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Control, Instrumentation and Automation in the Process and Manufacturing Industries November 2014

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How often should instruments be calibrated?

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CONTENTS

Claiming your share of $19 trillion…

Editor Suzanne Gill suzanne.gill@imlgroup.co.uk Sales Manager Lydia Harris lydia.harris@imlgroup.co.uk Production Tania Richards tania.richards@imlgroup.co.uk Business Development Manager Iain McLean iain.mclean@imlgroup.co.uk Dan Jago Group Publisher David May Production Manager Stuart Pritchard Studio Designer

According to Cisco analysts the ‘Internet of Everything’ (IoE) could be worth around $19 trillion, most of which will be made in the manufacturing sector. All you need to do to grab your share of this is to get everything connected to everything else in your plant and to use the information provided well. You may, of course, also have to work more closely with the IT department…but surely the benefits will outweigh any negatives! Cisco and Rockwell Automation are working together closely to help the sector gain its share of the benefits of IoE (pg 4). The SPS/IPC/Drives event in Nuremberg is also continuing to gain momentum and this year will be the biggest show ever, spread across a total of 14 halls. It is almost certain that the IoE and other Industry 4.0 themes will also be high on the list of discussion

points at this event. The entire Siemens stand, for example will be themed to demonstrate the interplay between automation and digitisation along the entire industrial value chain – showing how it is possible to make production processes faster, more flexible and smarter. Further details about Siemens latest offerings, and those of other exhibitors, can also be found in this issue. (pg 34). As usual the Control Engineering Europe team will be attending the event to bring you the latest technology news. If you think there is something that we need to be reporting on, please do let us know. Suzanne Gill – Editor suzanne.gill@imlgroup.co.uk

INDUSTRY REPORTS

FLOW & LEVEL

30 Dr Norman Glen explains how the use of synthetic reference fluids can help improve flowmeter calibration accuracy.

Making the most of IoT – At a recent automation conference Rockwell Automation and Cisco jointly presented their manufacturing vision for the ‘connected enterprise’. Suzanne Gilll reports.

WIRELESS TECHNOLOGY 32 A new day for wireless control – A report from Control Engineering.

EDITOR’S CHOICE 12 Wireless temperature and humidity monitoring solution; 3D scanner for continuous solids measurement.

INDUSTRIAL NETWORKS 16 FDI and FDT: working together for limitless integration.

SPS/IPC/DRIVES 2014 34 SPS/IPC/Drives 2014 takes place from 25 – 27 November in Nuremberg. The event continues to gain support as a showcase for innovation in n the field of electric automation.

INTERNET OF THINGS 20 Internet of things – finding security in the cloud.

HARMONICS 22 Exploring harmonics mitigation techniques.

FINAL WORD

MOTION CONTROL 28 Taking a look at the benefits and barriers to the use of centralised and decentralised servo technologies.

Control Engineering g g Europe p is a controlled circulation journal p published six times p per yyear byy IML Group pp plc under license from CFE Media LLC. Copyright py g in the contents of Control Engineering g g Europe is the property of the publisher.

39 To celebrate the 60th anniversary of the Control Engineering brand, Jeanine Katzel, reflects on some of big technology developments that have, and continue to, transform the industrial landscape.

Control Engineering (USA) Frank Bartos, Mark Hoske, Renee Robbins, Vance VanDoren, Peter Welander

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November 2014

INDUSTRY REPORTS

Making the most of IoT At a recent automation conference in Ireland – organised by Hanley Automation – Rockwell Automation and Cisco jointly presented their manufacturing vision for the ‘connected enterprise’ and explained how they believe it will overcome many of today’s manufacturing challenges. Suzanne Gill reports.

aul Taylor, responsible for the strategic alliance between Rockwell and Cisco on a global basis, set the scene by discussing the current global landscape and the issues it presents for the manufacturing sector. “There are three main issues shaping today’s global landscape,” he said. “The basic economics of the world are changing as emerging economies start to spend money and demand more consumer goods. These emerging economies are also demanding more energy. Finally, in the developed economies the industrial workforce is ageing and in some cases shrinking. “Cisco’s challenge is where and how to create new value in this changing landscape. We are seeing the Internet of things starting to become a reality and believe that this is key to solving many of the above challenges. “There are already far more devices connected to the Internet than in the recent past. By 2020 there are expected to be around 50 billion connected devices and a large percentage of these will be in the industrial sector.” Taylor went on to explain that the amount of data is doubling every two years and that 90% of the world’s data was created in the last two years, which has resulted in analytics becoming an increasing important tool to turn this data into useful information. According to Taylor the next step for Cisco is to “digitise the world!” He believes that the true value of this connectivity in the industrial sector will be seen when everything is connected to everything else.

November 2014

Paul Taylor of Cisco discussed the current global landscape and the issues it presents.

Cisco consultants have analysed the potential value of the Internet of Everything and conclude that it will be worth around $19 trillion. “This will come from innovation, increased productivity, improved efficiency and improved customer experience,” claims Taylor. “We believe that the vast majority of this value will be made in manufacturing sector, which is why Cisco is working very closely with Rockwell Automation in this sector.” Taylor explained that a degree of convergence between the currently opposed IT and OT arenas will become necessary, which will require a mindset change from both sides. “Our first joint step with Rockwell was to define what a connected enterprise actually looks like – and what happens when we connect the factory to the enterprise. This led to the joint development of CPwE (converged Plant Wide Ethernet) to connect the IT and OT worlds.” This architecture has

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been designed to address the cultural and technical challenges of Ethernet network convergence between IT and engineering. It comprises Rockwell Automation’s Integrated Architecture and Cisco’s Ethernet-to-the-Factory, to provide users with a foundation from which to deploy the latest technology by addressing topics relevant to both IT and OT professionals.

Connected enterprise benefits Dominic Molloy, marketing director EMEA & managing director UK and Ireland at Rockwell Automation, then took to the stage to discuss the benefits of a connected enterprise. “The Internet of things – having the ability to connect devices together – has opened up a new era for the manufacturing environment and is changing the way that factories are being developed,” he said. “Rockwell Automation’s vision for this is brought Control Engineering Europe

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INDUSTRY REPORTS

to life through the Connected Enterprise.” This model crystalises the company’s ideas about optimising the manufacturing supply chain for rapid value creation and driving productivity through the manufacturing environment in a sustainable and secure way. Manufacturers need to be more agile to keep pace with customers fast changing demands. Rockwell believes that the Internet of Things will allow for the better use of resources and will help develop an infrastructure to enable this agility. “For example, it could lead to a safer, more accessible food supply, giving the ability to track food products from field to fork,” said Molloy. It will also enable more affordable oil and gas production, allowing for the cost-effective utilisation of resources and will allow for more precise energy management.” Molloy believes that the manufacturing world is now at an inflection point. “Many companies have already invested in ERP and have achieved all the productivity gains they can from this. The information needed to drive productivity further and to help reduce costs and gain a safer, more secure and sustainable work environment must now come from investment in manufacturing and automation systems.” Rockwell has identified that 52% of manufacturers expect to migrate to hybrid cloud within two years – resulting in a six-fold increase in cloud traffic. There are huge benefits to be derived from this additional data, but security issues do need to be overcome first. For example, 63% of businesses currently allow employees to bring their own devices to work, yet only 46% of those businesses govern these devices. “In the manufacturing sector a lax approach to network security can pose problems and currently there are five terabytes of manufacturing data viewed on mobile devices every year,” said Molloy. “Another critical element of the connected enterprise is contexuralising the data and serving it up to the right

November 2014

Paul Taylor of Cisco (left) and Dominic Molloy, managing director UK and Ireland at Rockwell Automation (right).

people, at the right time in the right format, allowing them to make decisions in real-time to help drive productivity and profitability,” he said.

Mobility Data can now be presented via mobile devices in real-time, which allows decisions to also be made in real-time, impacting the manufacturing process much more quickly than has been possible in the past. The increasing use of mobile devices could also impact the displays used in the manufacturing environment. “Today many displays are still physically connected to the plant. As we take advantage of the Internet of Things for mobility and connectivity the number of fixed HMIs in the plant may well be reduced because an operator will instead carry a mobile interface, personalised for their use, with a secure ID, with the data being contexturalised to allow them to view information relevant to them about the state of a piece of plant,” suggests Molloy. To make all the benefits offered by the Internet of Things possible will rely on unlocking data and driving sustainable manufacturing through the integration of control and information over a single, safe and secure network. This is why Rockwell Automation, in partnership with Cisco, is looking at the creation of a common, secure Ethernet IP environment that allows plant manufacturing data to run over a single network – one that is able to pass

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information seamlessly from a sensor up to the ERP system so that information can be securely transferred to engineers with different levels of access and different needs for information. They will be able to access just the data they need, served to them in a meaningful way, which will allow them to perform their job more effectively. Of course, this goal would be a lot easier to achieve on a greenfield site. But many existing sites contain a great deal of legacy systems which makes it necessary to think very carefully about the existing operating model and a strategic assessment of how the plant is connected and what you would like it to be. This requires many questions to be answered… such as: How do you use data in the plant? Where is it stored? How do you collect it and serve it to users? What are the key metrics that need to be monitored to drive business more effectively? What benefits will you get by implementing a connected enterprise? What is your current relationship with your supply chain and customers and how can you adapt to their changing needs? “There are some big challenges ahead,” concludes Molloy. “However, the benefits are clear. If you have a connected enterprise you will get product to market faster, it will lower your total cost of ownership, it will drive asset utilisation to its optimum and it will reduce enterprise risk. Having a safe, secure and sustainable manufacturing environment will be good for business going forward.” Control Engineering Europe

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COVER STORY

How often should instruments be calibrated? Plant efficiency can be improved and costs reduced by performing calibration history trend analysis is only possible with calibration software that provides this functionality, says Beamex.

