for starting and stopping emergency parallel switchgear rarely receives the same level of attention. Sequence of operation parts, including considerations and what makes a good SoO, were covered in an Oct. 8, hour-long training course on the topic. Also covered was how transfer switches could be prioritized based on code and operation of the sequence of operation system. A live question and answer session followed the training, “Developing a great sequence of operations” produced by CFE Media and Technology, owner of Control Engineering, Plant Engineering, ConsultingSpecifying Engineer, and CFE Edu online training. Answering questions below was one of the course instructors (archived through December), Zach Goldsworthy, LEED AP BD&C, national healthcare market leader, Siemens Industry Inc.

Answers for SoO applications

1. How many other applications might benefit from electrical sequence of operations and why? Any electrical distribution that has automated operation should have a sequence of operation developed, which should include different operations/sources along with failure scenarios.

2. Even though the sequence of operation is automated, can we still have manual operation? The manual operation option is best practice and allows additional flexibility. It is also recommended that additional or follow up training is included. 3. If equipment failure changes SoO are there requirements for repair times? There are no published or required times for equipment to be repaired but best and recommended practice is as soon as possible to minimize the risk to the facility, occupants and community. This is also why many facilities require levels of redundancy. 4. Are there often overlooked details?

Failure modes are not always thoroughly considered. Most systems have one sequence that does not consider other variations. If the system is expected to be responsive to other failures, the detailed sequence www.controleng.com

Sequence of operations modes 1

Normal operation

Loss of normal source

Retransfer sequence

Failure modes

Load shed

Load bank

Monthly generator test

Seven modes of sequence of operation for emergency parallel switchgear are normal operation, loss of normal source, retransfer sequence, failure modes, load shed, load bank and monthly generator test. Courtesy: Siemens Industry

allows the system to be more responsive and resilient.

5. Are retrofit considerations different than working with new equipment? In what ways? Yes, retrofit projects need to take into account existing conditions and the overall ability of the emergency parallel switchgear and related equipment; this would include generators to parallel or in older transfer switches the ability to be shed. 6. What are SoO documentation best practices?

At the beginning of the project a comprehensive one-line diagram along with a thorough understanding of the facility is critical for understanding the full scope. At the end of the project, thorough as-builts and narrative are required. I also recommend reviewing the as-builts and sequence of operation at the end of the project with the complete team. The facility type or industry does not change the best practice recommendations but it is more important in critical power facilities, such as data centers, healthcare, and other areas, including critical industrial applications where power loss would be costly or dangerous.

7. What else needs explaining?

Thorough site investigation and review of the project scope are critical for a successful sequence of operation. Engagement with the manufacturer is also recommended to understand the impacts of the layout or configuration on emergency parallel switchgear and related equipment. ce Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com. control engineering

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KEYWORDS: Sequence of operations, emergency parallel switchgear Review risk considerations related to sequence of operation for emergency parallel switchgear and related equipment used in critical power applications. Consider sequence of operation failure modes, retrofit and repairs. Learn about documentation best practices for sequence of operations. CONSIDER THIS Need a refresher course on sequence of operations for emergency parallel switchgear?

ONLINE If reading from the digital edition, click on the headline for more resources. www.controleng.com/ magazine https://cfeedu.cfemedia. com/

December 2020

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ANSWERS

WEBCAST ON CYBERSECURITY Mark T. Hoske, Control Engineering

What you need to know about cybersecurity A webcast on cybersecurity offers information about cybersecurity architectures, training, best practices, risk assessment and trends based on research.

hat do you need to know about cybersecurity related to controls, automation, and instrumentation, especially with more remote connections resulting from the COVID-19 pandemic? Capabilities inherent in existing cybersecurity design methodologies and technologies will be explored along with what should be covered in cybersecurity training. When was your last cybersecurity risk assessment? The webcast is designed to help attendees:

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• Identify architectures for cybersecurity designs for controls, automation, and instrumentation. • Learn what should be covered in cybersecurity training. • Receive tips about cybersecurity best practices. • Review elements of a cybersecurity risk assessment. • Review related Control Engineering cybersecurity research results and advice.

ANSWERS

KEYWORDS: Industrial

cybersecurity, cybersecurity risk assessment Industrial cybersecurity webcast looks at what you need to know. Considerations include industrial control system cybersecurity Cybersecurity zones often are misunderstood.

