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All pneumatic motion requires clean and dry air with enough flow to provide the required pressure. The process of filtering, regulating and lubricating compressed air is known as air prep. The NITRA family of air preparation components include:

Solenoid valves are electrically controlled to direct air flow to sequence operations in pneumatic systems. Solenoid valves are used to control cylinders, rotary actuators, grippers and other pneumatic devices. Use a manifold to simplify plumbing for a bank of valves.

Modular systems even allow networked control of valve group.

The most popular style of pneumatic actuator uses compressed air acting on a piston inside a cylinder to move a load along a linear path.

• Filters with 40 micron filter element (5 micron option) in sizes from 1/8” to 1” NPT port sizes • Regulators with adjustment from 20-130 PSI and 4-57 PSI • Combination filter/regulators available with same options in one unit • Lubricators in 1/8” to 1” port sizes • Total air prep units that combine all air preparation functions in one compact unit

• Available as stand-alone units or as part of a compact modular valve system • Stand-alone units can be used with optional manifolds to make system configuration simpler • Available in 3-port/3-way, and 5-port/4-way styles • 4-way valves come in 2-position or 3-position styles with center closed or center open

Also Available Modular Solenoid Valves

NFPA Tie-Rod Cylinders

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• Round body cylinders available in single-acting or double-acting styles, with up to an 18-inch stroke and 2-inch bore. Also available in stainless steel. Magnetic pistons are optional.

• NFPA tie rod air cylinders come in double-acting style, with up to a 24-inch stroke and 4-inch bore.

All include a magnetic piston.

Adjustable air cushions are an option.

• ISO 15552 air cylinders are double-acting cylinders with up to a 600mm stroke and 100mm bore.

All include magnetic pistons and adjustable air cushions.

• Metric and Inch compact air cylinders as well as dual rod guided air cylinders also available.

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the #1 value in automation

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

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Vol. 68 Number 3

®

MARCH 2021

ANSWERS 21 | Motors and drives: Tips and tools for efficient motor management

21

COVER: Large dynamometer for motor efficiency testing is rated for up to 300 hp output at 1800 rpm. The motor coupled to the dynamometer in this photo is 200 hp. Courtesy: Advanced Energy

INSIGHTS 8 | International: Understanding ATEX and IECEx for flammable, explosive areas Technology Updates: 12 | More answers on what you need to know about cybersecurity 16 | More questions answered on IIoT cloud to edge 17 | What is a digital thread?

NEWS

18 | Changing winds of cybersecurity for ICSs, Global manufacturing contraction lower than expected for 2020, Online training for continuing education credits: Virtual Training Week, Headlines online 20 | Think Again: Moving toward automation interoperability

26 | Improved stepper motor systems support more application IIoT for Engineers:

p.21

29 | New edge devices and automation benefits

p.26

32 | Expanding edge control 36 | Operational technology: Data acquisition, data architectures, data analytics 39 | Interoperability best practices, integration, automation, controls ONLINE | For all links to all posts at www.controleng.com during February 2021, see p. 6.

INSIDE PROCESS

P1 | Six steps for supporting an automation system P3 | Digitalization crucial for food manufacturing processes

CONTROL ENGINEERING (ISSN 0010-8049, Vol. 68, No. 3, GST #123397457) is published 11x per year, Monthly, except in November, by CFE Media, LLC, 3010 Highland Parkway, Suite #325 Downers Grove, IL 60515.

Jim Langhenry, Group Publisher/Co-Founder; Steve Rourke CEO/COO/Co-Founder. CONTROL ENGINEERING copyright 2021 by CFE Media, LLC. All rights reserved. CONTROL ENGINEERING is a registered trademark of CFE Media, LLC used under license. Periodicals postage paid at Downers Grove, IL 60515 and additional mailing offices. Circulation records are maintained at 3010 Highland Parkway, Suite #325 Downers Grove, IL 60515. Telephone: 630/571-4070. E-mail: ctle@omeda.com. Postmaster: send address changes to CONTROL ENGINEERING, PO Box 348, Lincolnshire, IL 60069. Publications Mail Agreement No. 40685520. Return undeliverable Canadian addresses to: PO Box 348, Lincolnshire, IL 60069. Email: ctle@omeda.com. Rates for nonqualified subscriptions, including all issues: USA, $165/yr; Canada/Mexico, $200/yr (includes 7% GST, GST#123397457); International air delivery $350/yr. Except for special issues where price changes are indicated, single copies are available for $30 US and $35 foreign. Please address all subscription mail to CONTROL ENGINEERING, PO Box 348, Lincolnshire, IL 60069. Printed in the USA. CFE Media, LLC does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the material contained herein, regardless of whether such errors result from negligence, accident or any other cause whatsoever.

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March 2021

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MARCH 2021

®

INNOVATIONS NEW PRODUCTS FOR ENGINEERS

49 | Brushless dc motors, Automotive-grade interface integrated

circuit, Robot cell for industrial manufacturing applications, Distribution block series, Smart temperature transmitter with Bluetooth, Safety relay module, Asset management platform, OT network service platform See more New Products for Engineers at www.controleng.com/NPE.

BACK TO BASICS

51 | What to know about industrial Ethernet versus office Ethernet

NEWSLETTER: Industrial Networking • Functional safety networks for Ethernet communication protocols • PC-based control boosts sterile sampling bag production • Changing winds of cybersecurity for ICSs • Four ways TSN can boost manufacturing productivity • Field-level communications initiative improves interoperability.

Keep up with emerging trends: subscribe. www.controleng.com/newsletters.

CFE EDU: Virtual Training Week On-Demand Did you miss the last 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 Don’t miss Virtual Training Week starting March 29!

Control Engineering eBook series: Digital Transformation Spring Edition Digital transformation is a hot buzzword in manufacturing today, but what does it mean? What does it mean for manufacturers and what effect will it have for the present and future? This helpful eBook offers several examples of the many digital transformation is taking hold in manufacturing. Featured articles include how a mobile HMI strategy can lead to digital transformation, how to address future obsolescence in embedded computer systems, and three phases of industrial digital transformation.

Learn more and register to download at www.controleng.com/ebooks/.

Global System Integrator Report Supplement to December Control Engineering and Plant Engineering Advice from automation and control system integrators with System Integrator of the Year for 2021, System Integrator Giants and more. www.controleng.com/GSIR Control Engineering digital edition The tablet and digital editions provide links to additional article images and text online and links to other related, useful resources. www.controleng.com/magazine

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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control engineering

March 2021

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Online ®

Below are the articles posted in January 2021, in case you missed something. In the digital edition, at www.controleng.com/magazine, links are live!

PLC users can use cloud services without programming, https://www.controleng.com/articles/plc-users-can-use-cloud-services-without-programming/ Top 5 Control Engineering Articles Jan. 25-31, 2021, https://www.controleng.com/articles/top-5-control-engineering-articles-jan-25-31-2021/ Spotlight on Innovation: 2021 Engineers’ Choice Awards, https://www.controleng.com/articles/spotlight-on-innovation-2021-engineers-choice-awards/ Growing ICS vulnerabilities mandate prioritization, https://www.controleng.com/articles/growing-ics-vulnerabilities-mandate-prioritization/ Control Engineering hot topics, January 2021, https://www.controleng.com/articles/control-engineering-hot-topics-january-2021/ SCADA helps bridge the IT/OT gap, https://www.controleng.com/articles/scada-helps-bridge-the-it-ot-gap/ Four ways TSN can boost manufacturing productivity, https://www.controleng.com/articles/four-ways-tsn-can-boost-manufacturing-productivity/ Organizations agree to digital transformation liaison, https://www.controleng.com/articles/organizations-agree-to-digital-transformation-liaison/ Integrating flow, process control improves operations, https://www.controleng.com/articles/integrating-flow-process-control-improves-operations/ Lessons learned for new approaches in machine control, https://www.controleng.com/articles/lessons-learned-for-new-approaches-in-machine-control/ 3 data analysis tips: Adapt data, leverage skills... https://www.controleng.com/articles/3-data-analysis-tips-adapt-data-leverage-employee-skills-innovate/ What OSHA can teach us about cybersecurity, https://www.controleng.com/articles/what-osha-can-teach-us-about-cybersecurity/ IoT-enabled process validation system for COVID-19 vaccine rollout, https://www.controleng.com/articles/iot-enabled-process-validation-system-for-covid-19-vaccine-rollout/ Low-cost, easy-to-use electric motion, https://www.controleng.com/articles/low-cost-easy-to-use-electric-motion/ Light curtain operation is easier with wireless communications, https://www.controleng.com/articles/light-curtain-operation-is-easier-with-wireless-communications/ How industrial vision systems differ from the human brain, https://www.controleng.com/articles/how-industrial-vision-systems-differ-from-the-human-brain/ Modernize legacy distributed control systems for a competitive edge, https://www.controleng.com/articles/modernize-legacy-distributed-control-systems-for-a-competitive-edge/ How to ensure industrial Ethernet cables ... https://www.controleng.com/articles/how-to-ensure-industrial-ethernet-cables-meet-standards-applications/ Secure, remote industrial access, https://www.controleng.com/articles/secure-remote-industrial-access/ Insights on industrial networking, https://www.controleng.com/articles/insights-on-industrial-networking/ PC-based control boosts sterile sampling bag production, https://www.controleng.com/articles/pc-based-control-boosts-sterile-sampling-bag-production/ Partnership to secure ... networks https://www.controleng.com/articles/companies-expand-partnership-to-secure-industrial-critical-infrastructure-networks/ Top 5 Control Engineering Articles Feb. 1-7, 2021, https://www.controleng.com/articles/top-5-control-engineering-articles-feb-1-7-2021/ Mission-critical should be the mission, https://www.controleng.com/articles/mission-critical-should-be-the-mission/ Changing winds of cybersecurity for ICSs, https://www.controleng.com/articles/changing-winds-of-cybersecurity-for-icss/ Field level communications initiative improves interoperability, https://www.controleng.com/articles/field-level-communications-initiative-developed-for-improved-interoperability/ Water treatment facility targeted by hackers, https://www.controleng.com/articles/wastewater-facility-targeted-by-hackers/ Artificial intelligence applied to mill optimization, https://www.controleng.com/articles/artificial-intelligence-applied-to-mill-optimization/ Students learn to secure cyber networks, data https://www.controleng.com/articles/students-learn-to-secure-cyber-networks-data/ Nanowire could provide a stable superconducting transistor, https://www.controleng.com/articles/nanowire-could-provide-a-stable-superconducting-transistor/ Functional safety networks for Ethernet communication protocols, https://www.controleng.com/articles/functional-safety-networks-for-ethernet-communication-protocols/ Minimizing SCADA system security gaps, https://www.controleng.com/articles/minimizing-scada-system-security-gaps/ Advanced materials, hardware for next-generation computing, https://www.controleng.com/articles/advanced-materials-hardware-for-next-generation-computing/ Top 5 Control Engineering Articles Feb. 8-14, 2021, https://www.controleng.com/articles/top-5-control-engineering-articles-feb-8-14-2021/ Smart pneumatic flow control, https://www.controleng.com/articles/smart-pneumatic-flow-control/ Manufacturing analytics and machine learning benefits, https://www.controleng.com/articles/manufacturing-analytics-and-machine-learning-benefits/ Evolution of control systems with artificial intelligence, https://www.controleng.com/articles/evolution-of-control-systems-with-artificial-intelligence/ Compensating controls in ICS cybersecurity, https://www.controleng.com/articles/compensating-controls-in-ics-cybersecurity/ A quantification of design advantage... https://www.controleng.com/articles/direct-drive-vs-geared-rotary-servomotor-a-quantification-of-design-advantage-part-3/ The value in turnkey manufacturing, https://www.controleng.com/articles/the-value-in-turnkey-manufacturing/ Evolving control systems are key to improved performance, https://www.controleng.com/articles/evolving-control-systems-are-key-to-improved-performance/ Connected technology advances for workers after COVID-19, https://www.controleng.com/articles/connected-technology-advances-for-workers-after-covid-19/ Industrial automation partnerships build strength in numbers, https://www.controleng.com/articles/industrial-automation-partnerships-build-strength-in-numbers/ Four SCADA considerations for manufacturers, https://www.controleng.com/articles/four-scada-considerations-for-manufacturers/ Semiconductor group: support for manufacturing... https://www.controleng.com/articles/semiconductor-group-urges-support-for-manufacturing-research-funding/ Lens developed to focus at multiple depths without moving, https://www.controleng.com/articles/lens-developed-to-focus-at-multiple-depths-without-moving/ Automation benefits on the factory floor, https://www.controleng.com/articles/automation-benefits-on-the-factory-floor/ Global manufacturing contraction lower than expected in 2020, https://www.controleng.com/articles/global-manufacturing-contraction-lower-than-expected-in-2020/ IIoT, AI and control engineering combine... https://www.controleng.com/articles/iiot-ai-and-control-engineering-work-to-create-a-human-type-nervous-system/ Four ways to converge physical and cybersecurity... https://www.controleng.com/articles/four-ways-to-converge-physical-and-cybersecurity-in-industrial-operations/ Global silicon revenues rise in 2020, https://www.controleng.com/articles/global-silicon-revenues-stable-in-2020/ Understanding PID tuning, https://www.controleng.com/articles/understanding-pid-tuning/ Researchers develop speedier network analysis... https://www.controleng.com/articles/researchers-develop-speedier-network-analysis-for-computer-hardware/ Wearable sensor developed to detect COVID-19, other diseases, https://www.controleng.com/articles/wearable-sensor-developed-to-detect-covid-19-other-diseases/ Taking the time out of function blocks, https://www.controleng.com/articles/taking-the-time-out-of-function-blocks/ Future-proofing process control systems with Lean... https://www.controleng.com/articles/future-proofing-process-control-systems-with-lean-project-execution/

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The choice for harsh environments

NEW i550 protec frequency inverter for decentralized operations.

The i550 protec is exceptionally tough. Its NEMA 4X (IP66) protection rating makes it suitable for even the most demanding applications. Whether dusty or wet, indoors or outdoors – it can handle it all. The housing protects the technology – and performance remains excellent no matter the conditions.

Offering a compact design, it’s also the first decentralized drive in the market with IO-Link Device Interface. www.Lenze.com

input #5 at www.controleng.com/information

INSIGHTS

INTERNATIONAL: SAFETY STANDARDS Lee Ray, TÜV SÜD

Understand ATEX and IECEx The ATEX and IECEx directives are standards for environments at risk of fire or explosion.

D

ue to the use of flammable gases, vapors or combustible dusts, some modern industrial environments pose an increased risk of fire and explosion. Within the EU, compliance with the ATEX Directive (2014/34/EU) is required, and in other markets the IECEx Equipment Certification Scheme applies.