anufacturing plants require instruments that perform and measure to specified tolerances. If sensors drift out of their specification range, the consequences can be disastrous, resulting in costly production downtime, safety issues or the production of inferior product. Most process plants will have a maintenance plan or schedule in place to ensure that all instruments are calibrated at the appropriate times. However, with increasing demands and cost issues being placed on manufacturers, the time and resources required to carry out these calibration checks are often scarce which can lead to instruments being prioritised for calibration, with those deemed critical enough receiving the required regular checks, but others – deemed less critical to production – being calibrated less frequently or not at all. However, plants can improve their efficiency and reduce costs by using calibration ‘history trend analysis’ – a function available within Beamex CMX calibration software. With this function, the plant can analyse whether it should increase or decrease the calibration frequency for all its instruments. Cost savings can be achieved in several ways – by calibrating less frequently where instruments appear to be highly stable according to their calibration history; and by calibrating instruments more often when they are located in critical areas of the plant, ensuring that instruments are checked and corrected before they drift out of tolerance. This

November 2014

The benefits of calibration history trend analysis Analysing and determining the optimal calibration interval for instruments enables conclusions to be made regarding the quality of a particular measuring instrument. It can also offer time savings as faster analysis is possible when compared to the use of traditional, manual methods. It also enables engineers to check that instruments are performing to their technical specifications and are not drifting out of tolerance regularly. also calibrate their instruments more frequently than other industry sectors.

is common practice for companies that employ an effective ‘preventive maintenance’ regime. The analysis of historical trends and how a pressure sensor, for example, drifts in and out of tolerance over a given time period, is only possible with calibration software that provides this type of functionality.

Current practices Beamex conducted a survey that asked process manufacturing companies how many instruments in their plant required calibrating and the frequency with which these instruments had to be calibrated. It covered all industry sectors, including pharmaceuticals, chemicals, power and energy, manufacturing, service, food and beverage, oil and gas, paper and pulp. Interestingly, the survey showed that from all industry sectors, 56% of the respondents said they calibrated their instruments no more than once a year. However, in the pharmaceutical sector, 59% calibrated once a year and 30% calibrated twice a year. The study also proved that the pharmaceuticals sector typically possesses a significantly higher number of instruments per plant that require calibrating. In addition, these plants

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Analysing calibration history trends Regardless of the industry sector, analysing an instrument’s drift over time (the historical trend) can reduce costs and improve efficiencies. Pertti Mäki, area sales manager at Beamex, explains: “The largest savings from using the History Trend Option are found in the pharmaceuticals sector, but all industry sectors can benefit from using the software tool, which helps identify the optimal calibration intervals for instruments.” The trick is to determine which sensors should be re-calibrated after a few days, weeks, or even years of operation and which can be left for longer periods, without sacrificing the quality of the product or process or the safety of the plant and employees. Doing this enables maintenance staff to concentrate their efforts only where they are needed. There are other, less obvious benefits of looking at the historical drift of a sensor or set of instruments over time. Mäki explains: “When an engineer buys a particular sensor, the supplier provides a technical specification that includes details about its maximum drift over a given time period. With CMX’s History Control Engineering Europe

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Calibrations under control Test your existing calibration process is at: www.beamex.com/ calibrationsundercontrol

Beamex provides the equipment, software and services needed for an efficient calibration process. The calibration process starts from the planning and scheduling of the calibration work and includes performing of calibrations as well as documentation of results. An efficient calibration process saves time, automates procedures, is cost-efficient and assures that the results are reliable. The best-in-class calibration processes are integrated, automated and paperless. Learn more and test how advanced and efficient your existing calibration process is at: www.beamex.com/calibrationsundercontrol

www.beamex.com info@beamex.com

COVER STORY

Trend Option, the engineer can verify that the sensor actually performed within the specified tolerance over a certain time period. If it hasn’t, the engineer now has data to present to the supplier to support these findings.” The History Trend function also allows the quality or performance of different sensors from multiple manufacturers to be compared in a given location or set of process conditions. CMX Calibration software can also help with the planning of calibration operations. Calibration schedules take into account the accuracy required for a particular sensor and the length of time during which it has previously been able to maintain that degree of accuracy. Sensors that are found to be highly stable do not need to be re-calibrated as often as sensors that tend to drift. The History Trend function enables users to plan the optimal calibration intervals for their instruments.

Once implemented, maintenance personnel, for example, can analyse an instrument’s drift over a set time period. History Trend can display drift both numerically and graphically. Based on this information, it is then possible to make decisions regarding the optimal calibration interval and the quality of the instruments with respect to measurement performance. The ‘History Trend’ window enables users to view key figures of several calibration events simultaneously, allowing for evaluation of the calibrations of a position or a device for a longer time period compared to the normal calibration result view. For example, the user can

ISO 9001:2008 quality management requirements ISO 9001:2008 states that an organisation shall determine the monitoring and measurement to be undertaken and the devices needed to provide evidence of conformity of product to determined requirements. The organisation shall establish processes to ensure that monitoring and measurement can be carried out and are carried out in a manner that is consistent with the monitoring and measurement requirements. Where necessary to ensure valid results, measuring equipment shall: a) Be calibrated or verified at specified intervals, or prior to use, against measurement standards traceable to international or national measurement standards; where no such standards exist, the basis used for calibration or verification shall be recorded; b) Be adjusted or re-adjusted as necessary;

November 2014

c) Be identified to enable the calibration status to be determined; d) Be safeguarded from adjustments that would invalidate the measurement result; e) Be protected from damage and deterioration during handling, maintenance and storage. In addition, the organisation shall assess and record the validity of the previous measuring results when the equipment is found not to conform to requirements. The organisation shall take appropriate action on the equipment and any product affected. Records of the results of calibration and verification shall be maintained. When used in the monitoring and measurement of specified requirements, the ability of computer software to satisfy the intended application shall be confirmed. This shall be undertaken prior to initial use and reconfirmed as necessary.

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History trend user interface.

get an overview of how a particular device drifts between calibrations and also whether the drift increases with time. The engineer can also analyse how different devices are suited for use in a particular area of the plant or process. Reporting is straightforward and the reports can be tailored to suit individual needs, using the ‘Report Design’ tool option. Calibration frequency can be decreased if the instrument has performed to specification and the drift has been insignificant compared to its specified tolerance, or if the instrument is deemed to be non-critical or in a low priority location. Calibration frequency should be increased if the sensor has drifted outside of its specified tolerances during a given time period or if the sensor is located in a critical process or area of the plant and has drifted significantly compared to its specified tolerance over a given time period. Other reasons for increasing calibration frequency include when measuring a sensor that is located in an area of the plant that has high economic importance for the plant; where costly production downtime may occur as a result of a ‘faulty’ sensor; or where a false measurement from a sensor could lead to inferior quality batches or a safety issue. Beamex has produced a Calibration Whitepaper, which explores this subject in more depth. This can be downloaded from the Whitepaper section of www.controlengeurope.com Control Engineering Europe

visibly. better.

The control room of the future —today. The Experion® Orion Console increases operator effectiveness over a greater scope of responsibility. Large ultra-high definition screens allow flexible display layouts for at-a-glance assessment. Operate closer to the optimum with operating limits and targets directly integrated into overview displays. Capabilities include touchpad use, pan and zoom, advanced alarm management and context-specific views. Our advanced display technology combined with operator comfort and reduced fatigue increases situational awareness for faster response to changing conditions. Honeywell leads the way in utilizing process knowledge.

www.honeywellprocess.com

EDITOR’S EDITOR S CHOICE

3D scanner for continuous solids measurement Emerson Process Management has introduced the Rosemount 5708 Series of 3D solids scanners for the continuous measurement of level, volume and mass of bulk solids and powders in large vessels, bins and silos. The scanners use acoustic measurement and 3D mapping technologies to provide accurate and reliable results, even when measuring uneven or sloping surfaces under dusty conditions. Rosemount 5708 Series 3D solids scanners are said to provide accurate measurements of stored contents for improved process and inventory control. Unlike laserbased technologies that can take several hours to take measurements and require the process to be shut down, Rosemount 3D Solids Scanners provide continuous volume measurem measurements that are represen ntative of the material’ss surface. They can measure practically any kiind of material, including difficultto-measure fly ash and materials m with a low dielectric d that would d challenge other technologies. The selff-cleaning design n requires low maintenance m even when used in dusty environments. The sccanners can mea asure solids in siloss, large open binss, bulk solid storrage rooms, sto ockpiles and wa arehouses.

November N b 2014

Wireless temperature and humidity monitoring solution Monitoring temperature and humidity is important in many applications. However, too often, this vital data is manually collected at infrequent intervals which is not a suitable solution in situations that rely on stable temperature management to ensure product consistency. Traditionally, there have been two methods available for monitoring irregular fluctuations in temperature and humidity – data loggers and data monitoring systems. Data loggers offer a simple solution but, because the data needs to be acquired manually, this technique does not always inform users of temperature fluctuations. The alternative, data monitoring systems can be complex and time consuming to install. Testo has introduced a cloud-based wireless temperature and humidity monitoring solution which offers an automated, continuous monitoring solution. The Saveris 2 allows users to keep track of temperature and humidity levels remotely, without the need for software. The use of cloud-based technology stores data remotely, yet enables access to this data from anywhere, whenever it is needed. If temperature or humidity levels fluctuate beyond acceptable levels an alert can be sent by SMS and e-mail to responsible parties’ responsible, allowing appropriate action to be taken in a timely manner. The measurement values are automatically and securely transmitted to the Cloud via wireless LAN, so manual

readout of the wifi data logger is not required, eliminating recording errors. Data is accessed simply by logging on to the secure cloud location which requires only a standard internet browser – so can be accessed via a PC or smart mobile equipment. If monitoring on site, Saveris 2 can scan the logger’s built-in individual QR code, which will take the user to the individual logger’s secure cloud page. Using its experience with temperature logging, Testo was aware that many of its customers’ businesses expand and change over the life of a product. So the Saveris 2 system has been designed with flexible expansion capabilities allowing customers to start with a simple setup which can be added to over time, making it easy for the system to grow as requirements change. There are five different temperature and humidity probes available in the Saveris 2 range and there are three licensing models for the use of the Cloud service. The devices are available with sensors that are either integrated into the monitoring device or are external so can be positioned remotely to the monitoring device. There are a variety of sensing probes available for the system to allow it to be employed in a wide range of application scenarios.