CONSIDER THIS Are you reducing cybersecurity risk to an acceptable level?

ONLINE www.controleng.com/ webcasts www.controleng.com/ webcasts/past

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December 2020

Presenters are: • Brad Bonnette, technical director, Wood Automation and Control, Wood • Anil Gosine, global projects, MG Strategy+. Mark Hoske, content manager, Control Engineering, CFE Media and Technology will serve as moderator and present cybersecurity research.

ICS cybersecurity: Advice, integration, visibility, feedback

In discussions prior to the Dec. 3 webcast “Cybersecurity: What you need to know,” the presenters offered the following information.

control engineering

Gosine noted that cyber threats to the industrial control system (ICS) potentially can create health and safety catastrophes through the interruption of critical operations. Those involved with ICS cybersecurity should: • Make the security strategy your own • Build a security program will result in reduced perimeter operating costs and costs of compliance with NERC-CIP, NRC, CFATS, NIST, ISA-SP99 and other standards, guidance, and regulations. • Visibility of your operations, partners and vendors – know who is on your network, what they are running and how they are configured • Adopt security intelligence/situational awareness – it is about integration, visibility and system feedback • Have a governance structure that includes all stakeholders.

Mind your cybersecurity zones: consequence, vulnerabilities, threats

Bonnette said what distinguishes or defines a cybersecurity zone is often misunderstood. Unique zones may be driven by either a higher or lower consequence of the subsystem being compromised, or an increased likelihood (threat exposure) due to physical or logical access, such as “exposed” or “untrusted” edges. Bonnette said third-party interfaces are often lumped into one large zone, but they require additional zoning following a risk assessment as not all third-party systems have the same consequence, vulnerability or threat exposure. For more on these points, view the webcast; a question and answer session with the speakers will be archived with the webcast for one year from the Dec. 3 event. Access the Control Engineering webcast archive at www.controleng.com/webcasts/past.

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

INNOVATIONS

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

NEW PRODUCTS FOR ENGINEERS

Integrated servo drives can be placed on machine The AMI812x series of integrated servo drives expands the Beckhoff compact drive technology portfolio (up to 48 Vdc) with devices for distributed installation in the field. The integration of servomotor, output stage and fieldbus connection in a space-saving design makes the drives ideal for automation outside of control cabinets in the motion power range up to 400 W. The AMI812x integrated servo drive can be placed directly on the machine without a control cabinet and without upstream I/O, enabling the implementation of highly compact machines without control cabinets. At market introduction, the AMI812x series includes three overall lengths in the F2 flange code with standstill torques from 0.5 to 1.1 Nm. The AMI812x is optionally available with a multi-turn absolute encoder without battery backup and with a backlash-free holding brake. Beckhoff Automation, www.beckhoff.com

Input #200 at www.controleng.com/information

Non-fusible disconnect switches

AutomationDirect has added enclosed versions and non-enclosed DIN rail and panel/door mount versions of Merz disconnect/motor control switches. The non-enclosed UL 508/UL 60947 600Vac manual motor controller switches are designed for snap-on DIN rail mounting, base mounting or front mounting in a door. The terminal screws are all accessible from one side. ML1 compact switches are available for applications from 16 to 40A. For more demanding applications loads, the ML2 to ML3 series accommodates loads from 63 to 125A. Merz UL 508 disconnect switch with enclosure is a non-fusible, UL 508/UL 60947 manual motor controller 600 Vac disconnect switch rated at 25-125A (3-pole) and 40-63A (3-pole + neutral). The gray polycarbonate plastic enclosure with red handle is NEMA/ UL Type 1, 3R, 4, 4X rated. AutomationDirect, www.automationdirect.com

Input #201 at www.controleng.com/information

Advanced I/O for mechancal engineering

Wago Corp.’s I/O System Advanced is designed for mechanical engineering applications. Connectivity and speed are the foundations of modern production facilities. The system provides an IP20 solution that integrates time-sensitive networking (TSN) and OPC UA. As a gateway to the universal WAGO 750 Series I/O System, the new I/O System Advanced combines the proven benefits and functionality of the 750 Series with a fresh and ergonomic design, mechanical features that help prevent errors and outstanding performance. The results: short reaction times, high signal transmission synchronicity and the ability to use fast Ethernet fieldbuses (such as Profinet, EtherCAT, EtherNet/IP). Wago Corp., www.wago.com