Like all EU Directives, the ATEX Directive generally relies on the application of relevant standards to assess technical compliance. Compliance with the technical requirements of EU harmonized standards provides a presumption of conformity with the Directive’s essential requirements. As EU Directives are transposed into National Law, the UK already has a legal system in place that applies. The actual standards will remain the same as EU harmonized standards and will be carried across as U.K. designated standards to maintain a single standards model.

In cases where relevant harmonized standards do not exist, manufacturers are required ATEX: More than to apply other EU standards, or applicable national or international standards. In rare one harmonized cases, where a particular product is not covered by any existing standard, a manufacturer standard may be is required to complete a thorough evaluation of the product to demonstrate compliance. applicable to the Under the provisions of the ATEX Direcevaluation and certive, evidence of compliance is generally demonstrated by the issuance of a Declaration of tification process.

Conformity, from the manufacturer or supplier, based on an independent technical assessment. Special requirements apply to electrical products intended for use in high risk areas. The task of demonstrating compliance with the ATEX Directive rests with the party responsible for introducing a product into the EU marketplace. This is typically the product manufacturer, but it may also be an importer or wholesaler.

Annex II of the ATEX directive addresses design and construction requirements for equipment and protective systems. Specific technical requirements to demonstrate compliance for various types of equipment and operating environments are found in nearly 100 individual harmonized standards. Depending on the equipment and its intended use, this means that Updated harmonized standards lists are published in the Official Journal of the European Union.

Annex I identifies three equipment categories, which depend on the environment in which the

‘

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equipment is to be used. Cat 1 and 2 electrical equipment must be tested and certified by an EU Notified Body (NB), and an NB-certified quality system must also be maintained. Cat 2 and 3 non-electrical equipment does not require NB involvement, but technical documentation must be stored with an ATEX NB.

The IECEx scheme

Equipment certified in connection with the voluntary IECEx Certified Equipment Scheme meets the regulatory requirements of more than 30 countries. In addition, the IECEx System has been endorsed by the United Nations Economic Commission for Europe (UNECE). As a result, non-IECEx member countries can implement legal frameworks into their respective national legislation, simply by adopting the IECEx System and Schemes. Under the System, regulatory authorities in member countries accept certifications issued by IECEx-recognized Certification Bodies, regardless of their location.

The primary goals of the IECEx Scheme are to reduce testing and certification cost, speed up market access for new products and equipment, and increase international acceptance of product assessment results. The Scheme achieves these goals through the issuance of an International Certificate of Conformity.

Under the IECEx Scheme, testing and assessment activities are carried out by IECEx-approved Testing Laboratories, with certifications issued by IECExapproved Certification Bodies. Assessment is based exclusively on compliance with standards issued by Technical Committee (TC) 31 of the International Electrotechnical Commission (IEC).

Self-certification of products is not accepted under the IECEx scheme. Equipment certification under the IECEx Certified Equipment Scheme is based on a compliance assessment with the technical requirements found in the IEC 60079 series of standards (electrical products); the IEC 80079 series of standards for non-electrical products; and the application of quality systems which have been developed by TC 31. However, the IECEx scheme only assesses electrical equipment against the technical requirements of IEC standards issued by TC 31. This restriction can present an insurmountable hurdle for manufacturers of highly specialized electrical equipment, for which a relevant standard does not yet exist.

The IECEx Scheme classifies equipment by the hazardous environment areas where specific equipment can be used. Equipment protection level (EPL) www.controleng.com

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INSIGHTS INTERNATIONAL

Ga/Da and Gb/Db corresponds with the ATEX Categories 1 and 2 respectively; Gc/Dc corresponds with ATEX Cat 3 requirements.

The IECEx conformity mark is evidence that a manufacturer’s products have been independently assessed against the added requirements of the IECEx conformity mark licensing system. The mark license number is issued to a manufacturer by an accepted IECEx certification body (ExCB) that has entered into a mark license agreement with the IEC. The use of IEC standards and independent third parties for testing, assessment and certification are essential elements in the widespread acceptance of IECEx-certified equipment. Indeed, in countries that do not participate in the IECEx System, or that still require separate national testing and certification, IECEx equipment tests and assessment reports are widely accepted by regulatory officials, which may eliminate the need for duplicate testing.

Conformity route

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The ATEX Directive’s conformity assessment process provides a certification route for a broad range of electrical and non-electrical equipment. It offers significant latitude in the technical assessment of non-conventional equipment through use of a technical construction file. This can be important to manufacturers of customized equipment, or equipment designed for unique applications.

Other considerations include restrictions on the use and acceptance of previously generated ATEX test data. Under the IECEx Scheme, equipment must be tested and certified by IECEx-approved Testing Laboratories and Certification Bodies, and evidence of prior testing conducted by an EU Notified Body is not acceptable. EU NBs located in IECEx member countries are required to accept test reports generated by IECEx-approved Testing Laboratories in support of an ATEX certification submittal.

Given these considerations, the preferred conformity assessment path for many manufacturers has traditionally involved first obtaining equipment certification under the IECEx Certified Equipment Scheme. The IECEx testing KEYWORDS: ATEX, IECEx, data is then be submitted to an process manufacturing EU NB as part of the ATEX certi- Compliance with the ATEX Directive is required in the fication process. This path would European Union (EU), and in other still require that certain ATEX- markets the IECEx Equipment specific requirements are met, Certification Scheme applies. such as those related to equip- These standards protect workers ment marking and documenta- in hazardous conditions. tion. The effort involved is small The ATEX Directive’s conformity assessment process provides compared to alternatives. ce a certification route for a broad

M More INSIGHTS

Lee Ray is operations manager for Industrial Products (UK) at TÜV SÜD. This article originally appeared on Control Engineering Europe’s website. Edited by Chris Vavra, web content manager, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.

10 ©2021 Rittal North America LLC

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range of electrical and nonelectrical equipment.

ONLINE See additional stories about electrical standards at www.controleng.com.

CONSIDER THIS What benefits could your company gain from increased awareness about these standards?

control engineering

Simplifying industrial digitalization, while reducing cost and risk with advanced Siemens SIMATIC ET 200 I/O systems Worldwide, the digitalization of discrete and process industries continue to accelerate. One reason is that existing automation infrastructure is rapidly aging, along with the workforce that designed, engineered, and operated it for many decades. Parts may be hard to get.

Production disruptions and repairs are more frequent.

Expertise to operate older equipment and troubleshoot problems is getting harder to find as older workers retire.

Profinet, Ethernet IP or Modbus TCP, I/O is a critical area of IIoT connectivity that serves as a foundational building block for the digitalization of manufacturing and Industry 4.0.

What’s more, in the world of Industry 4.0, automation is quickly evolving into a practical model of autonomation, where machines are conducting plant operations with more autonomy than ever, with less and less human intervention. In this world, the importance of advanced yet compact programmable logic controllers (PLCs) with multifunctional discrete and analog input and output (I/O) capabilities have never been more important.

Siemens has designed and engineered its two mainstay SIMATIC ET 200 distributed controller I/O systems to counter these misconceptions: the SIMATIC ET 200SP and SIMATIC ET 200MP systems, each which include a wide range of CPUs for system monitoring and control.

These extremely cost-effective I/O systems can tremendously simplify industrial digitalization while reducing operating costs and disruption risks, as this paper will explain.

In short, I/O integrated with PLCs in distributed configurations, such as the SIMATIC ET 200 SP and MP models, are less expensive than having separate components; offer longer life cycle times unlike PC-based control systems; do not need air-conditioning to control temperature and humidity. In fact, compared to PC-based control systems, they can withstand wider temperature ranges and tolerate humidity and condensation much better.

Today’s PLCs have come a long way since their introduction decades ago. More features. More intelligence. More flexibility. More scalability. But without I/O signaling, PLCs cannot perform. When acquiring discrete and analog signals from the field devices using Industrial Ethernet communication protocols such as

Read the white paper: http://sie.ag/37DZ6D1

input #8 at www.controleng.com/information

usa.siemens.com/io

INSIGHTS

WEBCAST ON CYBERSECURITY Mark T. Hoske, Control Engineering

More answers on what you need to know about cybersecurity Below are more answers resulting from a cybersecurity webcast on cybersecurity architectures, training, best practices, risk assessment and trends based on research.

A

cybersecurity webcast Dec. 3, 2020, raised more questions than two expert responders had time for at the end, and their answers to those additional questions on industrial control system cybersecurity are available below. The webcast, with one PDH available, is archived for one year. Register for the webcast with the following link: “Cybersecurity: What you need to know.” Two presenters answered the additional questions below.

• Brad Bonnette, technical director, Wood Automation and Control, Wood • Anil Gosine, global projects, MG Strategy+

More ICS cybersecurity answers QUESTION: What are often overlooked cybersecurity best practices that represent weak links?

Do they differ widely by organization and industry or are there commonalities for all?

Bonnette: Seemingly simple things like, turning off or actively managing USB, Bluetooth and removable/portable media connections.

Lack of management of unused accounts, personnel departures, (temporary) personnel, contractor or vendor access credentials.

Not monitoring firewall or security moniKEYWORDS: Industrial cybersecurity, toring software reports or alerts. cybersecurity risk Gosine: Proper configuration of the sysassessment tems procured and under estimating the Industrial cybersecurity time/effort needed to continuously mainwebcast looks at what you tain and address issues. You want to avoid need to know. similar situation like operators ignoring Extra questions about cybersecurity are answered. alarms and then requiring another effort for alarm management years after initial ICS CONSIDER THIS deployment. An article published in Control What are you doing to Engineering, “Key security components and reduce cybersecurity risk to an acceptable level? strategies for ICS,” is a good reference.

M More INSIGHTS

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

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Q: Are there special cybersecurity recommendations for supervisory control and data acquisition (SCADA) and programmable logic controller (PLC)-based systems? control engineering

Bonnette: Edge protection and defense-in-depth are still principal base models. However, if the context of SCADA includes utilization of cloud or wide-area network (WAN) that is not exclusively controlled by the owner/operator, additional measures must be considered to authenticate traffic, endpoint devices, users, and protect (encrypt) data being carried over cloud or contracted carrier networks. The external network should be treated as an untrusted edge.

However, just because your company owns a specific LAN or WAN does not mean it may not need to be considered untrusted just as well, depending on technical and physical access control to the networks.

External networks should always be considered untrusted and considered a potential threat vector.

Reference: ISA-TR100.15.01-2012 Technical Report “Backhaul Architecture Model” Q: Is there a need for firewalls on Apple products?

Bonnette: Yes, both to protect the device, but primarily to protect the rest of the system from the device. Apple OS are just as exploitable as Microsoft Windows (Linux as well). At a minimum, any type of networked device may be used for distributed denial of service attacks (DDoS) attacks and robot data storm attacks, or as a pivot point for data, traffic or access to gain access to an operating technology (OT) system or network. Mobile phone malware has caused OT incidents, transmitting malware to the OT system by plugging in a mobile phone (smart phone) to a USB to charge it on an OT workstation, resulting in crypto locking or virus infection of facility control system.

Gosine: Apple Wireless Direct Link protocol to create mesh networks can be exploited as noted recent security notifications.

Q: Are there particular advantages to hard wiring? Or to keeping all data in house?

Bonnette: “Hard-wiring” may be easier to protect physically with barriers and physical access controls.

However, as soon as the network leaves a physically controlled boundary, any points of connection or distribution are accessible, but typically not as acceswww.controleng.com

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INSIGHTS

WEBCAST ON CYBERSECURITY sible as wireless systems. There is a lot of debate of keeping data “in-house,” if you are overwhelmed with maintain the security and integrity of your data systems and data, outsourcing may actually be means of improving the security or integrity of the system, but risks in the supply chain (the service supplier’s) integrity, security practices and capability need to be assessed as if it were your own estate.

Gosine: You need to weigh the risks/benefits of losing the cloud-based data analytics capabilities that increase productivity, efficiency and increase margins when keeping data internal.

Q: We’re trying to determine what cybersecurity staff training should include for whom and when?

Gosine: Know where your organization’s understanding is at through a baseline Q&A that follows the NIST Framework Categories. There will be a need for distinct training course materials for operators, security administrators, general users. Annual workshops for operation and security administrators. Operators - training on detecting anomalies; Administrators tools, management techniques and prioritization in risk assessment; General users - social engineering and situational awareness. Incorporating relatable

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Weigh the risks/benefits of losing the cloud-based data analytics capabilities that increase productivity, efficiency and increase

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margins when keeping data internal.

security information into available corporate news feeds/webcast updates also may be beneficial.

Q: What determines how often a cybersecurity risk assessment should be done? Should miniassessments be completed in certain areas more frequently than all of operations, all of the enterprise, or all of the connected supply chain?

Bonnette: The frequency of risk assessments should be commensurate with the previously assessed risk. Systems or zones with higher potential consequence of compromise should be assessed more frequently than lower potential consequence areas.

Interim risk assessments for a single zone or subset should consider conduit connections to other zones.

Gosine: Critical operational processes are getting done more frequently to show risk avoidance/mitigation to C-level (potentially every 18 months). This will be based on how fast remediation efforts are getting completed. Regulatory requirements where applicable will have minimum frequency requirements that are required.

Q: With software updates, vulnerabilities may be exposed. Is there a repository where control system software security status is available?

Gosine: Yes, see https://us-cert.cisa.gov/ics and https://www.strategicefficiency.org (membership required). ce Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com.

An architecture document that defines the cybersecurity architecture and risks helps in justifying what needs to be done and why, according to the Control Engineering webcast, “Cybersecurity: What you need to know.” See www.controleng.com/webcasts/past. Courtesy: MG Strategy+, Wood Automation and Control and Control Engineering

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INSIGHTS

TECHNOLOGY UPDATE Jeffrey Shannon, Wood PLC

More questions answered on IIoT cloud to edge Industrial Internet of Things (IIoT) can include cloud to edge architectures.

What mix of cloud and edge technologies should a particular application have?

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loud and edge technologies help Industrial Internet of Things (IIoT) implementations, but what mix of cloud to edge architectures should be used? See some answers from a webcast question and answer session from the Jan. 19 webcast, “IIoT cloud to edge.” A certified professional development hour (PDH is available.

The webcast presenter, Jeffrey Shannon, director – intelligent operations, Wood PLC, a system integrator, answered the questions below.

More

Question: How about missing and error data in IIoT? Shannon: We use data substitution methods to fill in the gap for missing data and replacement of bad data. The application for this is fairly extensive due to the enormous variety of problems that can arise. A manual method is needed, as well.

M INSIGHTS KEYWORDS: IIoT, edge,

cloud Industrial Internet of Things can benefit from edge and cloud capabilities.

What mix of edge and cloud technologies should be applied?

How does cybersecurity fit with edge and cloud implementations?

CONSIDER THIS How have your control strategies changed with edge and cloud capabilities?

ONLINE If reading from the digital edition, click on the headline for more resources. www.controleng.com/ magazine www.controleng.com/ webcasts/past See Wood in Global System Integrator Database

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Q: How would one best approach cybersecurity in IIoT using open-source software platforms?