There are models to deliver either level data only or both level and volume data using intuitive monitoring software. The scanner maps the uneven surface typically found in solids applications and can provide the minimum and maximum

level, the total volume and a 3D visualisation of the surface. The Rosemount 5708 series includes level scanners for silos up to 5m diameter and 70m height, and there is also a version for larger vessels and silos up to 12m diameter and 70m height.

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Control Engineering Europe

“ Key to our success was Mitsubishi Electric’s advanced drive systems that provided reliability, ﬂexibility and speed.”

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In developing its end-of-line solutions to meet the latest market needs, Packaging Del Sur chose Mitsubishi Electric motion control technology. The iQ Platform incorporates PLC, motion and robot CPU’s on one single controller platform for seamless connectivity. The iQ Platform also connects to higher business systems such as SAP for an integrated solution unique in the industry. Also to reduce positioning and cycle times, Mitsubishi Electric’s latest range of MR-J4 servo drives were used to meet the production demands of Packaging Del Sur’s customers. For the full facts on our range of Packaging Solutions visit eu3a.mitsubishielectric.com

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Significantly increasing productivity Smart and intuitive – electric automation solutions in the 21st century…

utomation technology in the 21st century offers perfection n speed, precision and quality – and is smart and intuitive too. “In addition to pneumatic automation technology, applications with electric automation technology, and all those featuring customer-specific combinations of the two technologies, are bringing automation of the future into new dimensions of productivity,” explains Dr Ansgar Kriwet, member of the management board, sales at Festo AG.

Enablers of productivity Even today, Festo offers networked and intelligent components and system solutions which make it an enabler of productivity, whether for electronics and small parts assembly in Finland; the packaging industry in Italy; special machine construction in Switzerland or in many other completely different global industry sectors which are dependent on high speed, precision, and quality. In addition to pneumatics, Festo is also continuously expanding its portfolio of electric axes, motors and controllers. Software allows electric actuators to be configured quickly and easily. Festo’s automation platform CPX provides a simple means of networking several levels of the automation pyramid.

Depending on the specific application requirements, the entire drive technology spectrum, incorporating both pneumatic and servo-pneumatic cylinders, is available with a choice of toothed belts, spindles, recirculating ball bearing guides and linear motor axes available in the case of electric drives. “Everything comes from a single source and is perfectly coordinated. This means there are no interface problems,” explains Kriwet.

This ready-to-install system allows fast positioning at speeds of up to 500 mm/ sec and repetition accuracies of the order of ±0.05 mm. This makes the compact H-gantry ideal for applications in electronics production and small parts assembly.

Ready-to-install robotics

Quick commissioning

In recent years, Festo has surprised the automation market with groundbreaking ready-to-install innovations for handling and assembly operations based on electric drive technology. This includes the delta robot EXPT, the high-speed H-gantry EXCH, the high-speed T-gantry EXCT and the mini H-gantry EXCM. A common feature of all of Festo’s ready-to-install handling solutions is their highly dynamic operation thanks to low moving masses, and the fact that the solutions are built using standard Festo components. H-gantry EXCM can save users a lot of work in electronics manufacturing. Precise and fast positioning in cramped installation conditions, the H-gantry EXCM makes this possible in a simple way. The H-gantry EXCM is a compact planar surface gantry which can approach any position within its working space. In its smallest version, its working area is not longer than a sheet of DIN A4 paper. The recirculating toothed belt moves the slide within a two-dimensional area. The fixed motors are

The pre-parameterised drive and controller package gives users the security of knowing that they can concentrate on their own core competences without having to concern themselves with the details of automation technology. Festo is therefore able to save users a great deal of additional work. The flexible interface concept provides users with a choice of Ethernet, CANopen and I/Os for up to 64 positions. The scope of delivery includes all design data and circuit diagrams and a comprehensive functional guarantee. With a single part number, users can obtain not only hardware in the form of a ready-to-install module or subsystem but also a complete value creation package.

The compact gantry EXCM efficiently approaches all positions in its working space and uses every available millimetre of space. The parallel kinematic drive concept ensures low moving masses. (Photo: Festo AG & Co. KG)

November 2014

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connected to the slide and thanks to the parallel-kinematic drive principle the moving masses remain low.

Fast positioning

Electromechanics at its best The continuous expansion of the product range from pneumatics to over 5,000 electric drive components ensures that customers across the globe have access to solutions for a wide spectrum of applications, ranging from small parts weighing just a few grams to large, heavy components weighing 100 kg. Whatever customers are producing – from microchips to toothbrushes, heavy cast parts or bulky cardboard boxes – everything is possible with the mechatronic motion solution kits from Festo. Control Engineering Europe

The future today: CPX Integrated automation for the 21st century: the electrical terminal CPX. For maximum PRGXODULW\ DQG Ä&#x2020;H[LELOLW\ ZLWK UHPRWH , 2V $QG for motion control or pneumatics par excellence. 0RUH LQIRUPDWLRQ ZZZ IHVWR FRP FS[ LD

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INDUSTRIAL NETWORKS

FDI and FDT: working together

for limitless integration Glenn Schulz, managing director of the FDT Group, recently spoke about the emerging FDI standard and explained how it will sit comfortably alongside the existing FDT standard. Suzanne Gilll reports.

because they need to seek out the right EDDL file for the network onto which they want to deploy a new device. One of the major requirements of the FDI standard which has been developed by the FDI Cooperation,* DI (Field Device Integration) was therefore to harmonise the to specify device behaviour and is an emerging standard EDDL language so that each of the device characterisation. However, automation foundations are able to that in the near future will the different EDDL-based networks start to gain prominence have each developed a very unique use exactly the same language, with some allowance for the uniqueness of in industry. It was created dialogue, to the point where they are each of the networks. to offer greater compatibility of not compatible. “This means that when an EDDL-based (Electronic Device “The release of the FDI standard will result in the creation of a single, Description Language) networks instrument manufacturer goes to such as HART, Foundation Fieldbus, common, interpreter for all the market with a new instrument, if they are releasing it on multiple different EDDL files across the EDDLProfibus & Profinet, and will allow buses, they will need to go through based networks. This will significant these networks to be more easily integrated with each other. Via a completely different certification simplify the architecture from a host existing FDT technology FDI will processes – with a different EDDL file perspective and should dramatically for each – even though the device improve interoperability going also allow EDDL-based systems to forward,” said Schulz. is the same for each one of the be integrated into a host of other industrial networks. networks.” The FDI standard will also add Glenn Schulz explained the improved graphics capabilities for EDDL harmonisation device configuration. “EDDL has reasoning behind the creation The different flavours of EDDL has been somewhat limited in terms of FDI. “On the surface, EDDL also posed problems for end-users of what it can do graphically,” appears to be a common language continued Schulz. “You can add graphics, but they are not highly interactive, and you do Device Definition (Def) Programmed User Interface not get a rich, graphical user Business logic (BL) Device Applications interface feeling. FDI, however, User Interface (UID) will bring this capability to EDDL.” FDI will bundle these Manuals Device Package Certificates capabilities into a device Protocol specific package that will incorporate AttachEDD UIP Files (GSD(ML), a collection of files – including Def BL UID Ments (optional) etc.) (optional) the device description, the FDI encoded file format device definition, business logic and a user interface description. Electronic Device Windows So, FDI-enabled devices will Description Presentation only require the matching FDI Language Foundation device package that holds all (EDDL) (WPF) the information and software needed to configure that FDI Device Package. device.

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> p18

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November 2014

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FDI DTM DTM UI UID Renderer

UIP Hosting

DTM Business Logic Information Modul

EDD Engine

FDT Frame Application

“One of the key considerations FDI-FDT interoperability. in the development of FDI was that, from the ground up, it was designed to be compatible with the FDT standard – and to avoid Device Package even more competing industry standards!” UIP AttachEDDL ments Import So, FDI is designed to support Optional EDDL-based standards. However, there are many other networks being used in industry today that need to be integrated, in order to build a complete solution. A method was needed to bring them all together, to create scalable solutions. This is where the FDT standard comes into play, with its ability to standardise the communication and will be created. Inside this FDI DTM configuration interface between all field devices and host systems. will be the common EDDL interpretor, The FDT technology provides a which is needed for the FDI standard, common environment for accessing as well as the other components that features of a device via a DTM (Device support the FDI standard. Type Manager. A DTM, which is “With an FDI DTM solution all the FDI functions will be fully enabled supplied by the device vendor, is a software representation of the device within FDT with no limitations. All and it can offer a host of functions. It FDT DTM features are also fully can assist with device configuration enabled, making it possible to take and diagnostics, it might be able DTMs for devices on any of the to handle troubleshooting and will industrial networks or fieldbuses also include a device manual. The and use them within this integrated network communication devices are solution.” also represented by a DTM making Earlier this year at the Hannover the standard highly flexible for the Fair, CodeWrights, an FDT Group end user. member, was able to demonstrate how FDI packages, inside an FDI “Although the FDT standard and the FDI standard share many DTM are able to communicate with similarities, they are not the same,” different devices, showing how far said Schulz. “An FDI host, for the technology has now come. example, is not able to support DTMs. As field devices gain ever more It can only support EDDL-based intelligence, they can provide networks. This is why we talk about huge amounts of data, which, if integrating FDI into FDT.” turned into useful information can offer big benefits. The creation Integrating FDI into FDT of a standardised way to describe Explaining further about how FDI will automation components and to be integrated into an FDT-based host, communicate with them is therefore becoming increasingly important. Schulz explained that any number Without it, the true potential of of DTMs can be loaded into the FDT decentralisation, transparency, host, which is able to talk to any integration and a central view of all number of industry networks. “When FDI-based devices do start to appear data and functions cannot be fully realised. a special DTM – called an FDI DTM –