Input #202 at www.controleng.com/information

Bluetooth dual-mode wireless modules

The FWM7BTZ61 series of Bluetooth Version 5.0 (dual mode) wireless radio modules compatible with Bluetooth Low Energy and legacy Bluetooth Classic BR/ EDR, giving designers the flexibility to choose between the two modes with one module. The symbol rate and data rate accommodates 1Mbps and improved 2Mbps to facilitate communication speed with other Bluetooth Low Energy devices. In addition, Classic mode supports 1Mbps (BR: basic rate) and 2 and 3Mbps (EDR: Enhanced Data Rate) communication. The series also supports a wide range of operating voltages from 1.71 to 3.63V, which enables the mating with various system design and power supply conditions. Fujitsu Components America Inc. www.fujitsu.com Input #203 at www.controleng.com/information

Thermal mass flowmeter measures pure and mixed gases

The Proline t-mass F300 thermal mass flowmeter are designed to measure pure gases and gas mixtures, and each has numerous alarm functions, as well as bidirectional measurement capability and reverse flow detection. Whether compressed air, natural gas, protective gas or oxygen, end users wanting to record gas flows with proven and robust state-of-the-art measuring technology no longer need to make compromises. The all-metal sensor design and monitoring functionality helps ensure optimum process measurement. Even when process conditions fluctuate significantly, gas flows can be measured with high accuracy. Even when process and ambient conditions significantly fluctuate, t-mass ensures high measurement accuracy (±1.0%) with excellent repeatability (±0.25%). Gas flows with low pressure and a low flow velocity can also be measured easily. Endress+Hauser, www.us.endress.com www.controleng.com

Input #204 at www.controleng.com/information

control engineering

December 2020

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INSIGHTS

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

CAST YOUR BALLOT

2021 Engineers’ Choice: Vote now!

hich products can help in your next project? Vote now! The official Engineers’ Choice ballot is open for voting for Control Engineering North American print and digital edition subscribers through December 2020. In the New Products for Engineers database, vote for the best Engineers’ Choice finalists of 88 entries across 21 categories. Based on your experience, please vote in as many categories for which you feel qualified based on technological advancement, service to the industry, and market impact. Details and photos are available for each product. Winners and honorable mentions will be featured in more detail in the February 2021 issue of Control Engineering.

New automation products

Learn more about 2021 Engineers’ Choice Finalists covering cybersecurity, human-machine interfac-

Learn more about each product here and link to the voting area: www.controleng.com/articles/2021-engineers-choice-finalists-vote-now

webcasts

es (HMIs), industrial PCs and CNCs, edge controllers for Industrial Internet of Things connectivity, software for IIoT connectivity, programmable logic controllers, machine vision and discrete sensors, motion control, drives and servo drives, Ethernet hardware and switches, I/O systems, energy and power protection, power supplies and uninterruptible power supplies, process sensors and transmitters, process control systems, machine safety, asset management and reporting software, control design software, data analytic software, and HMI software.

Informed voting, a responsibility

Voting on this ballot is only open to qualified* subscribers of Control Engineering products. One ballot per qualified subscriber will be accepted; multiple ballots from the same qualified subscriber will be invalid. Ballots received from non-qualified subscribers will be invalid. (*NOT eligible to vote, even if Control Engineering subscribers are employees of product manufacturers with a finalist in the current program and their properties, agencies, vendors, and representatives.) ce

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

Discover the latest on topics like: • Arc flash

• Compressed air

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2/1/2019 12:43:40 AM

INNOVATIONS

BACK TO BASICS: DIGITAL AUTOMATION Gregory Hale, ISSSource

Resiliency, security, automation Manufacturing’s resilience has been strong during the COVID-19 pandemic, and cybersecurity needs to be stronger than ever as the nature of work changes.

t is becoming more important to talk about the booming levels of digitalization in the manufacturing automation sector, and rightly so, the increased connectivity and the hike in efficiencies continue to grow at a huge rate. When talking about those increased levels of connectivity, however, what often is understood and never talked about out loud is how cybersecurity needs to be the backbone of the entire endeavor. Part of that sense of assurance comes from the construction of the resilient nature of the manufacturing enterprise, which has truly come to light in the COVID-19 era. “Think about the critical networks of our cities, the water networks, the electrical networks, think about the core chains of food, of pharmaceuticals, we were there to support the reliability and the continuity of service of those processes,” said Jean-Pascal Tricoire, chairman and chief executive of Schneider Electric during the Schneider Electric virtual Innovation Summit North America 2020. “And the one thing we have learned is that resilience comes from the automation of processes that can keep going locally without human intervention and that comes from digital monitoring of installations. If your installation is plugged in and if it’s under monitoring of analytics, of AI, then you are in a much better position to understand what is going on and prevent any breakdown. What we have learned also is that one is as resilient as the weakest point in their processes. Resilience is the sum of resiliency and actually is a multiplication of the resilience of the grid, of the power system, of the building system, of the IT system and of the process.”