Shannon: Open source does not mean it is not secure. Most open-source software will integrate with the platform security so depending on the specific problem, you should at least plan on integrating into the provided security layer. For an IIoT device that will connect to input/output (I/O) devices on the operational technology (OT) side, a firewall and data diode should be considered.

Q: What is the best way to integrate our pneumatic controls with Digital system?

Shannon: We are using pneumatics to control valves in class 1 div 1 environment, and there are not many commercially available choices. You need an I/P (current to pressure) converter with volume, and several electro‐pneumatic transducers are available that meet Class I Div. I, explosion proof requirements, but you need to review total compliance. Please note you really can’t

control engineering

open the enclosure during operation with this classification. I would put the junction box outside of this classified area.

Q: Are all cloud- or edge-based system provider manufacturers the same as far as cybersecurity?

Shannon: There is variability here, but most are open to the software, etc. you need to secure as much as humanly possible.

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For an IIoT device that will connect to input/output (I/O) devices on the operational technology (OT) side, a firewall and data diode should be

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considered.

Q: For cybersecurity, is the cloud service provider responsible for any hack or unwanted access?

Shannon: My view is they have responsibility, but are unlikely to accept contractual liability.

Similar service is available for cloud or on-premise (or an on-campus) system. Cloud is going to be cheaper than on campus because in the cloud, you are one of many users in the environment. On campus means you have to provide the infrastructure.

Q: How does one handle heterogenous legacy data formats from devices? Is there a simple fix to bring them together at the edge?

Shannon: Yes, but you need connectors to handle the interface. System integrators often have them and can provide customization. It is not that expensive to do. Typically, connectors are done once and enhanced over time. ce Jeffrey Shannon is director – intelligent operations, Wood PLC, a system integrator, and a CFE Media and Technology Content Partner. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com. www.controleng.com

INSIGHTS

TECHNOLOGY UPDATE Sam Russem, Grantek

What is a digital thread?

Digital thread describes how a profile of data is defined, created, populated and modified in the product lifecycle. Identify critical data, break barriers, be agile.

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odern manufacturing creates an enormous amount of data for every product that leaves the factory. From product design files, to quality test results, to supply chain logistics, to consumer feedback: we are reliant on the accuracy and availability of data throughout the product lifecycle. Different types of data come from different sources and are stored in different locations, which makes it challenging to collect a cohesive dataset that defines a product.

The digital thread describes how a profile of data is defined, created, populated, and modified through the product lifecycle. The concept has gained popularity in response to “data silos,” which inhibit collaborative problem solving, identification of inefficiencies and strategic decision making. The digital thread makes data available and accessible to various business units, suppliers and customers leading to products that are made faster, cheaper and of higher quality.

Three digital thread benefits

By adopting and committing to the idea of the digital thread, manufacturers should expect: 1) A single source of truth, which clearly defines critical data that describes a product or process, including where and how it is stored. 2) Data democratization, breaking down barriers to make data accessible to all who need it. 3) Improved agility and quality, making the datacommunication process faster and less prone to error.

The digital thread promotes data integrity, governance, and availability for Industry 4.0 and digital transformation. Businesses that leverage the digital thread take advantage of data to empower people, improve decisions and optimize the value chain. ce

Sam Russem is director of the smart manufacturing practice at Grantek. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com.

M More INSIGHTS KEYWORDS: Digital thread,

data analytics Eliminating data silos with digital thread Contextualizing data to make way for useable information Improving data agility and quality, decreasing errors.

CONSIDER THIS Is your data easily integrating to create information when and where needed?

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

GET ON THE BEAT Keep your finger on the pulse of top industry news

WWW.INDUSTRIALCYBERSECURITYPULSE.COM 2021_ICSpulse_HalfHorizontal.indd 1

3/3/2021 12:52:13 PM

INSIGHTS

NEWS

Changing winds of cybersecurity for ICSs

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The SolarWinds attack has been in the news a lot lately due to the widespread scope of the attack, which went beyond one company or one specific target industry. The SolarWinds attack affected more than four-fifths of the Fortune 500 companies and hit virtually every major sector in the U.S. government and military.

This was more than a one-off cyberattack, and it’s only going to increase, according to Eric Byres, CEO for aDolus in his presentation: “After the SolarWinds attack: What the SolarWinds fiasco tells us about the changing security landscape” at the ARC Advisory Group Forum, which was presented remotely via Zoom.

Cybersecurity attacks that take advantage of trust

“They’re taking advantage of the trust we [industrial companies] have with our vendors,” Byres said.

Industrial control systems supply chains are easy targets. Many supply chains are a mix of different programs, codes and standards. Finding an exploitable weakness isn’t that hard because there are many potential gaps in the networks.

And like companies, the actors behind these attacks seek a good return on investment (ROI). Given the level of sophistication of the SolarWinds attack and the depth of the infiltration, it’s safe to say they got their money’s worth. Hit-

Byres advocated a software bill of materials (SBOM), which is a nested inventory and a list of ingredients that make up software components. An SBOM, like a regular BOM, identifies and lists components, information about the components and the relationships between them.

Byres listed three things that are needed for SBOMs to work: 1. Cloud-based aggregation.

2. Machine learning for correlating multiple databases.

3. Graph database technology for component association and tracking.

Industrial control systems and the supply chain are the Software bill of materials for cybersecurity next wave of cybersecurity threats. Supply chain attacks benefits All that aside, why do manufacturers

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in these areas in 2020 were up 430% over 2019.

Nation-state-backed, multi-stage attack

The actors behind the SolarWinds attack, Byres said, were very professional and very well-organized in their attack.

It was likely financed and backed by a nation-state, and they played the long game, initiating a multi-stage attack that lasted more than 18 months.

This kind of attack might seem like the kind of thing manufacturers might not have to worry about. It’s all information technology (IT), right? Not so, according to Byres. Operational technology (OT) has just as much, if not more, to worry about.

Industrial control systems (ICSs) and the supply chain, Byres said, are the next wave of cybersecurity threats. Supply chain attacks in these areas in 2020 were up 430% compared to 2019. This is not going to stop. Why? Because they’re effective.

M More ONLINE

View Industrial Cybersecurity Pulse and learn about the latest developments engineers and manufacturers face at www.industrialcybersecuritypulse.com.

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ting a company’s supply chain and stealing information is no different.

It’s not like ICSs and the supply chain haven’t been a target before. Stuxnet was all about the supply chain and exploiting a particular weakness. In that case, it was stolen digital certificates, which underline the broader problem, according to Byres.

“There’s nothing wrong with digital certificates,” Byres said, “but they are being misused and misunderstood and being exploited. There’s more malware now than regular software. They’re not enough, and they need to be cleaned up.”

Cybersecurity cleanup: 3 software bill of materials

How can companies make their supply chain safer and help OT follow best practices? After all, this isn’t their field of expertise. They need all the help they can get. Byres likened it to a rich stew full of different ingredients. If the user doesn’t know what’s inside the stew, they won’t know how everything works together.

This can be very confusing and overwhelming and may lead to mistakes.

Clarity is needed in these cases.

control engineering

need a SBOM to improve cybersecurity?

What benefits can a SBOM provide to people on the OT side? Byres highlighted several points: • For ICS vendors, they help track dependencies and componentbased issues. They also help vendors track and detect evolving third-party security issues.

• For asset owners, they help create vulnerability and risk priority lists for deployed software.

• For security analysts, they provide critical threat-hunting info and give them information needed for malware hunting.

“We are going to see supply chain attacks as a regular problem,” Byres said.

“For us to be on the road to a secure supply chain, we need vendors.”

Like so many other changes in the world, it’s a question of adapting and taking the preventive steps now rather than becoming the latest victim that ends up in the news. ce Chris Vavra, web content manager, CFE Media, cvavra@cfemedia.com. www.controleng.com

Digital edition? Click on headlines for more details.

See news daily at www.controleng.com

Global manufacturing contraction is less The manufacturing industry output (MIO) tracker from Interact Analysis reveals unexpectedly strong overall global manufacturing performance. This is an upward revision on the previous MIO updates. At our most pessimistic point, we forecast a -4% contraction in industrial output for China. The country’s rigorous suppression of the virus meant that production was back on track by May 2020; that region is now posting 1.9% growth.

The Chinese recovery has had a significant impact on global growth, but it still represents considerable overall lost growth, putting China among the four global lossleaders, along with India, Japan, and the USA, who have together racked up in excess of $200 billion in lost MIO potential.

Korea’s track-and-trace strategy has been hugely effective, and the country has seen strong growth in the electronics and components sectors resulting in overall negative growth of only -2.4% for 2020.

In Europe, Germany’s economy in particular has suffered, and recovery will be sluggish. Key factors here are the country’s huge reliance on export markets in Eastern Europe and globally, notably in the automotive and metals sectors, which have both fared badly in the pandemic.

Headlines online Top 5 Control Engineering articles Feb. 15-21, 2021 Most-viewed articles include stories on the 2021 Engineers’ Choice Awards, control systems in artificial intelligence, VFD parameter changes and Ethernet protocols.

Students learn to secure cyber networks, data USC’s Intelligence and Cyber Operation Program (INCO) is designed to train students to proactively identify cybersecurity issues.

Semiconductor group urges support for manufacturing, research funding SEMI and 16 other organizations are pushing the Biden administration to bolster U.S. semiconductor manufacturing and research.

Industrial automation partnerships Partnerships and collaboration are the foundation for end-users and suppliers to develop complete solutions for industrial automation. www.controleng.com

The machine tools sector has been hit hard by the transporation industries’ slow-down. In Germany, machine tools is down 30%, reflected in weak performance in other European countries too.

Few major regions are likely to return to 2019 levels in the next 6 years.

COVID-19 has driven and will continue to drive demand for plastic and rubber medical supplies and personal protective equipment. The rubber and plastics machinery sector did experience a decline in demand in 2020; Korea, India and the U.K. see contractions of -15.8, -13.9 and -13.4% respectively. The top 10 regions are expected to recover to 2019 levels by 2023 at the latest. Strong APAC performance will bolster a growth that will see production values rise from $49.6 billion in 2020 to $53.4 billion in 2021.

Adrian Lloyd, CEO at Interact Analysis, said: “The semiconductor and electronics machinery sector is one of the few sectors to have come through the pandemic untouched. Most major regions are forecast to grow past 2019 levels in 2020, with global growth forecast at 9.9%. The few who don’t will be back up and running at a stronger level than 2019 by 2021. Growth will likely be slightly slower in 2022 and 2023 but will remain positive. APAC is the leading producer of semiconductor and electronics machinery. We forecast a 5-year CAGR for Korea of 9.1%. It’s a good sector to be in. But some regions really need to play catch-up.”

– Edited from an Interact Analysis press release by CFE Media. Interact Analysis is a CFE Media content partner.

Online training for continuing education FIVE DAYS OF ONLINE TRAINING are planned for March 29 through April 2 as a continuing education opportunity from CFE Media and Technology, owners of Control Engineering, Plant Engineering, Consulting-Specifying Engineer and other recognized industry resources.

Training include presentations from industry experts, videos, research, live Q&A sessions, and discussion forums. Topics for the week are Control Systems, Motors and Drives, Plant Safety and Security, Critical Power Considerations, Effective Maintenance Strategies and Digital Transformation and Advanced Manufacturing Technologies. A best practices session will start at 10 a.m., research or roundtable panel will start at noon, and an application will be at 2 p.m. central time. Daily details follow: • MARCH 29, Monday: Control Systems, Motors, and Drives Attendees will hear from industry experts and leading manufacturers about topics such as UL Standards, short circuit protection, and more.

• MARCH 30, Tuesday: Plant Safety and Security Hear from experts in the industry to learn about best practices in plant safety and security, electrical safety and more.

• MARCH 31, Wednesday: Critical Power Considerations Thought leaders in critical power will discuss transformers, uninterruptible power supplies, switchgear and more.

• APRIL 1, Thursday: Effective Maintenance Strategies Maintenance experts will discuss topics such as outstanding applications in maintenance for core manufacturing processes and Industry 4.0.

• APRIL 2, Friday: Digital Transformation and Advanced Manufacturing Technologies Hear from industry experts as they discuss topics including how to apply Industry 4.0 into existing operations. control engineering

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INSIGHTS THINK AGAIN

®

Moving toward automation interoperability More than 30 organizations developed the next version of the Open Process Automation Standard (O-PAS). A secure, standard and interoperable process control system architecture is the goal.

G

oal by 2025 to 2026 is commer- exchange, function blocks, and interface cially available, interoperable execution engines as well as physical platprocess control system hard- form standard and security that will allow ware and software. ExxonMobil suppliers to build products to the standard. and seven collaboration partners (Aram• O-PAS Version 3 will address applico Services, BASF, ConocoPhillips, Dow, cation portability and orchestration.

Georgia Pacific, Linde and • Work is underway to Reliance Industries Ltd.) are deploy the first wave of conforworking in the Open Process mance certification to reassure Automation Forum (OPAF). the market on 100% conforThe ExxonMobil testbed mance to the specification. in The Woodlands, Texas, will OPAF is moving ahead with be followed by field trials and an O-PAS adoption workshop commercial deployment of a to launch the marketplace and standards-based, secure and ecosystem.

Mark T. Hoske, interoperable distributed con- Content Manager • End users test beds are evaltrol system (DCS) infrastrucuating multiple prototype disture, said Dominic (Nick) tributed control node products.

Clausi, vice president of engineering, A DCN allows applications to reside where ExxonMobil Research and Engineering they make sense. at ARC Forum by ARC Advisory Group.

Dave Emerson, director, U.S. TechnolMore than 100 members are involved ogy Center, Yokogawa, described O-PAS with OPAF, four have announced a devel- as a standard of standards, referencing opment system. There are more than 20 eight standards in its seven parts. Think hardware and software suppliers and five again about interoperability and intermajor DCS suppliers. changeability across vendors, platforms, devices and systems.

Comment on O-PAS V2.1

According to an ARC Advisory Group summary, from the session “Open Process Automation: Where will end users find value?” Harry Forbes, research director, automation, ARC Advisory Group, said: • O-PAS V2.1 is nearly ready for preliminary release; it contains critical elements describing the information

ONLINE Automation-related standards support interoperability efforts. A few include: Open Process Automation Forum www.opengroup.org/forum/ open-process-automation-forum Open Manufacturing Platform https://Open-manufacturing.org OPC Foundation www.opcfoundation.org The Mechanical Engineering Industry Association www.vdma.org/en/

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Interoperability: “I’ll buy it”

The O-PAS v2.1 update delivers control functionality, function blocks and alarms, and cybersecurity has been applied to all 12 parts. The group is accepting feedback from those interested.