Communication DTMs

Nested Communication

* FDI has been developed by a group of industrial technology foundations and suppliers of process control systems and field instrumentation. Its specification is based on close cooperation with end users and end user organisations, and the requirements of NAMUR and WIB, the process automation users’ association, have been included in its specification, enabling it to offer an intelligent migration strategy from the past to the future using state-of-the-art and best-of-breed technologies. FDI Cooperation members include five major automation foundations - FDT Group, Fieldbus Foundation, HART Communications Foundation, PROFIBUS & PROFINET International, and the OPC Foundation. Major automation vendors supporting the organization include ABB, Endress+Hauser, Emerson Process Management, Honeywell, Siemens, Yokogawa and Invensys (now part of Schneider Electric). A whitepaper, produced by FDI Cooperation LLP provides an in-depth look at FDI technology. This can be dowlloaded now from the whitepaper section at www.controlengeurope.com Control Engineering Europe

leap forward

LEAP™— A New Paradigm for Automation Project Lean Execution. LEAP™ challenges the traditional way projects have been implemented implemented. It enhances our project services with our three most innovative, enabling technologies to revolutionize project execution — Universal Channel Technology, Virtualization, and Cloud Engineering. Lean execution already entails removing waste on projects—including redundant tasks and rework. LEAP takes a further step by removing the traditional dependencies that used to force project ﬂows to be sequential in nature, drastically improving the overall project schedule—keeping automation systems off the critical path. LEAP separates physical from functional design, allows parallel workﬂows, uses standardized designs, and enables engineering to be done from anywhere in the world. Reach up to 30% CAPEX savings. Take one giant LEAP forward.

INTERNET OF THINGS

INTERNET OF THINGS – finding security in the cloud What is the best tool for implementing security and locking down our devices? The answer is the cloud, says Donald Schleede, information security engineer at Digi International. The cloud does not have to be insecure or expensive; centralised data collection and management is the key to securing Internet of Things devices.

he cloud has the potential to help, more than hurt, cyber security for connected devices, the Internet of things (IoT). With all of the talk about the security – or insecurity – of the IoT, there is one thing we can agree on: security is both complex and critical. In the next five years, the Internet will become a larger global connection of computers, as well as an interconnection of everyday devices collecting data on their surroundings. With over 20 billion connected devices estimated in use by 2020, information and data will become ubiquitous, and our future applications will easily gather data from any source. What is the best tool for implementing security and locking down our devices? It is the cloud. Some suggest the cloud is insecure and expensive, but both of those accusations are untrue. In fact, centralised data collection and management is the key to securing IoT devices.

Centralised management When a company or individual is trying to manage thousands of devices independently, it is not going to be easy. One strategy for monitoring and securing connected devices is to centralise them; a central repository provides the ability to see how all

November 2014

This diagram shows the IoT device control channel flow. In this model, IoT devices report to a cloud service. Since the connection flow is from the device to the cloud, there is minimal need for device management services to be running on the device exposed to the public. Many of the security functions now shift to the cloud instantly, where traditional security solutions can be leveraged to provide a secure solution to the IoT device in the field. Image courtesy: Digi International.

devices are working, and allows a successful shift of security intelligence from each field or device into the cloud. While the cloud may be an aggregated layer, it also delivers greater intelligence. Rather than the cloud being a tempting target for hackers, it is very secure and can protect itself against attacks. The cloud delivers continuous monitoring of all devices and the capability to turn off web services with a click of a button so that the devices are no longer listening to the Internet – thereby mitigating risk. By shifting

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security from individual purpose-built devices to the cloud, you actually have more controls and functions over each individual device. The cloud also is costeffective; by deploying the right tools to predict malicious activities and identify patterns, security increases while cost decreases as individual devices can only do so little without driving huge costs. Many devices working together in the cloud is ‘smart.’ For example, with the Heartbleed vulnerability, devices using OpenSSL were at risk. However, those devices running from a device cloud allowed you to turn off your web services and immediately disable your devices from listening on the Internet – therefore, the device was not exposed to the threat. This process is very similar to what happens in an IT server room: When an attack on a computer or network server is exposed, there are tools that allow IT personnel to quickly combat the attack. In a cloud environment aggregating data, it is possible to look for the same warning signs and respond just as if it were a server. By connecting devices to the cloud, specialised protection is easy, accessible, and behind the scenes. Secure password protection: You should have one centrally managed password to best protect your devices. By using one central password, tools, auditability, and security are much more effectively managed in the cloud, which drives home the concept of identity. If someone gains access to the account, you are notified immediately and can lock down all devices. Go online – www.controleng.com/ archivess in August has more information with the online version of this article. Control Engineering Europe

UK INDUSTRY REPORTS

UK’s first digital factory demonstrator The UK’s first digital factory demonstrator has been installed at the Manufacturing Technology Centre (MTC) in Coventry. It has been designed to showcase how a ‘fourth industrial revolution’ could shape the future of British manufacturing. It features a virtual 3D factory alongside a physical production line capable demonstrating mass customisation of consumer goods. Siemens, the Electronic Systems Community (ESCO), automation trade association GAMBICA, HP, Shadow Robotics and Ubisense are among the organisations that have contributed to the project. The immersive, 3D virtual reality environment allows users to interact with a ‘living lab’, which has been modelled from an existing real-world machine. The machine mimics a continuous production environment and allows universities, manufacturers and key stakeholders to innovate production processes using the latest technologies

that help improve productivity, quality and energy efficiency. Commenting on the project, Brian Holliday, managing director of Siemens’ Industrial activities in the UK and Ireland said: “The UK must invest in digital and smart factories, not least because the concept of Industry 4.0 plays to our strengths and tackles many of the complex production and consumption challenges we face today. By investing in these technologies, UK factories stand to achieve up to 30% improvement in productivity, which could in turn aid accelerated economic rebalancing. “We are calling for the establishment of a living lab in the UK and believe this will have a tangible impact on job creation – specifically addressing the UK skills shortage, as well as improving manufacturing’s share of UK GDP. “We plan to engage with the Manufacturing Advisory Service to develop an Industry 4.0 work stream - which should be reinforced with a oneoff £3m funding boost to develop tool

kits for manufacturers wanting to invest. Ultimately, we support the suggestion of a Joint Technology Initiative with Germany and the EU for the funding of a pan-European industry research project into Industry 4.0.” Clive Hickman, CEO of the MTC said: “We are proud to be at the centre of the UK’s first digital factory demonstrator and it is absolutely vital that industry and Government partner together to build on the Foresight report which set out a road map for the future of manufacturing. In order for that to happen we must invest in technology and encourage its uptake throughout the supply chain. By doing this we can be at the forefront of the ‘great technology race’ - which in turn will result in greater inward investment for UK PLC.”

Sonepar enters the UK with Routeco

Skills shortage affecting productivity

Sonepar, a global electrical distribution company with operations in 40 countries, has entered into an agreement to purchase the shares of Routeco Group Holdings Ltd. The transaction, which is subject to approval from competition authorities in Austria, is expected to close during the fourth quarter of 2014. Routeco is a distributor of industrial control and automation products and services in the UK and has been a Rockwell Automation authorised distributor since 1992. The company has 13 branches across the UK and also has operations in Austria and in the Netherlands. This acquisition underlines the

A survey undertaken by Festo Training and Consulting identified that skills shortages are having a direct effect on productivity within the manufacturing and engineering sector. Skills shortages have affected productivity, according to 61% of respondents, with 25% saying that it is a frequent occurrence. Some respondents cited restricted growth due to recruitment slowdown, poor efficiencies and excessive downtime due to lack of fault-finding skills. The skills shortage within this sector shows little sign of abating, with 82% of companies suffering a skills shortage and 86% saying this is likely to stay the same or get worse.

Control Engineering UK

ongoing efforts of Sonepar to strengthen its position with entries into new countries as well as into the industrial automation sector. Routeco will continue to operate as a separate business unit within Sonepar Northern Europe. Ian Stewart (CEO) and the existing management team will remain in charge and the company will continue to work closely with Rockwell Automation and will be supported by Sonepar to improve the value proposition to its customers base, through providing support in offering more complementary lines, supply chain services and e-commerce capabilities.

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November 2014

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UK INDUSTRY REPORTS

App turns a smart phone into a measurement tool T Connect app is The available free of charge a ffrom Fluke to turn a sm mart phone into a useful meassurement tool. The app a allows the user to securely sh hare images and data and to communicate in real time with other authorised personnel using the same app, without leaving the field. Measurement data can be entered manually. Work orders can be scheduled from a remote location and data can be stored safely and free in the Fluke Cloud. The app features ‘ShareLive’ video call, which allows users to securely connect and collaborate with other

team members allowing them to see what the technician can see, which can speed up work approvals at remote locations. When used in conjunction with Fluke Connect enabled test tools, the app can wirelessly capture measurement data from those tools, allowing technicians to then utilise all of its functionality. More than 20 Fluke tools can connect with the app, including digital multimeters, thermal imagers, insulation testers, process meters, and specific voltage, current and temperature meters. The Fluke Connect app can be downloaded from the Apple App Store and the Google Play Store.