Remote collaboration, cybersecurity

As we are adapting to this work from home environment, digitalization is growing by leaps and bounds and it is making it possible to collaborate remotely to increase agility and ensure operations continue to move forward. Digital really started 30 years ago when the internet started to take off and it dramatically changed the way we live and work together, Tricoire said. We are now in the second phase of the digital revolution which is the Internet of Things (IoT) connecting us to machines and connecting machines to machines. On top of that, Big Data and artificial intelligence are also major innovations helping move the industry forward. Another disruption, Tricoire said, is the world will become massively more electric. But it will be a different kind of electric.

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“It is not the same electricity; it is about solar energy, decentralized microgrids, net-zero buildings, and electric vehicles,” he said. “By combining those two disruptions, the future will be smart and green.” To reach that level of sustainability, the industry has to grasp four elements to achieve a stronger environment.

Leveraging digital efficiency

“We get there by massively leveraging digital efficiency; digital technology to reach a much better efficiency in every building and every city and every manufacturing facility,” Tricoire said. “As digital brings levels of efficiency to a much lower cost point, then we can increase the rate of retrofit in existing installations. The problem is with the existing stock of buildings and manufacturing facilities, we need to digitize the existing installations to make sure everything we do is much more efficient.” The second element of the equation is circularity, he said. We have to develop a more circular economy, so we save on resources. The third point is everything will be massively more electrical, Tricoire said. In the next 20 years there will be a much larger investment in electricity. The final point, he added, is that it will be green electricity. “We are facing many crises at the moment,” Tricoire said. “Everybody is talking about COVID-19 and a recession and we are losing site that we are facing climate change. Climate change remains one of the big problems of our generation. We are the first generation to know about climate change, but we KEYWORDS: digitalization, may be the last generation to be able cybersecurity, COVID-19 to change the course of climate change Manufacturing has been resilient and strong during the COVID-19 because this phenomenon is accelerating pandemic. and needs us to change the trajectory.” Cybersecurity is an important, but If it isn’t already, digitalization will soon not always talked about, aspect of be the way of the world. It has to be secure, manufacturing’s resiliency. and the companies that take advantage of Digitalization is a transformative the efficiencies and advantages will be able – and disruptive – part of how manufacturing is changing for the to achieve great dividends. ce

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better.

Gregory Hale is the editor and founder of Industrial Safety and Security Source (ISSSource.com), a CFE Media content partner. This article is from ISSSource’s website. Edited by Chris Vavra, associate editor, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com. control engineering

ONLINE See additional stories from Gregory Hale and ISSSource at www.controleng.com.

CONSIDER THIS What steps are you taking to prepare for manufacturing’s future?

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control engineering

2/9/2017 2:25:34 PM

Technology

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Yaskawa America, Inc. Drives & Motion Division

1-800-YASKAWA yaskawa.com

input #13 at www.controleng.com/information

™

For more info: https://www.yaskawa.com/compass

Honey, I’m home! Tired of working nights and weekends on motion control projects? It’s time to contact an automation specialist at SEW-EURODRIVE for help. We provide a complete package from start to finish, including project planning, software, components, commissioning, troubleshooting, and worldwide support. Let our specialists be an extension of your team.

seweurodrive.com | 864-439-7537 input #14 at www.controleng.com/information

CE_20_12

Articles inside

Cybersecurity and the rise of IT-enabled OT systems

Think Again: Data flow, alarms simulation, cybersecurity, robotics

Technology Update: Benefits of an alarm management philosophy

Control system best practices wearable exoskeleton; Stretchable sensor gives robots, VR a human touch; Headlines online include Top 5

AMP upgrades to edge controllers

Secure-by-design industrial products are increasingly important

International: Flexible process control

How modern simulation software addresses intralogistics challenges