By using the new structures, a modular system can be setup with existing brownfield applications, then switched over, simplifying integration, according to Jacco Opmeer, program manager, DCS strategies, Shell Global Solutions. Opmeer said it’s very difficult to add technology to existing systems, but that will change.

Julie Smith, global automation and process control leader, DuPont, said products are under development. “Whoever makes it, I will buy it,” she said. “We want and need this technology.” ce

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

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

www.controleng.com

ANSWERS

COVER: MOTORS AND DRIVES Michael Lyda, Advanced Energy

Motors and drives: Tips and tools for efficient motor management Webcast presenter answers more motor management questions to improve process reliability and reduce energy costs.

M

otor-driven systems account for about half of all electricity generated in the world and are likely the biggest energy users at your facility. Reducing energy costs by improving these systems can be simple with improved motor management practices.

In a recent Plant Engineering webcast, available in its on-line archives, Michael Lyda, motor and drive engineer, Advanced Energy Corp. shared his expertise with attendees. He discussed how to streamline motor management practices, quickly

improve process reliability and reduce energy costs.

Following the presentation, Michael answered questions from the audience. Below are the questions, and Michael’s responses, that he was unable to address during the webcast because of time constraints.

The audience asked about purchase specifications and lifecycle cost analyses for electric motors, and operation and maintenance best practices.

Variable frequency drives (VFDs) were also covered, including basic operation, energy efficiency benefits and potential applications.

Figure 1: In a typical client witness test at Advanced Energy, clients witness testing at the lab and multiple engineers participate. Images courtesy: Advanced Energy www.controleng.com

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ANSWERS

COVER: MOTORS AND DRIVES Question: Please elaborate a bit on what you referred to as the life of the VFD. Lyda: Like motor life, VFD life depends on both environmental and operating conditions. Keep the VFD in an ambient temperature within its specification. Keep the cooling vents unblocked. Make sure the fan works as it is supposed to. One thing to note on the VFD fan is that it may cycle on and off in operation depending on current draw. Higher current will cause the VFD heatsink to heat up more, so the fan may not be running at lower loads. There are also maintenance best practices to follow for your VFDs, and I recommend consulting the manufacturer on those.

‘

If main loads are lighting, other capacitive sources or purely resistive sources, then VFDs will not improve the power factor, and could

’

even make it worse.

Q: Please compare the lifecycles of induction and PMAC inverter-driven motors.

Lyda: Commercially available permanent magnet alternating current (PMAC) motors are relatively new in this market. Although the designs have been around for many years, they have typically been built by special order only. Many manufacturers will have them in their catalogs these days, but they can be quite expensive and have very long lead times. We have completed testing at our lab on some PMAC motors but only for efficiencymapping and not for lifecycle or reliability. I would also be interested in those results if test data is out there.

Q: Is there a software tool for efficiently figuring real power consumed by a motor?

Lyda: Most measurement devices should come with some type of software. We use Yokogawa high accuracy precision power analyzers in our lab with National Instruments data acquisition hardware and LabVIEW software. One meter I like to use in the field for metering and verification is a Fluke

COVER: Figure 2: Large dynamometer is used for testing. It is rated for up to 300 hp output at 1800 rpm. The motor coupled to the dynamometer in this photo is a 200 hp engine.

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www.controleng.com

355. It will give you voltage, current and power factor. It is more expensive than a standard multimeter, but you can get real power data since you are acquiring the power factor also.

Figure 3: Although many induction motors may be similar, the quality of the build will dictate reliability and life cycle. Motor build inspection analysis analyzes the quality of the motor build and make recommendations on potential improvements.

Q: We have acquired a 250 HP AHU that will be equipped with a VFD. Is there any maximum distance that applies from the VFD to motor? Also, do I need filters for the harmonics?

Lyda: For this specific application, I would recommend consulting the VFD manufacturer.

They can best advise on cable length and ancillary equipment needed, whether it be a line filter, DC choke, load filter or other.

Q: What is the maximum cable distance between an ac motor and a VFD? Lyda: This is all relative to the application. The shorter, the better, since longer cable lengths will lead to higher peak voltage at the motor terminals. Consult the VFD manufacturer on a case-by-case basis.

Q: What are the differences between a “motor management relay” and a “motor protection relay”?

Lyda: I have limited experience with these, but I think motor protection relay refers to a current overload relay that focuses on current alone.

A motor management relay is more involved and may have capabilities to monitor current and voltage. Thus, phase sequence, overvoltage, undervoltage and voltage unbalance could all be monitored by this type of device. Advanced Energy has completed testing and research on two types of these devices in the past: phase monitors and overload relays. If you would like more information, please contact me.

Q: Should we consider service factor for calculation of overload?

Lyda: Service factor is meant for short-term overloading. If you run a motor at its service factor (e.g., 1.15 or 1.25) continuously, it will not likely last as long as it will at its rated load.

Q: Please address motor cooling fans on VFDs. What is the minimum speed before needing a separate fan motor to cool the VFD motor? Does installing VFDs impact plant power factor?

Lyda: This will need to be looked at for each application. Inverter-duty motors should have constant torque (CT) and variable torque (VT) ratings on their nameplates. As long as your load is within these limits, additional external cooling should not be needed. If operating the motor outside of these speed/torque ranges, the motor manufacturer should be consulted. Installing VFDs adds capacitance to the system, so if you have a www.controleng.com

primarily inductive load at the moment (i.e., a lot of motors), your power factor would likely be improved by adding VFDs. If your main loads are lighting, other capacitive sources or purely resistive sources, then VFDs will not improve the power factor, and could even make it worse.

Q: Will an over-dimensioned motor, driven by VFD, also exhibit a low power factor?

Lyda: Tough to say. A motor that is oversized for an application will generally exhibit a low power factor since the magnetizing current plays a larger role in the total current draw. However, when you add a VFD, the capacitance of the system is greatly increased, so the power factor will be increased across all loads. I am not sure by how much, though. We really could use some test data for a better answer.

Q: If there is a redundant motor & pump installed, what is best practice for operating the backup motor/pump?

Lyda: Lead lag process is popular for this. If you have a redundant or standby motor/pump, you can alternate with the main to ensure even wear of both machines over time. Each of the motor/pump combinations can take a turn as the standby and then pick whatever time period you think is applicable, by week, month or otherwise.

Q: Do belt-driven motors need needle bearings as opposed to standard roller bearings?

Lyda: Needle bearings would typically be used for either very high-speed or very low-load applicontrol engineering

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COVER: MOTORS AND DRIVES If you are currently using a Class F insulated motor, upgrading to a motor that is Class H insulation may give you a higher allowable running temperature.

Figure 4. When grid power is fed to an electric motor a clean sine wave is seen. Once a variable frequency drive (VFD) is added to the circuit, the capacitive nature of the VFD will lead to voltage and current harmonics in the system. This is a waveform taken at the input VFD terminals with a fully loaded electric motor connected to the VFD output (size unknown).

cations. They are more common in the automobile industry. For belt-driven motors, you should use roller bearings as opposed to standard ball bearings.

Q: Is it typical to see complaints of electrical noise (e.g., problems with controls, etc.) related to the deployment of VFDs? Lyda: Yes, this can be quite common. This is one reason you should use VFD-specific cables for any VFD-to-motor connections. Most VFD manufacturers recommend this anyway, and the cables are more expensive than standard ones, but you can mitigate some noise issues by using them.

Q: How do we derate a motor for 115°F Texas ambient + 10°F inside a boiler room? (I need a 55°C motor, but they are not normally available.)

Lyda: I would think if you are running above the rated ambient then you should derate the motor temperature rise. In other words, if you had an Insulation Class F motor at 40o, the temperature rise should typically be 105o or less. Bringing the ambient up to 55o would mean the temperature rise should be derated to 90o or less. As far as derating the horsepower output, I have no idea.

I think the manufacturer should give you advice on that. Here is one other thing that may work: 24

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Q: My utility is supplying unbalanced phase voltages (5% at times). Any advice on how to convince them to fix this and what the cost of the present situation may be in terms of premature motor failure?

Lyda: Per the power purchase agreement, a utility should be held to a higher standard than 5% unbalance (most that I have reviewed state 2-3%). I would contact them directly to send a licensed professional to meter and verify the voltage at your facility. If they refuse, you will need to measure and verify yourself or hire a third party. If your motors are running at this high of an unbalance for long periods of time, it is definitely costing money in the long run. A common industry adage is “7% current unbalance for every 1% voltage unbalance.” At 5% voltage unbalance, it is likely that at least one of your three-phase line currents is well beyond the rated amount at each actual motor.

Q: For a 50HP motor, how much energy does the motor consume when running no load? Does it make sense to shut down the motor when it is not running? What about the wearing that comes from frequent restarts?

Lyda: At no load, a 50HP motor will likely still consume 1-2kW (at very low power factor). However, you likely do not want to shut the motor off completely if you have a frequent restart application. This is where a VFD and process control can really help you out. When a load is not needed, the VFD will slow the motor to stop, and when it is needed, the VFD can ramp the motor up without an extreme inrush current (like what happens at line-starting).

Q: At what point does a soft-start on a motor pay for itself? Is there a break point for applying soft starters based on motor horsepower?

Lyda: Not sure. I think this is facility- and application-specific, depending on incoming transformer size and frequency of motor starts plantwide. Soft starters can be beneficial if all you are trying to do is reduce inrush current. For real energy savings, spend extra capital upfront and install (and program) a VFD instead.

Q: You mentioned that an oversized electric motor is inefficient. Does a VFD overcome this inefficiency for load matching?

Lyda: For a variable load application, a VFD can be programmed to reduce the speed of the www.controleng.com

motor while lower loads are required. Reducing the speed of the machine provides energy savings based on the affinity laws. However, if you are starting from scratch, the VFD and motor should match the necessary load as close as possible for maximum energy efficiency. Keep in mind, a larger motor will have higher magnetizing current than a smaller one. For instance, if you have a 5 hp application and use a 10 hp motor, you are not getting the efficiency you should be at only 50% load, and you’re getting higher kW usage due to the higher current draw.

Q: What will be the power factor when we measure at line side of the VFD? Lyda: VFDs generally improve power factor of the system since the capacitance of the VFD “offsets” inductance of the motor and distribution lines. If the VFD is properly sized and the motor is running close to full load, the power factor should be high. However, not all VFDs are created equal.

I have witnessed multiple VFDs over the years that show poor line side power factor.

Q: How do VFDs reduce motor life? Should motors with a specific insulation class be used with VFDs? Lyda: There are many ways VFDs reduce motor life. I covered quite a few in the presentation.

One way is by overheating the motor. From experience in the lab, when running a motor at 60Hz grid power and then running the same motor at 60Hz from a VFD, a 10° to 15° temperature rise is expected. I advise using at least Class F insulation, and maybe even Class H, with VFD-driven motors.

Also, make sure the motor is inverter-duty.

Q: Are VFD manufacturers able to give the har-

monics configuration to simulate the harmonic distortion reports for utilities?

Lyda: Harmonics will be greatly impacted by the size of the power supply at your facility as well as your incoming voltage. If a VFD manufacturer knows the size and impedance of your incoming transformer and your precise input voltage, they should be able to supply the harmonic content of their product. Consult the AHRI Certified list for VFD manufacturers if you want to see harmonic values submitted for actual VFD products.

Q: What is the definition of “short” with regard

to cable length?

Lyda: Unfortunately, this is all relative. The shorter, the better in every case. NEMA MG-1 lists recommendations for dv/dt limits. Dv/dt is a better way to judge the VFD quality to a specific motor application than just cable length. www.controleng.com

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Harmonics will be greatly impacted by the size of the power supply at your facility as

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well as your incoming voltage.

Q: Do you know of good general data for motor

efficiency at various loads and speeds when driven by a VFD? Lyda: Motor efficiency data with a VFD is hard to find, although we do this type of testing often in our lab. Unfortunately, most of the results are proprietary. If you look at the AHRI Certified list for VFD manufacturers, you will find system efficiencies that these manufacturers have submitted for their products with motors:

Q: Can a VFD be connected to any 3-phase motor with 3 leads?

Lyda: Generally speaking, yes. However, make sure the VFD matches the voltage, current and frequency ratings of the motor. Just installing a VFD into an application will not do much for you, though. I would advise the motor should be inverter-duty before using a VFD. It is also good practice to use shaft grounding and have at least a Class F insulation rating. Finally, the VFD will need to be correctly programmed after installation to verify you are achieving proper process control and desired energy savings.

Q: We are finding a large number of equipment sets that use multiple induction motors in situations that range from no load to full load, applied in short time frames on a frequent basis. Metering shows terrible power factor, voltage irregKEYWORDS: motors and drives, ularities, and undesired harmonics. variable frequency drives, VFDs Solutions that fit within the existing Variable frequency drive (VFD) life control scheme and physical spacdepends on both environmental and operating conditions. es are a challenge. Any thoughts?

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Lyda: Are you currently using VFDs? If not, this could offset some of the power factor and voltage irregularities while also keeping the inrush current of individual motors lower. Using one VFD to control multiple motors or using many VFDs and a programmable logic controller (PLC) are both options. ce Michael Lyda, motor and drive engineer, Advanced Energy Corp. This article originally appeared in the January/February issue of Plant Engineering.

The AHRI Certified list for VFD manufacturers offers advice on system efficiencies and harmonic values.

A three-phase motor can be connected to a VFD, but the settings need to match.

ONLINE Read this article online at www.controleng.com for about adjustible speed drives.

CONSIDER THIS What challenges do you have with motors and drives and how do you overcome them?

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MOTION CONTROL Joe Kimbrell, AutomationDirect

Improved stepper motor systems support wider uses Stepper motor systems deliver more precision than standard variable-speed motors without servo motor expense and complexity. See 5 motor technologies.

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ew stepper motor technologies can be applied to more applications than before and at a lower cost than other options. Most industrial machinery applications involve creating and controlling motion of some type. As designers consider price and performance requirements, pneumatic options can be a good low-cost choice and hydraulics can deliver the ultimate amount of force. The most versatile motive force is some form of electric motor.

For industrial applications, motion control is understood as more than spinning a motor. True motion control usually involves using some actuation to accurately command the position, velocity, and/ or acceleration of equipment elements. Standard ac induction motors and dc motors are best for simple on/off and continuous operation at fixed or varying speeds, but they are not ideal for positioning and fine control. Servo controllers, drives, and motors deliver exceptionally high performance for motion control, but complexity adds costs (Figure 1).

Stepper motors occupy a sweet spot, offering greater control precision than standard ac induction or dc motors at lower cost than servo solutions. Stepper motor systems have some limitations, but newer high voltage bus versions overcome some of those issues and make the technology a viable choice for more applications. Know when a stepper motor system can be the best motion control solution.