Research funding to reduce cyberattack threats to critical infrastructure New research, co-funded by the Engineering and Physical Sciences Research Council (EPSRC), will focus on the cyber-security of the UK’s vital industrial control systems such as manufacturing plants, power stations, the electricity grid, and the rail network. The research will look at understanding and mitigating threats from hackers or malware infiltrating the systems behind critical national infrastructure. The Research Institute in Trustworthy Industrial Control Systems (RITICS), based at Imperial College London, will be co-ordinating the research with new projects being launched at Queen’s University of Belfast, the University of Birmingham, City University London and Lancaster University. Investment for this research comes from the EPSRC and the UK’s National Cyber Security Programme. The Centre for the Protection of National Infrastructure (CPNI) and GCHQ are

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actively supporting the research. Research teams will work alongside industry partners to understand and analyse the risks from cyber-attack, examine how risk is communicated to business and provide effective interventions to counter risks. Metrics and software tools will be produced so that non-technical decision makers are able assess cyber-security in the context of their business. Professor Chris Hankin, from the RITICS at Imperial College London, said: “Where control systems are linked to the internet we need to understand how failures could cascade across the system. We will be looking at new ways of repairing damage to systems if an attack happens. We need to address how to approach network maintenance for industrial control systems, particularly as most systems operate on a 24/7 basis. So we will be looking at ensuring better protection without compromising performance.”

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Nanotechnology and big data – the next industrial revolution? A report commissioned by the Lloyd’s Register Foundation looks the potential implications of nanotechnology on the safety and performance of engineering assets and the infrastructure on which modern society relies on. It concludes that nanotechnology will have a far reaching impact on almost every industry including energy, transportation, manufacturing, medical, computing and telecommunications. The report identified five key areas of impact: Miniaturisation of sensor technology: Embedded nano-sensors in structural materials such as concrete, or ‘living’ inside engines, providing feedback on corrosion or stresses, will give continuous readout of real-time structural and systems performance data. This technology will also enhance robotics and un-manned vehicles across the transport sector (UAVs). Big data: Not so much a development but an implication of ubiquitous sensing is the massive increase in data being collected, with major implications concerning assurance about quality, security and traceability. Engineered smart materials: The development of new engineering materials and manufacturing techniques, using lighter, stronger materials with designer properties could see, for example, ships being glued together from lightweight composites. Parallel developments in 3D printing will also enable printing of metals. Energy storage: Small compact batteries with massive storage capacity combined with the ability to harvest energy from their environment could deliver profoundly different transportation systems or enable white goods to be powered for life at point of purchase. Nanoparticles: The report also highlighted the need for research into methods for assessing the safety, quality assurance and traceability of nanoparticles in the supply chain. Control Engineering UK

UK INDUSTRY REPORTS

HART and Foundation organisations to merge as the FieldComm Group The members of HART Communication Foundation and Fieldbus Foundation have approved a merger, proposed by their respective boards through a voting process that concluded on 30 August. This will result in the creation of a single organisation to lead both process automation communications and integration technologies. The new corporation, called FieldComm Group, will be led by a board of directors composed of representatives of the collective companies’ from the current boards of each Foundation. Hans-Georg Kumpfmueller has been elected as the inaugural chairman of the Board. He will lead the direction of the FieldComm Group and oversee the addition of FDI LLC in mid-2015. Kumpfmueller has served as a leader in setting the course of device integration in his role as Chairman of the FDI LLC board and as CEO of Sensors and Communication at Siemens. He is convinced that the formation of FieldComm Group is “a major step forward for the process industries… leveraging the strengths of each industry-leading protocol and adding the value of the next generation integration strategy.” The board has appointed Ted Masters as president and CEO of FieldComm Group. Masters brings instrumentation and controls experience to bear in addition to a deep understanding of the use of data analytics in enterprise systems. He said: “The creation of FieldComm Group is an unprecedented opportunity to build upon existing technologies and develop a single future vision toward harmonisation of standards for the process automation industry worldwide. I am excited about the opportunity to work together with distinguished leaders and technologies around the globe to integrate valuable process intelligence from devices to improve the operations of our users.” FieldComm Group will consolidate offices in Austin Texas, and is expected to function as a single entity from 1 January 2015.

Control Engineering UK

November 2014

www.mac-solutions.net/atvise

UK technical distributor M.A.C Solutions (UK) Ltd

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Units 6-7 Kingfisher Business Park, Arthur Street, Redditch Worcestershire, B98 8LG. www.mac-solutions.net

ROBOTICS

Robots eat their way into the food sector To date there have been few applications that have employed robots in the food processing industry. Chris Evans, of Mitsubishi Electric, believes that this is now changing and predicts that in five years time they will be considered very much the norm.

odern food processing industries were born out of the gradual industrialisation of traditional techniques, with automation being adopted as equipment became available. A generation ago, a food processing plant would consist of conveyors bringing ingredients to manual or mechanised workstations. Over the years the equipment improved and the arrival of automation, particularly PLCs, led to the integration of separate workstations into continuous processes. As computing power increased, the automated processes were optimised for lean manufacturing and constantly improving productivity. The dominant trend in the food sector over the past five years has been a drive to reduce costs. Raw material prices have risen while consumers’ spending power has declined. However, other trends, such as the need to reduce carbon emissions, improved hygiene requirements and the development of new processes and products, have also have continued. Food processing industries innovate in both products and processes as a matter of course, with around £1billion being spent every year on research and development, as the sector strives to meet the end-customers’ expectation of product quality, variety and availability.

Meeting consumer demands Meeting increasing consumer demands

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requires agile product changeovers and rapid product redesigns. From an engineering point of view, the needs are to reduce costs and waste and increase yields, improve ingredient handling and maximise plant usage. For many years food processors have embraced a constant drive for improvements in production processes and productivity. They have already embraced automation and increasingly are now adopting robots. Until recently, however, food engineers have been wary of robots. They have been considered to be expensive, complicated, unreliable and unable to provide the sort of flexibility that a team of people can achieve, in terms of learning new tasks, switching between tasks and being prepared to work irregular hours. More recently, robots began to appear in the packaging section. This was a proving ground and it was soon seen that few if any of the assumed problems were reality. Confidence in robots started to grow and now they are increasingly spreading across the whole plant.

Attributes Food processors now realise that robots have many attributes that are particularly well suited to their industries. They are flexible and can hold multiple programs in their memory, so are able to easily switch from one job to another. They do not tire or slow down, or do unexpected things that

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could compromise safety, or breathe over foodstuffs. They also do not need comfort breaks. They can work through the night or other long hours. They are completely consistent in their movements, thus ensuring product quality and their own safety in a way that human operators cannot. Robots, when coupled with advances in gripper technology, can now also have a very delicate touch, helping to reduce the risk of product damage. Mitsubishi Electric has recently introduced a new family of robots – the F-Series – which is aimed at the food and other hygienic industry sectors. These robots are designed to meet IP67, allowing easy cleaning of the arm, while food safe HG1 food grade grease is used for lubrication. A clean room version is also available for ultra-hygienic requirements. Typically, robots cost around £5 per hour to operate which is half the cost of a human. Because they can run continuously, they are also highly productive and generally offer a return on investment of around 18 months. Companies that invest in robots will be securing their long-term future far better than those that choose to subcontract out work. Control Engineering UK

Remove your production headaches The MELFA F-Series industrial robots from Mitsubishi Electric are designed to be fast, flexible, functional and food production safe. MELFA robots cover a wide ranging portfolio from 4-axis SCARA arms, 6-axis vertical arms to an innovatively designed ceiling mounted SCARA. The MELFA F-Series robots can be integrated into Mitsubishi Electricâ&#x20AC;&#x2122;s unique iQ Platform, providing a complete automation solution by placing the robot controller onto the PLC rack and controlling it from a HMI. This enables the HMI to function like a teach box. A single software tool is used to configure, program and maintain the system.

For more information on our robot solutions call: 01707 288 780 email: automation@meuk.mee.com or visit: gb3a.mitsubishielectric.com

ROBOTICS

Ensuring workforce safety around robots Darren Whittall, technical manager at FANUC UK, explains why worker safety should be a top priority in all robotic applications and offers advice on the steps that should be taken to avoid robot-related accidents when humans are sharing the same workspace.

nsuring worker safety around robots is a moral issue that should be a key consideration in all robot automation projects. There are some key differences in the safety requirements for conventional automation solutions and robotic applications. Robots can produce powerful and rapid movements through a large operational space. The path of a robot

and/or its arm can be difficult for a human to predict. Important safety considerations should include: Scope out all potential hazards – Safety risks will vary depending on the chosen robot and application. Start with a welldocumented risk assessment. It is worth noting that most robot-related accidents occur during non-routine operating conditions, e.g. operators entering the

cell for programming, maintenance, testing, setup, or adjustment tasks. Revisit the regulations – The Health and Safety Executive (HSE) offers industrial robot safety guidance in the HSG43, Industrial Robot Safety publication. International standards are set out in EN ISO 10218 – Part 1 Robots and robotic devices – Safety requirements for industrial robots, while EN ISO 10218 Part 2 goes into more detail about robot systems and integration. Use simulation software to plan out and test robotic concepts – As well as flagging potential new-build issues, simulation software can model all of the variable robotic movements, obstacles and potential collision scenarios, in a 3D virtual world, helping to make the application safer when it comes on line. Introduce safeguards – Seek expert guidance when building a safety related control system (SRCS) early in the design phase, as there are many different concepts to consider, including whether your SRCS should be a dedicated

Robot palletising system increases operational efficiency Barry Callebaut, a manufacturer of cocoa and chocolate products, has succeeded in increasing operational efficiency through the installation of a robotic palletising system at its Banbury plant. Following the initiation of a major investment programme and in line with a ‘cost leadership’ strategy, developed to run across all areas of the manufacturing process, the company wanted to achieve an increase in capacity and optimise production flow. To further improve efficiencies, a three-phase investment over two years was also planned for the palletising area with the implementation of a fully integrated robotic solution to an existing line. The new system was required to provide greater flexibility and reliability, utilise limited floor area, simplify operational procedures and reduce maintenance costs. In addition, it would have to overcome the challenges of

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picking up multiple sizes of boxes (between 10kg and 25kg), increased cycle rates and be fully compliant with the company’s stringent health and safety disciplines. Barry Callebaut commissioned CKF Systems as its project partner to design, build and install an integrated robotic palletising system within its manufacturing plant. Explaining why, Barnz Parkin, project management engineer at Barry Callebaut, said: “We were impressed by work CKF had recently undertaken for a major confectionary brand. We spoke to the project manager there and he provided a sound endorsement. “We looked at nine different organisations, but only CKF demonstrated a complete understanding of

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our situation and submitted a working solution that would improve our capabilities in line with budget and expectations. It was a major undertaking for the business and therefore essential that we made the right decision.” The initial project is designed around a single robot cell but with the ability to palletise three different SKU’s at the

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ROBOTICS

system or integrated within your robot controller or robot safety software. Provide employees with clear instructions – Reduce the risks of incidents by ensuring your employees receive regular operator training and are issued with appropriate personal protective equipment (PPE). Consider the cost benefit and effectiveness of software-enabled technology – Commonplace in the automotive sector, having less hardware means that safety can be integrated more cost-effectively – up to 50% cost-

reduction is possible for a small single robot with multiple safety devices. FANUC’s latest DCS software can monitor the robot’s position and speed. The removal of limit and zone switches also makes work cell configurations tighter and simpler. Create adaptive zones – It is now possible to programme, enable and disable the zone that the robot can or cannot enter, depending on the task in-hand. This feature, available through DCS Position Check, is especially useful for compact cell configurations.