5 motor technologies, common uses

Specifying any electric motor system involves understanding the load and how it needs to be moved in terms of force, speed, and accuracy. Durability and initial/operating costs are important. The most common motors types for industry are: • AC induction: Available in a wide range of form factors and horsepower ratings, suitable for general applications, operated at fixed speeds with simple contactors or at adjustable speeds with a variable frequency drive.

• DC motors: Provides good torque at low speed and requires an associated dc drive, which usually provides reasonable speed control.

• DC stepper: Provides better speed control than ac or dc motors because rapid pulses command the motor to move quickly in small steps, but these motors operate at lower speeds and with smaller force.

• High bus voltage stepper: Essentially the same as dc steppers, but the drive accepts ac power and generates a higher dc bus voltage for greater speed and torque capability.

• Servo: Delivers high speed with full torque throughout the speed range, with ultra-precise control of position, velocity, and speed.

To operate these motors at variable speeds, each of the listed motor types needs an associated drive.

Figure 1: Standard ac induction and dc motors are suitable for basic speed control, but stepper and servo systems provide progressively improved positioning and fine motor control capabilities.

All images courtesy AutomationDirect

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Figure 2: Microstepping (green)

Advanced control commands, especially coordinated motion, require a separate controller which can be a dedicated motion controller or could be a higher end programmable logic controller (PLC) or a PC. In some cases, controller and drive functionality may be available combined in one device.

It is often possible to integrate motors, drives and controllers from different vendors if all ratings match, but for more complex systems (servo and stepper in particular), many users find it is more effective selecting products from within a single portfolio for best compatibility. It also is easier to obtain support from one vendor instead of several.

Feedback and motion control

Motors used in motion control service often connect to mechanical equipment with gearboxes, toothed belts, rack-and-pinions and similar setups so they can maintain a direct slip-free motion transmission relationship with the driven equipment regardless of whether the end result is rotary or linear.

Open-loop motor control describes when a motor is commanded to operate, but actual motor or equipment operation is not monitored, so there is no feedback to identify motion accuracy.

Closed-loop motor control relies on sensors installed on the equipment or the motor itself, providing operational feedback so the controller can precisely regulate the commanded motion.

AC induction and dc motors are generally considered the easiest types of motors to install and maintain. This is partly because they are usually operated as open loop, although there may be some sensors on the equipment to provide indication. For example, a simple crane may use a reversing motor to lift or lower the load, relying only on end-of-travel limit switches.

Servo motors require comparatively more design and installation effort. They incorporate precise motor sensors, making them ideal for operating robot arm joints or X-Y-Z cartesian positioners because they are updated with the motor (and therefore the driven equipment) position, velocity, and acceleration.

Precise, closed-loop stepper operation

Most stepper motors occupy a middle ground because they are commanded with fine precision, although there generally is not constant closed-loop feedback. However, it is possible – and becoming more common – to operate stepper motors as closed loop. More advanced stepper motors with integrated drives are becoming available and offer a form of built-in closed-loop control. To understand when stepper motors can be the right design choice as a lower cost motion control alternative as compared to servo motors, a few more details are relevant.

For motion control applications, each travel path is called an axis and can be rotational or linear. Sometimes complicated assemblies like robots, positioning equipment and printing presses have many axes, which must be closely coordinated with

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achieves the same final position as full steps (blue), smoothing motion operation at the expense of requiring a higher command frequency.

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Robots, positioning equipment and printing presses have many axes, which must

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be closely coordinated with each other. each other. For these situations, servos operated by a dedicated motion controller with a built-in path planner is often best.

For many single-axis applications steppers can provide a better price/performance ratio. Stepper motors have other unique features which are helpful for certain applications: • No jitter/dither at zero speed • An idle current reduction option which saves energy and reduces heating when the drive is at a standstill and not loaded by gravity or some other force.

Stepper motors are driven by a pulse train generated from a drive. There are commonly 200 steps correlating to a full 360-degree motor revolution, so each full step represents 1.8 degrees of rotation. Most users choose finer stepping modes – called KEYWORDS: Motion control, microstepping – such as half-step, quarstepper motor use ter-step and even up to 10,000 or 50,000 Five motor technologies, common uses steps per revolution (Figure 2).

When to use a stepper motor versus Microstepping provides smoother servo motor operation, with some tradeoffs due to Wider applications for steppers the fact that as the microstepping mode motors. becomes finer, the maximum pulse freCONSIDER THIS quency required from the controller Have you evaluated use of stepper gets higher. Stepper torque falls off as motors given new technology motor speed increases, so the available developments? speed must be balanced with mechaniONLINE cal motion transmission provisions.

If reading from the digital edition, Standard stepper systems do not have click on the headline for more positive closed-loop feedback built-in, resources. www.controleng.com/ so it is necessary to include design provimagazine sions for homing and position verification www.controleng.com/NPE to identify if a stepper motor has stalled or www.controleng.com/ lost synchronization. These require some discrete-manufacturing/ motors-drives/ programming effort, up front design con-

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MOTION CONTROL 4. From a stopped position, accelerate to a velocity, then decelerate back to zero speed after completing a certain number of degrees of motion (trapezoidal move) 5. Match the speed of an external encoder (gearing) 6. Follow a cam profile (follow a complex motion profile based on an external encoder input).

Basic stepper drives are not intelligent because they simply receive a pulse train commanded by a controller and amplify it to provide the voltage pulses needed by the motor. Some stepper drives do incorporate controllers, but often external controllers like PLCs or PCs with high-speed digital outputs are used. In particular, PLCs used with high-speed discrete output cards and stepper drives are attractive for single-axis control because many automated machines already use PLCs.

Newer steppers: More power, uses

Figure 3: Suppliers like AutomationDirect offer traditional dc stepper systems (top) that require a separate power supply; high bus voltage stepper systems that enable compatible stepper motors to achieve higher torques and speeds so they can work in more applications.

siderations, and have the potential to consume operational time. Just as a weigh scale must be tared to zero before reading a load, a stepper system must undergo a homing procedure to establish a position baseline for future moves. Homing must be executed during commissioning or power-up, and may be periodically performed during operation.

Position verification is like homing, but is more of a quick check during operation to confirm the position is as expected. It can be performed intermittently, although the most rigorous applications might require verification one or more times per cycle.

Homing and position verification are performed by driving the equipment to a known location monitored by a position switch. It also is possible to install an incremental or absolute encoder on the stepper motor or driven equipment to monitor motion, for a pseudo-closed loop method of position verification.

Six motion control applications

A controller is often used to command motor rotation. Here are some typical types of motion control, in order of increasing complexity: 1. Rotate at a constant velocity 2. Rotate a certain number of degrees and stop 3. Accelerate from one velocity to another (linear, or S-curve)

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Typical stepper motor drives must be supplied by low level dc voltage (12V, 24V, etc.), but newer designs can be supplied with 120/230V ac and generate a correspondingly higher bus voltage (Figure 3). This in turn enables compatible motors to achieve higher torque at higher speeds than standard steppers.

Stepper motors are available in many standard NEMA sizes and are compact, for easier machine designs. Larger versions are available, such as a NEMA 42 offering the equivalent torque of a 7.5 hp ac induction motor (at low speeds). Because stepper motors don’t have the overload capability of other motor types, one rule of thumb is to size stepper motors and drives so the expected load uses only 50% of the available torque to avoid potential stalling conditions.

Designers also must consider the speed limitations of steppers. Look at the stepper motor’s speed-torque curve to determine if the motor will be able to provide enough torque at the application’s desired speed.

Most designers are familiar with using ac induction and dc motors for basic equipment movement and know servo motors are the high-performance solution for demanding motion control applications like robotics. For low-force applications where accurate singleaxis or simple multi-axis motion is needed, stepper motor systems can provide reliable motion control at about 25% the cost of servo systems. Newer high bus voltage stepper hardware provides improved torque characteristics, making steppers fit more applications.

Designers should work with suppliers offering a portfolio of stepper motor options to evaluate options. ce

Joe Kimbrell is the product manager for motion control products at AutomationDirect. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com. www.controleng.com

ANSWERS

EDGE

Rashesh Mody, Aveva

New edge device benefits Build smarter end-to-end automation systems: See three ways to prepare automation for edge success and case study with a 5% increase in yield.

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n environment that prioritizes worker safety now means an environment where remote capabilities are not only possible, but secure. Enterprises are realizing they need to do more to connect their people and systems, more efficiently, and at a lower cost. To unlock maximum value from operations, automation systems should be end-to-end, meaning they are able to help employees at every stage of the business understand the information critical to them, while offering a holistic overview of operations that allows rapid decisions to be made.

Using connected edge solutions, which are automated industrial computing systems that protect and deliver reliable and efficient business critical applications can help provide situational awareness to both upstream and downstream operations. In conjunction, decision-making at appropriate levels of an organization should be empowered by utilizing a decentralized but connected approach with edge devices.

Challenges to edge architectures

Edge devices help offload tasks from machine or process controllers and keep factories or facilities running. However, data from sources like edge devices have historically proven difficult to bring in sight of the supply chain. Traditional barriers to using edge solutions include being able to stay ahead of the technology curve and having access to the full scope of such technologies as and when they become commercially viable and are ready for production.

A lack of purpose-built, “off-the-shelf ” solutions leads many companies to rely on proprietary software and in-house engineering capabilities to incorporate new technologies. As a result, companies find by using isolated or unconnected systems, they have little context to the greater process; conversely, connected systems are often a one-way data feed with little pull-down insight. An additional challenge is integrating smart systems while accounting for the interoperability required to collect and aggregate data. These challenges limit key system benefits like those that cloud capabilities make possible in terms of key performance indicator-level data democratization, and hamper production transparency from the shop floor to the top floor.

A large fleet of remote or physical equipment can be very time-consuming to update and maintain.

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Pushing new application versions or making changes to configurations is often done on an individual or ad-hoc basis, which can result in an edge system acting out of sync. A hardware, software, and platform-agnostic approach to interoperability simplifies connectivity between disparate systems and data silos. In total, this makes system integration, maintenance and upgrade far easier to accomplish.

Build smarter edge architectures

Edge devices are used to build smarter end-toend automation systems. Among the benefits of deploying edge technology are the integrated application development environment, native systems that monitor performance and enable communication across multiple platforms, and remote monitoring and control capabilities, all features that allow for the edge solution to scale and grow with the business.

The integrated development environment that edge offers reduces the time it takes for a company to develop applications. Using built-in capabilities, many edge solutions are then able to deploy applications across multiple platforms, such as industrial computers, laptops, smartphones and tablets or the cloud.

Native drivers also allow seamless communication between human-machine interface (HMI) and supervisory control and data acquisition (SCADA), as well control engineering

Aveva Teamwork enables industrial organizations to implement skills development, knowledge sharing, and collaboration management across the enterprise from the cloud. Whether providing training videos, digital logbook or answering a call for help, the software solves many challenges with traditional training and knowledge retention. The edge-to-enterprise architecture is for complex industrial and infrastructure monitoring and control. Courtesy: Aveva

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EDGE

as programmable logic controllers. The tiered architecture of edge also facilitates IIoT-based applications that grows the number of interconnected devices.

For companies’ work environments that are increasingly remote, but still require connected workers and operational excellence, many edge devices have monitoring and control capabilities on smartphones and tablets. Companies can monitor machine status and performance against the

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The tortilla factory achieved a 5%

improvement in yield, improved visualization and reaction times and made continuous

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improvement much easier to achieve.

Organization for Machine Automation and Control (OMAC) packaging machine language (PackML) data and overall equipment effectiveness (OEE) standards. As a best practice, edge devices should be able to operate independently, but also connect to a larger centralized operations platform for endto-end visibility.

3 ways: Prepare automation for edge

Of course, edge solutions are most successful when they meet the goals of the business and don’t overburden users with superfluous information, so it’s important for companies to be able to tailor their edge solution to their business needs.

Companies are looking to connect artificial and human intelligence for better insights and building automation systems that are end-to-end is one of the best ways to achieve this. Edge, which is a great place to start, should be met with the consideration of three tasks:

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KEYWORDS: Cloud to edge,

digitalization Optimize factory architecture, machine design, operations How to prepare automation for success at the edge.

Combine existing factory floor systems into one cohesive view.

CONSIDER THIS Are your automation systems delivering edge to cloud benefits?

ONLINE From the digital edition, click on the headline to read more on how to “Optimize factory architecture, design machine design, operations.” www.controleng.com/magazine

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1. Identify the target areas, scope and digital technology and implement them.

2. Prepare the workforce to perform the new tasks that deliver value in the optimized plant.

increased competitiveness, reduced costs, stronger regulatory compliance and ultimately, a solidified and resilient business.

Case study: Tortilla factory achieves real-time monitoring, reporting

A California-based tortilla factory has grown to be one of the largest and most popular tortilla brands with tortillas distributed nationwide at most major retailers.

The company wanted to implement a shop floor system that would allow it to have real-time data at its fingertips to improve and drive costs down. After evaluating its factory operations, the company found its traditional way of manually doing things was no longer a viable option. A range of disparate systems that previously did not work together had to be able to provide accurate performance data. Moreover, the operations team was unable to successfully achieve day-to-day performance improvements since critical information was not available in real-time and manual reporting was hindering access to key data metrics.

Automation was key to the tortilla factory’s ongoing and future success.

One cohesive factory floor view

The tortilla factory implemented a customized solution to easily integrate with and manage the existing equipment and processes. First, the company implemented a system platform that enabled it to build a single, unified plant model that represents processes, physical equipment, industrial systems and even legacy equipment, making the design and maintenance of these systems more flexible and efficient.

An edge solution was used as the system platform’s visualization tool, which provided the factory’s shop floor team real-time visibility into their processes. The edge device also included a more effective HMI design, better troubleshooting, ease of application maintenance, as well as visual enhancements to improve the ability to identify and address abnormal situations before they impacted factory operations.

Results included:

3. Execute a plan to implement the business transformation, technology and change management needed for the workforce to scale and realize the gains.

• The tortilla factory achieved a 5% improvement in yield.

• Company-wide visualization of operations data improved teamwork and reaction times.

• Edge software has made the company’s culture of continuous improvement much easier to achieve. ce

With edge technologies and proper execution companies can reach new heights, heading towards a future with boosted collaboration,

Rashesh Mody is senior vice president and head of monitoring and control, Aveva. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com.

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SECUR BUILT-ITY IN

MOVE SECURELY INTO THE CLOUD DIRECT FIELD TO CLOUD CONNECTION • • • •

IIoT-ready with Sparkplug, native MQTT and TLS encryption Built-in VPN and Firewall for increased network security Run Docker Containers in parallel with PLC logic Interface with existing controls via onboard fieldbus gateways

www.wago.us/IIoT input #11 at www.controleng.com/information

ANSWERS

EDGE COMPUTING Don Pham, Idec Corp.

Expanding edge control Edge control can take many forms to access stranded data, with modern programmable logic controllers (PLCs) often the preferred alternative.

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Figure 1: The message queuing telemetry transport (MQTT) protocol is a comprehensive yet lightweight way for field devices like sensors and PLCs to communicate with centralized cloudbased brokers, and to other clients like mobile devices.

Images courtesy: Idec Corp.

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or as long as operators have interacted with machinery and equipment, the concepts of the industrial “edge” and “edge control” have existed. Control at the edge could be an operator’s manual interaction with the equipment, or it could be hardwired controls performing some required functionality. A more sophisticated arrangement could consist of digital automation, usually with a programmable logic controller (PLC) monitoring input sensors at the edge, processing logic, and commanding outputs to control edge devices.

If the concept of edge control is so familiar, then why is it gaining newfound attention? Traditional edge control has often been quite remote and isolated, and it was expensive and complex to connect edge assets to each other or to higher-level systems. Today’s concept of edge control maintains all the robust automation functionality of previous technology generations – while incorporating modern hardware, software, and networking advances –making it economical and easy to connect edge assets to on-site and cloud-based systems. This ready access to edge data is often described as an Internet of Things (IoT) implementation.

Smart sensors, modern PLCs and advanced edge controllers or PC-based platforms are among the ways designers can incorporate IoT concepts into systems. PLCs with IoT capabilities help automation system designers and end users access data more easily.

Complete connectivity is important to users as they recognize the need to access data available from edge control systems. This data can be

control engineering

sensor signals, derived machine information, or other values—and it may be used just for simple remote visualization. But more operational value is unlocked when the data can be stored and analyzed, often via cloud-based computing, so users can take action to optimize operations.

Sensor, machine connectivity

For new industrial projects, it is becoming mandatory for designers to select automation platforms with built-in IoT connectivity, even if they will not immediately use it. Some end users also are investing to upgrade existing assets to gain IoT capabilities.

Designers might consider incorporating PC hardware and software, or more specialized edge controllers with some general-purpose computing ability, to create an IoT-enabled system. These options offer a higher level of computing power and capability, but they can be quite a step change in cost and effort required for implementing them. In many cases, this may not be warranted.

This is why modern PLCs often occupy the sweet spot for automation devices able to act as practical IoT platforms, while still performing as edge controller. As an established and familiar automation technology, PLCs are already the go-to solution for most industrial automation projects. PLCs also are ideally positioned to access, consolidate and transmit edge data. Because they are controllers, they can do more than just move the data. They also can act on it directly or send data to and receive direction from

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input #12 at www.controleng.com/information

ANSWERS

EDGE COMPUTING

Figure 2: MQTT enables PLCs and other smart field devices to interact with mobile users, supervisory systems, and analytical applications via cloud-based services.

higher-level systems. A few key features transform PLCs into IoT-capable edge controllers.

Five IIoT edge functions for PLCs

Modern PLCs in edge installations can gather useful information. A PLC can fulfill the edge controller role with these features: • Field and network connectivity • On board data logging to support store and forward operations • Web server functionality • Support for cloud-capable communications protocols, like message queuing telemetry transport (MQTT) • Simple configuration to support two-way communications.

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KEYWORDS: edge computing,

message queuing telemetry transport (MQTT), programmable logic controller (PLC) Modern PLCs can act as practical Internet of Things (IoT) platforms, while still performing as an edge controller.

Many edge devices use message queuing telemetry transport (MQTT) to transmit data.

Edge control is best fulfilled by using PLCs that can support IoT initiatives right out of the box.

ONLINE In the digital edition click on the headline to read “MQTT as an networking enabler.”

CONSIDER THIS What benefits could your facility gain from edge computing and edge devices?

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Even the most basic PLC is capable of interacting with field devices via wired input/output (I/O) signals. Most of today’s PLCs also incorporate serial and Ethernet connectivity, which provides the ability to interface to a wide variety of intelligent field devices.

A PLC intended for the edge control role should include industrial network protocols such as EtherNet/IP, Modbus TCP and RTU, and BACnet/IP to ensure it can communicate with the widest range of I/O systems and other intelligent edge devices. More specialized protocols such as SAE J1939 make the PLC suitable for vehicles and heavy equipment.

Certain features can make it easier for users to interact with PLCs. Local wireless Bluetooth connectivity, along with convenient configuration and monitoring using mobile apps, makes it convenient for users to access, monitor, and adjust

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modern PLCs. On-board data logging, web server functions, and file transfer protocol (FTP) communications give remote access options.

Edge controllers transmit data over the network and/or internet to site-located or cloud-hosted systems. Among communications protocols, MQTT is widely used. Many smart instruments support MQTT. MQTT is a good option for more complex edge controllers. Controllers supporting MQTT are ideal for many automation applications (Figure 2). PLCs can be configured as MQTT subscribers to receive data from supervisory systems and execute user commands and directly control field equipment.

Original equipment manufacturers (OEMs) for industrial machinery are moving to MQTT-capable PLCs for many reasons. OEMs already use PLCs for many machine automation needs, so it is a small step from technical and cost standpoints to specify MQTTenabled PLCs and future-proof such systems.

Specific business needs make adoption of IoT desirable. Many are leasing machines and need to monitor machine functionality and usage. Some OEMs base lease values on uptime or machine production or may take advantage of remote connectivity to sell more support services or consumable parts.

PLCs are affordable and fit with business models and skillsets. Integrating a PC-based or relatively complex edge controller device for small- and mediumsized systems often is not realistic.

For many users, edge control is best fulfilled by using PLCs that can support IoT initiatives out of the box. PLCs with support for MQTT, combined with cloud services such as AWS IoT Core, help merge modern practices with traditional automation to deliver optimal results. ce Don Pham is senior product marketing manager at Idec Corp. Edited by Chris Vavra, web content manager, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com. www.controleng.com

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ANSWERS

DATA ANALYTICS FOR OT Joe Martin, MartinCSI

Operational technology: Data acquisition, analytics Using Big Data for operational technology (OT) automation and control applications is increasingly important and can be a bewildering journey if the right questions aren’t asked. See four elements of data analytics system architecture.

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ow data is treated for operational technology (OT) automation and control applications is increasingly important as people talk about Big Data analytics role in meeting enterprise goals. Data design, data architecture and data acquisition profoundly affect data analytics, or, in old-school terms: Garbage in, garbage out. Learn best practices for data gathering so data can be turned into information and value beyond its original purpose.

Consider this scenario: Two travelers are on a journey. The first one says, “We’re lost.” The second replies, “We’re not lost, I know exactly where we are. I just don’t know how to get to our destination.” This highlights three pieces of information are need when trying to reach a destination.

Knowledge of the destination, our current location, and a path to get there.

Data collection and analytics is similar. It is easy to “jump in” and start collecting data. However, before it is important to review the three points listed above before doing so:

Solving a problem roadmap requires users to determine the problem, gather data and find the solution. Image and table courtesy: MartinCSI

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1. The destination: What is the problem we want to solve?

2. The location: What data is available to the solve the problem.

3. The path: How does the data we have move us toward the solution?

The data analytics destination: Identify a problem, ask a question

The first step in data analytics is to identify a problem and then ask a question. For example, a manufacturing company may have a product with a wide variance in material strength, resulting in poor quality (the problem).

The company suspects variations in pressure or temperature during the manufacturing process are the reason. Next, restate the problem in the form of a question, which we will use data to answer. In this case we can ask, “Are variations in pressure or temperature affecting the strength of my product?”

The location: Gather data needed to answer the question

The next step is to decide what data is needed to answer my question. The available data can be thought of as my current location. A user may say: “On the surface, the data I need to collect is obvious, pressure and temperature. But, to have a complete picture, I also must look at where, when and how the data is gathered.”

For example, the user may have a sensor measuring the temperature of a process tank. However, the sensor may be mounted at the top of the tank and not measure the exact temperature where the reaction is occurring. So, the user may need to add a second sensor to more directly measure the reaction.

The user also will need some form of linking data, which allows them to associate each quality measurement with a corresponding process measurement. In this example, the user will record a common batch number that is associated with www.controleng.com

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input #14 at www.controleng.com/information The Emerson logo is a trademark and service mark of Emerson Electric Co. ©2020 Emerson Electric Co.

ANSWERS

DATA ANALYTICS FOR OT both the process data (temperature and pressure) and quality data (material strength). They’ll also need to generate a batch number, which will be tracked through all steps of the process.

The data analytics path

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Analyze, follow the data: Analytics methods include regression and classification algorithms, neural networks and supervised

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learning.

Analyzing and following the data will lead the user to the destination, which is an answer to the original question. There are a number of paths to choose from. These include analytics methods ranging from regression and classification algorithms to neural networks and supervised learning. However, the user needs to have a good understanding of the relationship between the data and the problem before starting on the path. They might want to know how variations in pressure and temperature affect my product quality in the form of material strength. It may be tempting to select a model, plug the data in and look for results.

Having a good understanding of process will achieve better results. If the user knows a temperature overshoot by 2 degrees will weaken the product, then they can select a model that will help look for this in the data. Also, if it takes an hour of this over-temperature to impact quality, that helps with selecting an appropriate resolution and sampling rate. It may require making some assumptions, but the better the assumptions, the easier it will be to answer the questions.

Four elements of data analytics

With everything addressed and answered, the user now has a road map to the destination and can

Local, cloud, edge, or data concentrator?

Edge Device

Edge Concentrator

Is the data I’m collecting in a raw format? Can it be processed or converted to a standard format before being collected?

X

X

Do I have a variety of devices that communicate using different protocols?

X

Will calculations be performed on the data in real time?

X

Local Server

Cloud Server

KEYWORDS: system integrator, Big Data, data

X X

Is the data of value enterprise-wide or just corporate?

X

X

Does the data span multiple plants or facilities?

X

X

Is there a need to provide access to reports and analytics over a public network?

X

Is there a need to run advanced data analytics?

X

Table: Asking questions can help users determine whether they need a local server, cloud server, an edge device or a data concentrator.

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Joe Martin is founder and president of MartinCSI and is a Control Engineering Editorial Advisory board member. MartinCSI is a CSIA Certified control systems integrator in Central Ohio. Edited by Chris Vavra, web content manager, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.

M More ANSWERS

Is the data of value to just the local plant or process area?

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embark on the data collection. The vehicle used to get there will be the system architecture. Common components can build this architecture. See several components and use cases below.

Edge device: Provides an interface between the devices on the local network (the source of the data) and the public network. They can be used to buffer and format data and perform calculations.

Some edge devices have options to configure a firewall, provide cellular access and act as a protocol converter.

Data concentrator: This device, which is often a programmable logic controller (PLC), is used to collect and aggregate data from existing sensors and PLCs. It can be used to buffer data, format data, and perform calculations before uploading to a server computer.

Local server: Server PC, hosted on premise. It is often used to provide monitoring, reporting and data warehousing.

Cloud server: Server PC, hosted in the cloud and accessible over the internet. It can be used to provide dashboards, reporting, notifications, data warehousing and advanced analytics.

The path from data acquisition to solutions can sometimes resemble a long and winding road.

However, the extra effort spent identifying the problem, asking questions, and gathering quality data will lead to a more direct route. The system architecture, built on a set of common components, is the vehicle that will take me to my destination. So, enjoy the drive. ce

acquisition Users looking to solve an operations technology (OT) automation problem need to know what problem they want to solve.

Following the data and asking questions along the way helps shape the answer.

Once the answer has been found, the system architecture will help make it a reality.

ONLINE See additional system integration stories at www.controleng.com.

CONSIDER THIS How do you design and develop your automation roadmap? www.controleng.com

ANSWERS

INTEROPERABILITY Mark T. Hoske, Control Engineering

Interoperability best practices, integration, automation, controls Standardization frameworks encourage more automation interoperability.

Interoperability is trying to move from one or a few automation ecosystems into a wider world. See four levels of cybersecurity.

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ergers, acquisitions and pilot programs have exposed organizations to multiple control systems and various automation vendors’ products, and greater automation interoperability across vendors is becoming possible with more attention to standards. Interoperability efforts are widening automation buy and specify opportunities. With manufacturing production and supply chain disruption from the pandemic, manufacturers are seeking greater agility on the way to global economic recovery. Technology enables greater sustainability and stronger resiliency in the event of future disruptions.

Universal automation is resilient

Nathalie Marcotte, president process automation, Schneider Electric, said at an ARC Advisory Group workshop, “A Resilient and Sustainable Future,” companies cannot have smart operations with a single vendor model, explaining open automation is required for efficient and resilient operations to protect the planet.

At the Feb. 9 online event for technology end users and media, Marcotte described a more collaborative and universal automation future, with plug-and-produce automation software components that solve specific challenges, such as in a software app store. The IEC 61499 standard creates an interoperable and portable layer across vendors’ event-driven function blocks in distributed industrial process, measurement and control systems. It enables easier distribution of applications across multiple devices and systems. End users will demand IEC 61499 interoperability from automation vendors, Marcotte said.

Such interoperability creates universal automation so application code will work across vendors’ automation systems. Code written only using the IEC 61131-3 standard for automation programming for one vendor may not work with another vendor’s software or hardware, a source of frustration for end users, system integrators, and some automation

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vendors that want automation users to more easily integrate devices and systems from many suppliers.

Universal automation creates savings

Lisa Johnston, chief sustainability officer and chief marketing officer (CMO), Aveva (Schneider Electric sold its software business to Aveva and owns a majority share), said use of digital solutions can cut carbon up to 15% and suggested the next 10 years needs to be a decade of action.

Henkel, a consumer goods company, Henkel, a consumer is using 16% less energy year over year (YOY) and has installed approximately goods company, is 3,500 sensors per site saving a total of 8 million Euro per year. Increased digitausing 16% less energy lization creates real-time visibilities on year over year and has production lines with better tracking of energy and materials. installed approximately Elias Panasuik, senior program director, EcoStruxure power and pro3,500 sensors per site cess, Schneider Electric, described other saving a total of 8 million savings in capital costs and operating efficiency over a facility’s lifecycle.

Euro per year.

Application of open digital automation, Panasuik said, can save up to 20% in operational expenditures and up to 30% in capital expenditures, reduce downtime 20%, add up to 3 percentage points in profitability and reduce carbon emissions 7 to 12%, among other benefits.

Designing automation from the start of a project helps build-in these advantages and removes automation from the critical path (the crunch time) before startup, he added.

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Four levels of cybersecurity

Increased cybersecurity threats mean that cybersecurity should be addressed on multiple levels, according to Jay Abdallah, cybersecurity services, Schneider Electric, such as: 1. Cybersecurity for the operation lifecycle with consulting, integration and managed security services control engineering

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ANSWERS

INTEROPERABILITY 2. Technology partnerships helping situational awareness, compliance, change management and big data security

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Increased digitalization creates realtime visibilities on production lines with better tracking of energy and materials.

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3. System deployment with secure deliver of project and services for products or systems 4. Cybersecurity by design for products, solutions and software.