Define maximum robot speed – This can be done during normal operation or adjusted to a defined event, enabling an operator to work safely within the proximity of the robot. FANUC’s DCS Speed Check monitors the speed of the robot, ensuring the whole robot, including the end-effector, remains motionless when required. Compliance with machine safety standards – Check whether your system meets the PL (performance level) safety standards specified in BS EN ISO 13849-1. As a benchmark, FANUC’s DCS Position and Speed Check functions are certified to PL d and Safe IO Connect to PL e. Stay on top of your safety requirements – In today’s fast-paced manufacturing environments, robotic work cells and plant layouts evolve quickly. It means constantly revisiting and modifying your safety considerations. With software being more flexible and simpler to upgrade and integrate, this is when a softwarebased robot comes into its own.

same time. The cell, incorporating an ABB IRB 660 with a bespoke gripper, has been designed by CKF. It utilises 3D Inventor and Robot Studio simulation to ensure the full range of case sizes, weights and configurations can be handled and are able to pick layer sheets. The case feed system comprises a high level interface, complete with divert station and bar code detection to direct the flow of designated cases to the robot cell and separate them into three defined collation stations. Each station incorporates an identical conditioning section to orientate and collate the cases into defined rows and counts for the robot pick to create the pallet pattern. A dedicated pallet load station is positioned at the end of each collation station and the cell also includes two separate layer sheet feed sections to handle both Chep and Euro pallet sized sheets. The overall system includes two dedicated pallet denesters – Chep and Euro, loaded pallet discharge station

and twin shuttle car. The shuttle car arrangement is designed to receive individual pallets, on demand, from the designated denester and deliver to the relevant pallet load station at the start of production. The shuttle is also designed to receive and exchange both loaded and empty pallets, with the loaded pallets delivered to the unload station before the car returns to the denester stations to collect the next pallet. The final configuration of the system includes provision for the introduction of a second robot cell and a fully automatic spiral wrapping machine. The complete operation is fully contained within a guard enclosure incorporating strategically positioned light beams, roller shutter door and interlocks to meet the very highest safety standards with zoned safety areas to maximise overall system efficiency. “We are delighted by the initial results and the mindset shown by CKF,” said Mike Parkins, chief engineer at the site. “We attached great importance to

maintaining scheduled output without disruption and CKF ensured that during installation and commissioning our existing machine continued to pack at all times. There was a close collaboration throughout between CKF’s engineers and our own team, ensuring that when it was necessary to break into the line this was done with minimal disruption.” The project was fully operational within six months of placing the order and significant benefits have been achieved from the investment. Reliability has increased and the capability of the single cell has more than doubled, from 300 to 700 cases per hour. “The new line fits perfectly with our long term capacity-increase model,” concludes Parkins. “It is easy to operate, requires minimal maintenance and reinforces the company’s commitment to improving health and safety. Investment in robotic and automation applications is fundamental to our future, improving efficiencies whilst reducing the environmental impact.”

Control Engineering UK

www.controlengeurope.com

November 2014

UK7

MACHINE VISION

High-speed vision system inspects high technology web A bespoke high-speed vision inspection system has been developed for a manufacturer of high technology web that is fabricated for use in green energy projects.

he system, which was designed, developed and installed Optimal Industrial Automation, uses Cognex VisionPro software to process critical dimensional and physical attributes of the web while the line is running at high speed. The whole 500mm width of the web is inspected to a resolution of 125Âľm while the web is running at 1.5m/sec. Initially, the client investigated the use of a vision inspection system from a standard supplier. However, due to the complexity of the task, no standard product was found to be suitable. Optimal, however, was able to create a bespoke solution. Part of the inspection task was to detect very small surface contaminants, these often being black. On a high contrast surface this should not be an issue, however for this project the target substrate was dark in colour and provided a low contrast, which made the task much more challenging. A further part of the project related to the dimensional verification of key surface details, and these too had to be measured to a high level of accuracy with the web running at high speed. A further complication is that the web has to be inspected on both sides, before another operation is carried out on the product, and it is then inspected a third time. This requires the inspection system to have three inspection stations which means that, with the resolution requirement across

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the whole web, the amount of data that has to be continuously read and then processed in real time is huge.

A three-pronged approach Optimal adopted a three-pronged approach to the project. The first stage involved developing vision inspection techniques that suited the challenging application â&#x20AC;&#x201C; both from a data (image) acquisition point of view and a physical point of view. Various camera systems were tested, from multiple area scan through to individual and multiple line scan systems, but each had their issues. The company had to overcome problems such as camera frame rate, physical space aspects, and how the system would work in combination with the computers that had to process the data. After testing all these types of camera, a state-of-the-art Contact Image Sensor used in combination with Cognex VisionPro software was chosen as the best solution, even though it had to be configured in a specific way. Optimal also had to develop special lighting techniques, which were critical to the success of the project. The third project stage was to develop a high-level software application and networking techniques which are able to handle and process the huge amounts of data in real-time. The data processing requirements of the system were such that multiple computers were required to provide decentralised

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There are four powerful PCs being used in total, with one machine being dedicated to each inspection task and the fourth to carry out user interface functions.

processing; and this necessitated extensive data exchange between all of these machines and the cameras; this having to be in real time. This took a huge amount of development and testing work before the best solution was finalised. After testing and the development of the necessary image processing algorithms it became clear that the computing power demands were going to be much higher than originally anticipated, the computing requirements necessitating the use of four powerful machines with one Control Engineering UK

ENERGY UNDER CONTROL

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. v SP ri A D l3 al H

MACHINE VISION

The system can detect 125µm defects, similar in size to the diameter of a human hair moving at 1.5m per second, across a 0.5m wide web.

being dedicated to each inspection task and another carrying out user interface functions. This computer ‘array’ necessitated the development and testing of various data exchange techniques that would keep up with the system’s real time requirements. Finally, a method was developed that coped with the required speeds and was robust enough to ensure that no data was lost. Optimal designed a test rig that enabled the end product to be tested in real time outside of the production

facility. The whole system was brought together and tested in real time. After extensive testing the system was installed at the client’s plant, where it is now running on a continuous production line. Since installation, which was achieved on time and to budget, the manufacturer has reported no faults in downstream products resulting from defects that the Optimal system is inspecting. The success of this first system has resulted in another order from the same client for a second identical system.

High-resolution 3-chip CMOS cameras Two new Toshiba three-chip CMOS high-resolution cameras are available in the UK from Stemmer Imaging. The IK-HD5 is a progressive-scan full-HD 1080p/1080i video camera that features a removable optical low pass filter for dual-mode imaging applications which allows the camera to be optimised for visible light or nearinfrared radiation. The IK-HD4 is an Ultra High Definition 3840 x 2160p, 50/59.94 Hz camera system, that has been designed to provide extremely sharp detail and rich colour in 4K resolution. With up to 1000 TV lines resolution and a binning mode for a 4x increase in sensitivity, the IK-HD5 can be used for any HD video application as well as near IR imaging for applications such as medical diagnostics using indocyanine green (ICG) and other Control Engineering UK

fluorescing agents. Other applications include surgical microscopy, endoscopy, IR inspection and defence imaging systems. For enhanced NIR applications the removable optical low pass filter provides a switchable output between full-HD video in the visible and near-infrared wavelengths while the 3-chip CMOS sensor gives approximately 3dB increased sensitivity in the NIR. The ultra compact IK-HD4 can be switched between 4K and 1080p/1080i resolution, and offers up to 1600 TV lines resolution. It is ideally suited to applications where colour fidelity and resolution are critical including broadcasting, clinical and defence imaging. Both the IK-HD4 and IK-HD5 feature a C-mount lens mount and remote control via RS 232.

November 2014

UK9

HO A RANGE OF CHOICES A bre ak through in the trade of f between performance, cost, size & mounting versatility. 3 families cover nominal currents from 10 A to 250 A, PCB-through-hole, or multiple panel mounting versions, and offer an aperture or integrated primary conductor. LEM ASIC technology brings Open Loop transducer performance closer to Closed Loop transducers, providing you with better control and increasing the efﬁciency of your system, but at a signiﬁcantly lower price. s Single +5V or +3.3V power supply s Up to 8 mm creepage and clearance + CTI 600 for high insulation s Half the offset & gain drifts of previous generation s Overcurrent detection s Fast response time from 2.5 to 3.5 μs s Over-drivable reference voltage s Fault reporting function s Versatile panel mounting version (3 ways) s -40 to +105°C operation

www.lem.com At the heart of power electronics.