With COVID-19 operating protocols that allow more and wider remote access, Abdallah suggested those augmenting cybersecurity should consider: • Vendor-agnostic capabilities • Ability to understand and apply information technology (IT) cybersecurity solutions within operational technology (OT) contexts and perspectives • Flexible security solutions to maximize value and efficiency • Customized controls based on customers’ requirements • Deep understanding of OT priorities and concerns.

Integrating cybersecurity into an operational lifecycle, Abdallah said, means considering cybersecurity in design and implementation (defense in depth, secure architecture, asset management, security assurance level, system hardening and solution integration); cybersecurity monitoring (firewall security, device management, threat management, device security and OT and security information and event management [SIEM]); cybersecurity maintenance (system upgrades security patches, incident response); cybersecurity training (security awareness, security engineer, security administrator and advanced expert); and cybersecurity consulting (policy and procedure, asset inventory, gap analysis, risk KEYWORDS: Universal and threat and compliance). automation software, interoperability Speed helps. Nidal Ghizawi, managUniversal automation ing R&D director, Schneider Electric, after can help create a resilient, another ARC Forum presentation, noted sustainable future. that everyone is trying to figure out how Four levels of cybersecurity to play in an open world, especially comreduce risk. pared to competitors. “Those who figure Open automation is software out faster will have an advantage.” centric.

M More ANSWERS

CONSIDER THIS Think Again about open process automation updates, in this issue.

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

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Open automation software, collaboration

In a Feb. 8 announcement at ARC Forum, Schneider Electric made three announcements related to open automation.

1. Schneider Electric advanced plugand-produce industrial automation with EcoStruxure Automation Expert v21.0,

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accelerated release schedule to every six months for what it calls the world’s first software-centric industrial automation system, and intensified its call for wider support for IEC 611499 to create a universal automation layer.

2. Schneider Electric called for stronger collaboration in industries of the future by renewing commitment to transforming the industrial sector through open, sustainable technology; urging adoption of universal automation and software to drive sustainability, efficiency, and health and safety across industry; and points to industrial businesses as key to global economic recovery.

3. A Schneider Electric and Wood partnership aims to accelerate open automation by giving operators unprecedented operational agility and step-change improvements with interoperable universal automation, separating control algorithms from runtime hardware to advance industrial digitalization, and collaborate with highly efficient and innovative engineers proficient in IEC 61499 technology.

In the Schneider Electric press conference, Kaishi Zhang, EcoStruxure automation expert/product management director, and John Conway, vice president business transformation next-gen automation, discussed how future industries will require a fundamental technology change, stronger collaboration, and an industrywide commitment to sustainable eco-efficiency.

Software-centric automation: A quantum leap

Conway said tools can empower all to make the most of energy resources, using digitalization to advance sustainability and shift energy use to more decarbonized sources. Software-centric universal automation is the next quantum leap in industrial automation.

High efficiency automation systems and industrial operations are needed. Plug-and-produce universal automation can learn from IT world about openness. He called the IEC 61499 standard for interoperable and portable automation code an Industry 4.0 enabler; as people understand its benefits, customers will demand it from automation suppliers.

Zhang said the software supporting the standard, such as Schneider Electric ecoStruxure Automation Expert v21.0, will help push users toward 100% energy efficiency and operational effectiveness with future-proof software centric automation.

Zhang expects new releases every 3 to 6 months based on customer requests in advanced manufacturing and process industries. ce

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

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ANSWERS

INSIDE PROCESS: SYSTEM INTEGRATION Ed Miller, Avanceon

Six steps for supporting an automation system There’s nothing revolutionary in this six-step process; however, it is a workable model for helping to find, analyze and correct system issues

E

very automation system eventually develops a situation requiring advanced engineering support. This type of break-fix support may be due to power outages, server maintenance, operator error, etc. But no matter what the root issue turns out to be, sooner or later, every system will need it.

Like coding, troubleshooting is a unique and special set of skills, and each person may have a slightly different approach to resolving issues.

When in a break-fix situation, following this sixstep procedure can not only fix the problem but also help determine the root cause of the issue.

STEP 1: Ask questions

Always begin by discussing the symptoms of the issue with the person reporting it. If you think about it, how can you solve a problem if you don’t know what the problem is? Asking the right questions in this first phase of the support process is vital to enabling a successful resolution.

STEP 2: Replicate the issue

Sometimes the information you’ve gathered in the first step may not quite paint the full picture of the situation. Replicating the issue often provides insight into what the user is actually reporting. It can confirm symptoms, and reveal others not reported.

‘

STEP 3: Check the log files

A well-built system will provide evidence of what is happening in the event something is not working properly. If you’re lucky, error messages will provide the context for understanding the actual problem. Even if the system hasn’t generated error messages, the system logs may provide details regarding behind-the-scenes issues in a script or database transaction. Analyzing these messages often can reveal the issue at hand.

STEP 4: Trace backwards

Start at the point in the system where the issue has been reported and trace backwards. For example, assume a user is experiencing an issue on a specific application screen. Begin with drilling down into the specific elements of the screen that are not working—for example, a button. Then dig into the code/ function behind the button to see how it’s supposed to work. Perhaps the button triggers a script that queries a database for data, but that data isn’t displaying on the screen. Tracing through these individual elements/functions often can help understand where in the process the malfunction occurs.

STEP 5: Restart/redeploy the system

Usually, it’s not going to be possible to restart servers in a manufacturing system without taking down other, still functional parts. However, it is

Asking the right questions in this first phase of the support process is vital to enabling a successful resolution. Replicating the issue often provides insight into

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what the user is actually reporting.

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www.controleng.com

‘

Tracing backward through individual elements/functions from the point in the system where the issue has been report often can help understand where in the process the malfunction occurs. Did you try

’ More

turning it off and back on again? amazing how often “turning it off and on again” will fix a system when some underlying aspect gets out of sync.

STEP 6: Document the findings

It’s always good practice to document the issue—both for the customer’s benefit and to provide insight to the support team. One of the main benefits of documentation in a support situation is to provide guidance should the same situation reoccur. You don’t want to spend valuable time trying to reanalyze an issue if you don’t have to.

ce

Ed Miller is a project engineer at Avanceon, a CFE Media content partner. Edited by Jack Smith, content manager, Control Engineering, CFE Media and Technology, jsmith@cfemedia.com.

M ANSWERS

KEYWORDS: System integration; automation support Like coding, troubleshooting is a unique and special set of skills, and each person may have a slightly different approach to resolving issues.

A well-built system will provide evidence of what is happening in the event something is not working properly.

Usually, it’s not going to be possible to restart servers in a manufacturing system without taking down other, still functional parts.

It’s always good practice to document the issue—both for the customer’s benefit and to provide insight to the support team.

ONLINE Link to additional System integration and related content at www.controleng.com/archives, under January 2021.

CONSIDER THIS Can following this six-step procedure help your facility fix problems and determine root causes of automation-related issues?

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ANSWERS

INSIDE PROCESS

Suzanne Gill, Control Engineering Europe

Digitalization crucial for food manufacturing processes Smart and proactive digital solutions can help support ongoing operations even through disruptive global events like the COVID-19 pandemic. See 7 tips.

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he COVID-19 pandemic has laid bare the fragilities and inequities of food systems. Today food producers are facing increased pressure on their essential workforce as they try to meet fast-changing demands, and there is a growing realization that there is a need for change, to ensure more agile and efficient processes to meet fast changing consumer demands.

For companies like Tetra Pak, this means that nothing has changed, while at the same time everything has changed. Alex Bromage, food safety and quality director at Tetra Pak, said, “While manufacturing processes are as good as they have always been, there is now the need to strengthen – or even rebuild – consumer trust in the quality and safety of food. Digital solutions can achieve this by supporting a transition towards more resilient, sustainable, data driven, and most importantly, transparent food systems.”

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Digital solutions can support a transition towards more resilient, sustainable, data driven, and most importantly, transparent food systems.

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Bromage said he believes that when deployed in facilities, smart and proactive digital solutions can help support ongoing operations even through disruptive global events like the current pandemic. “Through the course of the pandemic, digital technologies have been instrumental in helping our service engineers provide remote support, allowing us to connect with customers digitally, via voice, video and even direct connection to the packaging equipment electronic control systems, maintaining quality and keeping tight control of

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food safety through the course of the pandemic,” Bromage said.

Layers of complexity: Analytics, less waste, faster learning

Matthew Wells, vice president product management at GE Digital, pointed out that hygiene practices to protect against the spread of COVID19 has added further layers of complexity to food production processes. He said that digitalization, including predictive analytics and machine learning, has a critical role to play in modeling the actions and consequences of actions in a way that is always valuable, but proves to be absolutely critical when circumstances are volatile.

“Analytics can optimize production uptime, reduce waste and accelerate learnings from one plant to another, and from one line to another,” he said. “Now is the time for manufacturers to put a strong focus on optimizing production and packaging agility, not only for the situation at hand but also to prepare for future demand changes to come. This includes lowering line changeover times with rapid line changeover solutions and putting data more easily into the hands of operators to enable quick decision making.”

With so many food and beverage manufacturers still operating in a paper-based environment when it comes to information collection and reporting there is too much room for human error. “No matter how experienced people are, they will inevitably make mistakes,” continued Wells. “This situation can be exacerbated when working across a range of equipment types within 24/7 operations, with multiple employees from different shifts potentially affecting the process over the course of a day.

“Managing data from diverse equipment and multiple suppliers presents another challenge.

When looking for a solution to help move from paper to data, look for manufacturing and supply chain solutions that can interface with a wide range of industrial equipment and protocols, either directly or through relevant standards. The crucial www.controleng.com

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ANSWERS

INSIDE PROCESS

step is to digitally transform manufacturing operations to create a paperless environment.”

Growing importance of digitalization for industrial quality, safety

Greg Hookings, head of business development – digitalization at Stratus Technologies, said he believes that the pandemic has only increased the need for digitalization within food and beverage production. “Even pre-COVID, this was important because the sector is highly regulated and food and beverage manufacturers are always striving to meet the required compliance standards. Post-COVID the compliance issues will likely grow stronger. Any issue with hygiene could mean huge reputational damage for any brand and with COVID-19 in mind, hygiene standard lapses could mean further spreading which absolutely nobody wants.”

Citing one hygiene example, Hookings points to hazard analysis. “With the computing power now available on the plant-floor, the traditionally manual process of collecting sample lots and sending them to the lab for analysis can be easily automated which would allow data to be presented immediately to centralized quality systems.”

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Digital technologies help service engineers provide remote support and connect with customers digitally, via voice, video and even direct connection to the packaging equipment electronic control systems, maintaining quality and keeping tight control of food safety.

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Hookings said that the barrier to wider uptake of digital technologies within the food processing sector is because it is so focused on return on investment (ROI). “Without a measurable numerical answer to the question: ‘What is the ROI on the IIoT?’ digitalization can rapidly fall down the priority list. Other more quantifiable questions that food and beverage manufacturers should be asking themselves could include: What is the ROI on the continued running of a food and beverage plant? What is the ROI on real-time quality analysis? What is the ROI on avoiding a recall? By urgently advancing a digital transformation journey, enterprises are potentially avoiding catastrophic brand damage,” he said.

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Taking stock of Industry 4.0, industrial digitalization

Andy MacPherson, food and beverage industry manager at Festo, was very positive in his assertion that the effects of COVID-19 on the food and beverage sector have made the industry take stock, with many starting to realize the benefits of embracing digitalization to maximize the efficiency of existing equipment.

Indeed, MacPherson says that some of the larger food producers have already set up specific engineering teams who are 100% focused on digitalization/Industry 4.0 and they are implementing many digitalization projects on existing and new production lines. “In the UK we also have seen an increase in the use of robotics in production processes,” he said.

Of course, connectivity to existing legacy equipment and the factory’s data architecture can be a challenge – with many machines using different protocols on a single site, linking them together and extracting and interpreting data and information can be difficult. In some cases, gaining the basic wireless data can grind to a halt due to existing IT security measures. MacPherson suggested that these challenges can be overcome by involving IT as well as production and engineering from the outset with any digitalization project.

For industrial digitalization, one source of truth

Keith Chambers, head of operations execution business at Aveva, points out that data is the only source of truth when making critical decisions and digitalization is the only path to achieving this.

In such uncertain times resilient production relies on being adaptable – for example pivoting to deliver higher volumes of a smaller number of SKUs. “The efficiencies and improvements to production processes that may mean the difference between profit and loss must be identified and implemented through real-time data,” Chambers said. “When coupled with labor shortages, teething pains from altered production processes can become crippling. Delays too irregular or small for engineers to track without data from IIoT sensors can add up to a missed shipment or a disrupted production line. Operations today may be working with reduced people per shift – so there is likely to be fewer colleagues to assist when they get stuck with a problem. Digital technologies can help fill the gap with digital collaboration and guidance.

“Poor data governance is a common stumbling block for many food processors looking to digitally transform. With such a vast volume and velocity of data recorded across multiple variables, businesses often struggle to extract real value from it,” continued Chambers. “Havwww.controleng.com

ing the right governance processes in place is critical to ensuring that data is collated, cleaned and organized before undergoing any analysis.

The data-driven insights that result from digital transformation will only be as good as the quality of the data you put in,” he warns. “Digital transformation is often understood to be simply the implementation of new technologies. When approached this way, the benefits can be underwhelming. Businesses need to take a strategic and holistic approach to digital transformation. It is about fundamentally adapting your organization to become more agile and resilient so that it can better meet the needs of the customer. The benefits of digitalization are far greater than the sum of its parts when the solution spans the enterprise, breaking production silos.”

It is a common misconception that digitization requires companies to immediately rip out legacy systems and replace them with digital processes. According to Chambers, digitalization should be a gradual and iterative process.

He advises that businesses start by creating a digital twin of one asset in a factory, for example.

Once, it has proved its value, the technology can be applied to other assets and a network of connected assets can be established to form the foundation of a smart factory.

“Businesses with legacy systems are set to gain the most from digital transformation. AIpowered predictive maintenance can help identify maintenance issues before they occur, reducing unplanned downtime, minimizing costs and increasing productivity,” Chambers said.

Having the vision for real-time processes, data analytics

According to Keith Thornhill, head of food and beverage industry U.K. at Siemens Digital Industries, the only real barrier to the adoption of Industrial Internet of Things (IIoT) and digitalization projects is the vision of the company.

“This is the only thing holding most companies back,” he said. “It is vital to have a midterm and a longer-term view of what is needed to satisfy the demands of the consumer in the retail sector.”

Thornhill goes on to say that the vision should be guided by the need to be different in the future – agile and dynamic – aiming to have real time processes and real time data analytics.

These, he said, are the features that give companies insight to actually improve and make their businesses more efficient.