PANEL BUILDING

Space saving power supplies When bdtronic GmbH developed a new concept for its mixing and dispensing machine, the aim was to create a more compact design. Space also needed to be saved in the control cabinet.

dtronic GmbH is a machine builder with many years of experience in process and automation. Its machines and systems are used in many industries - including automotive; electrical and electronics; medical technology; aerospace; and the food and beverage industry. One area that is important for the company is developing and producing modular machines and process solutions for dispensing reactive resins and material preparation, which can be adapted to the specific requirements of the user. Its fully automatic lean dispensing cell, the B5090, offers an efficient system for processing components in batch production with liquid to pastelike reactive resins. A high level of automation ensures an application of consistent quality and high productivity. In the course of reengineering the product, the company’s designers wanted to find a more compact design for the machine.

Posing a challenge This posed a challenge for the technicians from electrical engineering. Due to the machine’s smaller dimension the control cabinet also needed to be smaller. However, identical technical components had to be housed in this limited space which meant that every millimeter mattered. The electronics engineers made the decision to use Murrelektronik’s Emparro power supply units which supply the same amount of power as the units used before. However, with a width of 85mm (the 20 A unit) or 65mm (the 10 A unit)

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they are clearly smaller. Due to their high efficiency (up to 95%), Emparro power supplies generate only a very low heat loss. Therefore, not much safety distance is required. Bdtronic uses the intelligent VDC current monitoring system, MICO Basic, to protect the cables. Four channels that used to be protected with individual circuit breakers are now monitored by just a 35mm wide cabinet component. In the event of overload they are safely switched off in a channel-specific way. Signal contacts that require extra space when circuit breakers are plugged together are already integrated in MICO Basic. In the end there is a total saving in space on the cabinet’s DIN rail of 85mm (total width 185 instead of 270mm). The company has noted other benefits.

The integrated push in terminals require considerably less wiring efforts. Emparro’s high efficiency reduces the energy costs. MICO’s integrated LEDs make sure that the current load of the individual paths can be checked at a glance. This makes it possible to early counteract downtime.

Bringing the human touch to TFT displays TFT modules with integral capacitive touchscreens are now available as a standard product from GTK on TFTs with screen sizes of 3.5in, 4.3in and 7in. The TFT modules are said to be suitable for industrial applications and have wide viewing angles, good contrast and brightness ratios and an operating temperature range of between -20°C to +70°C. Customisation options include a cover lens, and optical bonding to improve readability in bright conditions and sunlight. Clive Dickinson, business manager for optoelectronics at GTK, explains further. “The addition of the capacitive touchscreen to the TFT module essentially brings the technology

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associated with consumer products, such as smartphones and tablets, to industrial products. Users are familiar with the swiping gestures they use on their home devices, and by using this technology on industrial equipment there is less of a learning curve involved which can result in greater productivity and lower error rates. We have already seen a high level of interest in the marketplace for this technology for quite diverse applications, including a VOIP phone screen, security equipment, and an audio console for use in the entertainment industry. The common theme for all of these was for a display which was easy to read, intuitive to use and fast to respond.” Control Engineering UK

INTELLIGENT POWER CONTROL â&#x20AC;&#x201C; MICO Safeguarding machine up-time The power supply is the heart of every control cabinet. Advanced power supply systems have to be protected in a consistent and targeted manner

MICO monitors currents: Select a maximum individual current value for each channel and MICO will monitor this value. When the value is within the appropriate range the LED will be solid green.

MICO indicates when current is approaching the maximum load: When 90% of the selected current load is reached the LED will flash green.

MICO detects overload: In case of short circuits, or if the load current exceeds the selected value, MICO switches off the affected channel and the LED will flash red.

MICO provides flexibility: Every channel can be manually switched on or off by pressing the button. When this happens the LED will be red.

M I CO

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PNEUMATICS

Pneumatic automation solution

for water pumping station Guernsey Water has made the decision to use a pneumatic automation solution for the control of a K finds out more. remote pumping station. CEE UK

uch like the mainland UK, Guernsey has been greatly affected by the forces of nature this year. However, the use of a remotely controlled, pneumatically operated pumping station completed in 2013, has helped one area of the island to escape flooding. The pumping station is part of a network of facilities that forms Guernsey Water’s infrastructure for the catchment, storage and transfer of raw water for the production of the island’s drinking water. Marais Stream pumping station was originally built in 1938 and required an upgrade to allow an increased volume of water to be collected and delivered to the nearby water treatment works with less going to waste. The whole infrastructure was changed apart from an old tank that remained. “There were two reasons for the upgrade, partly its age and partly because the area had, traditionally, suffered from a flooding problem,” explained Andy Benstead, water production manager at Guernsey Water. “The equipment is much bigger, more reliable, easier to control and we can now pump up to 1000 litres every second.” Marais Stream collects the run-off water from the local area and this is fed via the three inlet penstocks through fine screens that remove debris that would damage the pumps in the pumping station. The water is then pumped either into the treatment works or, in the case of heavy rainfall can be diverted and discharged straight into the sea. The pumping station is the first on the Island that could be considered ‘multifunctional’. It incorporates three

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Festo’s CPX remotely operated control system

vital elements. Firstly, raw water is caught and transferred into a reservoir for conversion into drinking water. Secondly, stream water is used to maintain the cleanliness of the screens at a new wastewater treatment centre. Finally, the new pumping station enables excess water to be pumped out to sea, which might otherwise overload the capacity of the Barker’s Quarry Reservoir and lead to localised flooding.

Isolating the flow “Festo supplied three pneumatically operated penstocks, driven by linear actuators, and located in the incoming channel, to isolate the flow,” explained Tony Gillard, business development manager at Festo. “DNC cylinders with rod clamps are used to control the raising and lowering of the penstocks. These distribute the incoming water into the storage basins. From the storage basins, the water is distributed to various parts of the site by butterfly valves operated by pneumatic quarter-turn actuators.” The entire system is run by Festo’s CPX remotely operated control system. The site itself is unmanned, being controlled via a SCADA system from the Guernsey Water Offices five miles

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away. “The CPX platform is a complete automation solution that integrates a choice of pneumatic and electrical, analogue and digital I/O,” Gillard explains. “CPX systems configured for specific requirements are delivered prebuilt, tested and ready for installation, enabling system integrators to meet tight deadlines and budgets. For additional flexibility, the CPX platform can operate as either a self-contained industrial PLC, or as a local unit on a fieldbus or industrial Ethernet-based distributed system. In addition, a wide choice of I/O and connector modules makes interfacing to process sensors and actuators easy. “Remote operation is becoming more common and, with pneumatic control you have the functionality to remotely operate the system,” said Gillard. Unusually for the water treatment sector is the selection of pneumatically controlled valves rather than electric. “On the mainland UK it is more usual to have electric actuators However, the advantages of pneumatics are beginning to sway the market,” said Gillard. “In most other applications, such as petro chemical and industrial applications, pneumatics are the preferred solution, but for some reason in water treatment and sewage plants electric actuation is still predominant for now.” Pneumatic automation presents an extremely reliable alternative to electrical automation systems and reduces the costs of investment, installation and operation compared with conventional electrical installations.”

Fine filter screens and pneumatically operated penstock driven by linear actuators, to isolate the flow, located in the incoming channel Control Engineering Europe

COVERING CONTROL, INSTRUMENTATION AND AUTOMATION SYSTEMS

Control, Instrum

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TECHNOLOGY IN ACTION

Control solution for multiple lifting jacks Jenkinson Electrical Engineering, a specialist panel builder and system integrator, has chosen Eaton to supply automation products which form the basis of a new versatile train lifting system developed by Mechan.

he new lifting system allows a virtually unlimited number of lifting jacks to be synchronised with an accuracy of better than 2mm, allowing even the longest trains to be conveniently and safely lifted for servicing. A key requirement for the jacking

system is that the jacks needs to be accurately synchronised while the train is lowered and lifted, so that the risk of distorting the vehicle bodies is eliminated, and the weight of the train, which may be as much as several hundred tonnes, is evenly distributed between the jacks. Also, to ensure

Motor choice for shredder application Sims Metals Management, an electronic and metal recycling company, has chosen WEG to help design, build and supply a new, bespoke, high voltage motor for its metal recycling operations in the UK. Designed to fit into the exact footprint of the legacy OEM equipment, the new 6.6kV, 3MW motor was found to be the most cost-effective option available for use on the company’s giant shredder based in Newark, which processes over 1,000 tonnes of scrap every day. WEG has been working with Sims Group for many years, since it first installed a motor at the company’s Newport site. The reliability of this project resulted in the specification of a further ten high voltage WEG motors by Sims. The most recent installation required a robust, reliable and efficient motor. However, the principal demand was for a motor which would fit exactly into the footprint of the legacy motor, without the need for any additional engineering.

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Site engineers from WEG visited the installation to discuss the requirements for a new motor and to record all the necessary measurements for the design team. Based on the WEG ‘M’ Line motor range, the casing for the 800 frame motor was designed so that the fixing points and the footprint of the new motor would exactly match those of the old motor. With the precise measurements for the drive shaft height and diameter, the installation time for the new motor would be minimised, allowing the Sims installation team to complete the testing and commissioning with a minimum of lost time. “We looked at a number of options for replacing lacing the existing motor, includin ng a new OEM unit and repairing the existing motor, but the most co ost effective solution was presented by WEG,” explained Wayne Oscroft,, electrical engineer for the Northern Region of Sims Metal Management. “Key for us is mainta aining our operationa al

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that the system is fully compatible with current and future train types, the individual jacks must be physically separate units so that they can be positioned as required to suit different types of train body. The control system that Mechan was already using offered satisfactory performance but was limited to controlling a maximum of 24 jacks simultaneously. Because it was based on proprietary electronic systems, developing it further to handle more

efficiency so, while cost is always a factor, we needed to minimise the downtime imposed by the motor change as well as ensuring that the new motor would provide excellent efficiency and reliability.” Oscroft continued: “Sims has worked with WEG on other projects in the past and that experience, combined with its reputation, has given us the confidence to place another order with them. The new motor was installed by our engineers without any problems and it has been performing at more than 96% efficiency, which is excellent for this size of motor.” WEG’s ‘M’ Line motor range is designed for larger applications in the output range up to 20MW and voltage range to 13,800V.