“Obsolescence should not pose a problem,” Thornhill said. “It can be mitigated by adopting the right technologies. As technology vendors we are in a position where we can interface a 1970s technology at one end and future tech-

www.controleng.com

nologies at the other end and it is possible to collect data from different aged control systems and bring it all together in some standardized format.

We can look at an aging production line and find the weakest link in a particular machine. And because we now have the real-time evidence, we can apply root cause analysis and tackle each condition independently – whether it is the labelling machine or the filling machine. We can analyze every aspect of an aging plant and provide a solution based on accurate ROI calculations.”

‘

Analytics can optimize production uptime, reduce waste and accelerate learnings from one plant to another,

’

and from one line to another.

Overcoming resistance to advanced automation

Gary Ingram, sales manager – digital transformation at Emerson, argued that the economic and operational impacts of COVID-19 should be a driver for operational change. These changes, he said, include implementing more advanced technologies, such as touch-free operations and virtual and augmented reality technologies to enable production targets to be met with more agility and resiliency.

Ingram highlights the biggest challenge to deployment of IIoT and digitalization projects as being resistance to change. “Digital technology empowers workers, but organizations must implement changes to work practices to maximize the ROI, so resistance to change must be addressed.

The application of processes such as lean manufacturing, six sigma and value stream mapping can help to eliminate or minimize non-value work and change work processes to focus on value-added activities. But the organization needs to make its team part of the solution, mobilize stakeholders, identify sources of resistance to change, and implement strategies to overcome that resistance.”

Ingram highlighted the lack of clearly defined ROI for applications and programs as being another major barrier – a recent survey by Emerson showed that over 70% of companies do not have a clear vision for data analytics and a roadmap for success. “It is essential to know the problem that needs addressing – just running analytics at data looking for insights doesn’t work. Many manufacturers find the IIoT and other enabling techcontrol engineeering

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ANSWERS

INSIDE PROCESS

‘

When considering digitalization return on investment, also consider ROI on continued uptime, on real-time quality analysis, and on avoiding a recall.

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nologies too complex, costly and time-consuming to implement. Food and beverage producers are staffed to operate not change. Many manufacturers are finding it difficult to know which solutions, if any, best fits their own particular plant. However, the reality is there are practical, easy-to-implement steps which can be taken to make digital transformation a reality.” Ingram pointed out that digital transformation does not have to entail an all-ornothing type approach. “Once you figure out your production goals, design your system and assess ROI objectives, the next step is to start with a small pilot project on a few machines. We recommend starting small and scale up when appropriate.”

Digital communications from factory floor to director level

There can be no doubt that there is a requirement to look towards digitalization and automation of food and beverage production processes to provide the agility needed to meet the fast-changing needs of the retail trade and consumers – the events of 2020 conKEYWORDS: Digitalization, firm this imperative. There is, therefore, Industry 4.0, food and a requirement for everyone involved in beverage production ensuring company success – from the COVID-19 added layers of engineers on the factory floor, right up complexity to food production; to director level – to inform themselves digitalization, predictive analytics, about the benefits of digitalization, and machine learning can help. to push forwards on the journey. As we Digitalization helps improve industrial quality, safety. have heard above, it is possible to do this Data governance and data gradually, in a manageable way which analytics can improve with gives engineers the ability to evidence digitalization. the benefits and prove the ROI. There is CONSIDER THIS widespread agreement that organizations Have measures implemented who acknowledge and accept digitalizabecause of COVID-19 going tion will be the ones that emerge as winto be slowed or abandoned ners in a post-COVID world. ce post-pandemic, or continue to

M More ANSWERS

accelerate your organization?

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

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Suzanne Gill is editor, Control Engineering Europe. This article originally appeared on Control Engineering Europe’s website. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media, mhoske@cfemedia.com.

control engineering

Seven digitalization tips for industrial operations DIGITAL SOLUTIONS can help industrial operations transition towards more resilient, sustainable, data-driven and transparent production systems. Tips include:

1. Bolster remote connections: Digital technologies helping service engineers provide remote support, connect with customers digitally, via voice, video and direct connection to control systems, maintaining quality and keeping tight control of safety and cybersecurity through the pandemic.

2. Increase uptime, optimization: Digitalization, including predictive analytics and machine learning, helps model actions and consequences of actions, especiall critical when circumstances are volatile.

3. Help compliance: Digital tools help with compliance standards in many industries, adding to safety and quality and avoiding risk.

4. Add efficiencies to legacy equipment: Embracing digitalization can maximize the efficiency of existing equipment.

5. Help with labor shortages: Operations may be working with fewer people per shift. Digital technologies can help fill the gap with digital collaboration and guidance.

6. Integrate data use for better analytics in standardized formats: With aligned real-time evidence, it’s easier to apply root cause analysis and tackle each condition independently to provides solution based on accurate return on investment calculations.

7. Apply other advanced automation technologies, such as smarter robotics, augmented reality and touch-free operations for greater flexibility, agility and ability to attract next-generation talent. www.controleng.com

INNOVATIONS

NEW PRODUCTS FOR ENGINEERS

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

PE

Brushless dc motors, integrated encoders The DFA68 and DFA90 series brushless dc motors from Nanotec are now also available with integrated encoder. Owing to their extremely compact design, the new external rotor motors are particularly suitable for applications that require precise positioning in confined spaces. Inductive scanning principle, which is insensitive to magnetic interference, made it possible to integrate the encoder directly into the motor and restrict the installation length to 42 mm. The DFA90-E with a diameter of 90 mm has a rated power of 168 W at a rated speed of 2,000 rpm.

The smaller DFA68-E with a diameter of 68 mm achieves 106 W at a rated speed of 3,500 rpm.

Due to their high pole construction the motors run very quietly at low speeds.

Nanotec Electronics, www.nanotec.com

Input #200 at www.controleng.com/information

Robot cell for industrial manufacturing applications

The Grob robot cell (GRC), when combined with the company’s G-modules, provides flexibility and customization for manufacturing of aerospace, mold & die, medical and many other industry applications. The GRC is capable of part handling as well as pallet handling which allows for maximum flexibility. It has a shared base frame enabling quick installation. The standardized software allows the cell to be acommissioned quickly. The innovative feeding system with part drawers enables longer unmanned production. An automatic clamping fixture and part gripper change is available for different clamping fixtures and part types. The robot cell also can be configured with a variety of modules such as deburring, washing and measuring all in the same cell. The GRC can be expanded to feed multiple machining centers.

Grob Systems, www.grobgroup.com

Input #201 at www.controleng.com/information

Automotive-grade interface integrated circuit, signal conditioning algortithms

Allegro’s A17700 is an automotive-grade interface integrated circuit (IC) for resistive bridge pressure sensors has signal conditioning algorithms. Features include flexible compensation algorithms for accuracy over temperature and sensing bridge variation. It also has precise pressure information delivery in low delay analog, PWM, or SENT outputs. The A17700 is configurable for resistive bridge pressure sensors in a wide range of critical applications in today’s efficiently designed cars; from high-pressure systems like dynamic brake systems (DBS) in turbo and hybrid electric vehicles (HEV) or gasoline direct injection (GDI) to medium and low-pressure systems, such as brake boosters, HVAC applications for electrified vehicles, and automatic transmission oil management.

Allegro MicroSystems, www.allegromicro.com Input #202 at www.controleng.com/information

Smart temperature transmitter with Bluetooth, easy operation

Endress+Hauser’s iTemp TMT142B is a smart temperature transmitter with Bluetooth. The transmitter delivers accurate and reliable measurements, wireless communication via Bluetooth, and user-friendly operation—all packaged in a robust single-chamber field housing. The technology offers significant improvements in process efficiency and plant availability while reducing costs. The transmitter features a secure integrated Bluetooth interface that enables users to wirelessly visualize measured values, NAMUR NE 017 diagnostic information, as well as configuration tasks. The newly developed backlit display provides excellent readability under all environmental conditions, both in the dark and bright sunlight. Diagnostic messages are highlighted when the normally white background turns red.

Endress+Hauser, www.us.endress.com

www.controleng.com

Distribution blocks series has offset connections

Weidmuller’s WPD distribution blocks have a unique echelon form and screw heads in an offset position. The latter ensure at every echelon level a safe and comfortable connection in systems and housings, even in confined spaces. The energy and zero potentials that are fed into machines and plants often need to be distributed even further to supply, for example, motors. Those extensions have to be safe, efficient and spacesaving. They are designed for oil and gas, wastewater and similar industries.

They have a self-extinguishing, halogen-free plastic housing and short-circuit resistance.

Weidmuller, www.weidmuller.com Input #204 at www.controleng.com/information

Input #203 at www.controleng.com/information

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March 2021

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INNOVATIONS

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

NEW PRODUCTS FOR ENGINEERS

PE

Safety relay module, diagnostics, monitoring

The Idec HR6s safety relay module is a microcomputer-based device that supports a wide variety of connections, input devices, and operating modes. It also adds convenient diagnostic and status monitoring important for the growing number of manufacturing sites relying on important internet of things (IoT) data. The HR6S is designed to meet ISO 13849 requirements, with one model for low-risk safety category 1 applications, and six models suitable high-risk safety category 3 and 4 processes requiring redundancy.

Up to eight different start modes are dial-selectable, including options for manual and automatic start, providing extensive flexibility. Certain models have adjustable off-delays, and all use a compact DIN-mountable form factor.

Idec, www.idec.com

Input #205 at www.controleng.com/information

Asset management platform, cloud

Rotork’s Intelligent Asset Management program of advanced analytics for the management of intelligent flow control assets. Intelligent Asset Management is a cloud-based asset management system for intelligent actuators and the flow control equipment they operate.

It is a system of advanced analytics to improve reliability and availability of key assets (such as valves) across all industries that use flow control processes. Failure of key equipment on any site or plant can result in unplanned downtime, poor performance, reduced output yields and reputational damage.

Rotork, www.rotork.com

Input #206 at www.controleng.com/information

OT network service platform has high security

Siemens’ Sinec INS makes it much easier to effectively use operational technology (OT) network services with a high degree of security. The uniform user interface provides a rapid overview of all OT focused network services like IP address management (DHCP), time synchronization of devices (NTP), gathering network events (Syslog), authentication (RADIUS), and firmware updates for network components (TFTP). It enables users to establish networks that are separate from IT services and to host them in an OT data center. It can be used in machine building, metal, automotive and other manufacturing industries.

Siemens, www.siemens.com Input #207 at www.controleng.com/information

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INNOVATIONS

BACK TO BASICS

Jon Breen, Breen Machine Automation Services

Ethernet versus office Ethernet Be aware of important differences between industrial Ethernet and office Ethernet.

T

here was a time when industrial field networks had different hardware requirements. HART requires a unit capable of injecting and reading signals overlaid on an analog signal, RS232 requires two signal wires and a ground, and RS485 requires two pairs of differential signal wires. Machine builders and end users had to invest in cables, adapters, and training to service different networks. While many networks remain, they’re losing popularity for new installations. Ethernet has overtaken other standards, with 52% of new installations in HMS Industrial Networks’ 2018 annual study. There’s no sign this trend will slow.

This convergence means we don’t have to learn as many standards or keep special cables around. We see Ethernet in our homes and offices. We’re familiar with the blue cables, the clear plastic RJ-45 connectors and the routers. A lot of that familiarity can support Ethernet use in industrial automation, but be aware of differences. This article is based on the Breen Machine “Industrial Ethernet Design Guide.”

Determinism and noise immunity

We often hear network speed defined in terms of megabits per second (MB/s). In industrial applications, network hardware is most often rated for 100 MB/s, with 1000 MB/s gaining popularity. In the office, this is usually the important speed metric, but in an industrial control network, determinism is most important. When we’re controlling or monitoring real events at high speed, we have to communicate with devices in a consistent time frame. A 2-second delay is no problem for an office-network printer, but a 2-second wait could be catastrophic for a servo. The most important design consideration is to keep the automation network separate from the office network.

The industrial environment is electromagnetically noisy. Large currents, often driven by switching power devices like variable frequency drives (VFDs), are notorious for creating high frequency harmonics and electromagnetic interference (EMI) that can affect other devices. Reducing EMI’s effect on a network with segregation, twisting signal pairs, bonding and shielding. A good design includes all four. Following a manufacturer’s recommendations helps. VFD manuals always talk about grounding and bonding.

Environment and industrial protocols

Industrial environments can be very harsh on components. Extreme temperatures, moving parts, reactive chemicals and high voltages are all com-

www.controleng.com

mon. Each cable and device need to be rated for the environment or enclosed to protect it.

Network cables can be purchased to resist all sorts of harsh environments. All cables must have insulation rated for the highest voltage in the enclosure or wireway. Even though Ethernet is low voltage, it often still needs a 600V rated jacket. If the cable will be flexed during normal operation, get a flex-rated cable. If it’ll be routed through an exposed tray, NEC requires a tougher jacket to protect against mechanical damage (buy a tray-rated cable). For other mechanically challenging environments, there are crush-rated and abrasion-resistant cables. Cables can be acquired with ratings for extreme temperatures, flame resistance, and oil/chemical resistance.

Plugging in an Ethernet cable at the office usually just works. In industry, not all Ethernet is compatible.

A protocol is a language that devices use to communicate over an Ethernet cable. Often, protocols are used in layers, with a low-level protocol providing the foundation for a high-level protocol. Since industrial applications have different needs than building/office/ home networks, protocols exist to fit these needs, each with trade-offs. When an industrial protocol is defined “on top of ” a widely used protocol (often TCP/IP), standard architectures and hardware can be used.

When a protocol is defined at a low level (stacked on few other protocols), architecture and hardware options may be more limited. Also, a low-level protocol will usually be more deterministic than a high-level protocol.

In practice, Ethernet protocol is usually dictated by programmable logic controlKEYWORDS: industrial Ethernet, ler (PLC) choice. Each PLC manufacturer Ethernet protocols has a preference, and while some offer a Industrial Ethernet and office few options, you’ll usually get the best Ethernet might seem similar, but there results (easiest implementation, best supare key differences. port) if you stick with that manufacturer’s Key aspects to keep in mind include determinism, electromagnetic standard. Each manufacturer has played a interference (EMI), noise immunity and key role in the standards organization that environmental ratings. defines their favorite protocol.

For manufacturers, Ethernet Know the small differences between protocols are often dictated by the office and industrial Ethernet for smoothkind of programmable logic controller er implementations. ce (PLC) they use and the manufacturer’s

M More INNOVATIONS

preferred Ethernet protocol.

Jon Breen, founder/owner, Breen Machine Automation Services, a CFE Media content partner. This article originally appeared on Breen Machine Automation Services’ blog.

Edited by Chris Vavra, web content manager, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.

ONLINE See additional articles from the author at www.controleng.com.

CONSIDER THIS Which of these considerations is the biggest priority for you and which is the biggest challenge?

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input #17 at www.controleng.com/information

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seweurodrive.com | 864-439-7537 input #18 at www.controleng.com/information