Control Engineering UK

TECHNOLOGY IN ACTION

jacks and to add other new features would have been costly and time consuming. Jenkinson Electrical Engineering proposed a solution based on modern automation products that incorporate the latest technology and are readily available off-the-shelf. The key products chosen were Eaton XC100 PLCs and XV100 touchscreen operator interface units. “We have had long experience of working with Eaton products,” said Keith Atkins, general manager of Jenkinson Electrical Engineering, “We knew that by using the XC100 and the XV100 we could produce a versatile control system that

Control system order for a waste-to-energy facility Yokogawa France S.A.S. has won an order from VINCI Environment UK to supply control systems and safety instrumented systems for a waste-to-energy facility for SITA Cornwall in the UK. When completed, the facility will be capable of handling 240,000 tons of residual waste per year, and will generate sufficient electricity to power around 21,000 homes. For the control of the boilers and all auxiliary facilities at this plant, Yokogawa will supply the CENTUM VP integrated production control system and the ProSafeRS safety instrumented system. In addition to being responsible for the engineering of the facility’s automation systems, Yokogawa France will support both the installation and commissioning of these systems. In this capacity it will work closely with VINCI Environment UK, which is the engineering, procurement, and construction (EPC) company for this project. In 2011 Yokogawa also received an order from VINCI Environnement to supply control systems for VERNEA, one of the most innovative waste treatment facilities, which was built in central France for SITA (Suez Environnement Group). The systems delivered for that project have been working with no problems. In the UK and other European countries, strict regulations on the landfill disposal of waste materials are being introduced to protect the environment. As an alternative, many waste-to-energy plants are being built. Yokogawa has delivered more than 140 control systems for waste treatment facilities in Japan and other countries. The Cornwall project is Yokogawa’s fourth control system order for a waste-to-energy facility in the UK. By exploiting its engineering experience in this field, Yokogawa aims to expand its waste treatment facility control business worldwide, with a focus on Europe, and thereby help to build a sustainable society. Control Engineering UK

November 2014

UK15

could be easily upgraded, should the need arise, simply by making software changes.” Jenkinson Electrical Engineering selected XC100 PLCs for the Mechan project as they are compact modular devices that can easily be expanded to meet future requirements, and because they support the CANopen fieldbus system without the need for additional hardware. The XV100 operator interface panels were chosen because of their robust construction, high quality colour screens and their ease of programming. “The PLC software needed for this project was quite complex, as we have built in a large number of options to cater for different configurations of jacks,” said Keith Atkins, “Eaton’s XSoft-CoDeSys-2 programming system, which is IEC 61131-1 compliant, made the programs easy to develop and test. The result is a system that is dependable, and offers all of the flexibility and versatility that Mechan was looking for.” Mechan has now used the new train lift control system based on automation products from Eaton on several train lift systems ranging in size from a small single-vehicle lifting system with just four jacks, to a full train lifting system with 44 jacks. In every case, it has performed well and delivered synchronisation between the jacks that easily meets the 2mm accuracy requirement. In principle, any number of jacks can be synchronised using the new control system, and the Mechan is planning to use it extensively on future projects.

On the safe side SAMSON Ty T pe 3241 Valves, which are listed in the EXIDA database, ensuree that you stay on the safe side. You won’t have to worry about them failing thanks k to there high MTBF. Step response tests are automatically performed and the resulting data stored in the device. Stay safe and sound with products from SAMSON

Call 01737 766391 today for further details SAMSON CONTROLS LIMITED Perry r wood Business Park, Honeycrock Lane, Redhill, Surrey RH1 5JQ. Fax: 01737 765472. Email: Sales@samsoncontrols.co.uk Internet: www.samsoncontrols.co.uk

NEW PRODUCTS – FLOW & LEVEL

Precise flow measurement at high temperatures Capable of operating up to 110°C, the High Temperature Atrato ultrasonic flowmeter from Titan Enterprises is designed for applications requiring precise flow measurement at elevated temperatures. The Atrato is an inline non-invasive flowmeter without the contorted flow path and disadvantages of alternative ultrasonic designs. It can handle flows from laminar to turbulent and is therefore largely immune to the effects of viscosity. It is also said to offer good turndown, linearity and repeatability. The flowmeters use a ‘time-of-flight’

Level sensor improves measurement quality Gill Sensors & Controls can offer a new capacitive liquid level sensor designed to improve measurement quality in industrial machinery applications. The new industrial specification liquid level sensor is an extension to the company’s GS level range, providing a 4-20mA and 0-10V configurable output and both SAE 5-bolt and 1.25in BSP thread mounting options. The sensor utilises solid-state capacitive technology and is compatible with various liquid types including water, saline, fuels, oils and chemicals. The sensor has no moving parts and is designed to operate in -40°C to +125°C temperature. www.gillsc.com

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ultrasonic technology that enables them to operate over wide flow ranges with accuracies of better than ±1.5% over the whole span. Ruggedly constructed the compact Atrato is compliant to IP54 standards. Its clean bore construction makes it suitable for a wide range of flow applications. Titan’s proprietary signal processing system permits flow measurement over the whole Reynolds number range, allowing viscous and non- viscous products to be accurately metered. www.flowmeters.co.uk

Automated online documentation for flowmeters Litre Meter has introduced a new electronic documentation system that uses a combination of QR codes and mobile technology to deliver quick access to flowmeter information on the fly. Because QR codes have greater storage capacity than a standard barcode they are ideal for product tracking, item identification, time tracking and document management. Details of each meter which the company supplies as part of a single project will be held at a unique URL. The website will include all the relevant documentation for each meter including calibration certificates, PMI certificates and material certificates as well as specifications, manuals and instructions. The address of the website is printed on a chemical-resistant and wear-resistant label that is securely attached to each meter. www.litremeter.com

Flexible flow control solution Durapipe UK has introduced a new variable area flowmeter range to offer increased flexibility for those looking to specify an effective solution for monitoring flow rates. The new flowmeter is designed to operate as a visual check for engineers who need to monitor a flow rate for control or quality purposes. When very precise measurement is not required, the flowmeter can offer an effective method of confirming that a flow rate is being maintained. Offering a choice of three different tube

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materials, it can carry a wide range of fluids. The polypropylene coated float inside the tube can be switched for a magnetised float after installation, which is a necessity if a flow switch is required to identify any fluctuations in flow rate. The flowmeter requires no external energy source and works independently from electrical conductivity, speeding up installation and reducing maintenance and replacement costs over the lifetime of the product. www.durapipe.co.uk Control Engineering UK

Leading open automation networks for Asia | CC-Link & CC-Link IE

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Access markets closed to your current network strategy Youâ&#x20AC;&#x2122;ve implemented the local open network technologies in your products. But now itâ&#x20AC;&#x2122;s time me to t look lo further afield. Chances are these technologies leave a large part of the Asian marke market arket ket in inaccess inac inaccessible. cessible. So how can you also capture that? CC-Link and CC-Link IE are market leading ding ng g technologies tec technol ttech hnologie ogies for open automation networking in Asia. Adding this connectivity can lead to a significant sign signif gnifica nificant cantt business bus ness increase increas crease in critical markets such as China. Our Gateway to Asia (G2A) programme amm amme mme me eo offers offe fferss a comp ccomprehensive omprehens ehensive packag package of development and marketing benefits to capture this additional ditiona itiona tional onal nal al m market marke arket ket share share. hhare. SPS/IPC/Drives 2014 Hall 2, Stand 2-540

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HARMONICS

Exploring harmonics mitigation techniques Jonas Persson, of Comsys, offers a comparison of harmonic mitigation techniques in a range of applications and settings. He provides theoretical and practical comparisons between active and passive series and shunt filters with the aim of reducing harmonic loading in a drive system.

armonics in power systems are predominantly caused by a variety of semiconductor-based loads. Most common loads are drive systems – typically transistor based variable frequency drives and occasionally also line commutated DC drive systems. Put simply, harmonics are multiples of the fundamental frequency. Hence, the 5th harmonic in a 50 Hz system is the 250 Hz frequency component. Taking, for example, a three-phase rectifier – In a simplified case where the output of the rectifier is a constant DC-current the harmonic orders visible on the AC line can be written as h = p * k ± 1, where k = 1,2,3…

Figure 1: THD shown as a function of loading for a fixed set of voltages unbalances.

November 2014

The amplitude of the harmonics will depend on a number of factors. The grid strength will interact with the semiconductor load, as well as the equivalent series line impedance, if present. In general, a stronger grid gives higher amplitudes on the current harmonics, but lower amplitudes on the voltage harmonics. There are a number of reasons to limit the amount of harmonics in a system. Symptoms could include: • Notching. • Motor vibration. • Bearing current. • Overheating. • Nuisance tripping. • Generator tripping/ malfunction. • Production stops. • Electrical fires. Compensation solutions will be divided into four broad classes, with two defining factors – whether the solution is active or passive, and whether the solution is used in shunt or in series with the load or device to be compensated.

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Passive solutions - series Line reactor – A line reactor is a threephase series choke placed in front of the rectifier on the line side of a drive. The line reactor will cause a voltage drop as seen from the rectifier; due to being inductive, the series impedance and hence voltage drop will be larger the higher the frequency is. Typical inductance values are 2-5%. Lower values than 2% have a very limited impact on the harmonics. Advantages include low cost. It significantly reduces current distortion and adds protection to the rectifier. However, on the negative side, it is impractical in large drives and will not meet harmonic regulation levels on its own. Series harmonic filter – The series harmonic filter is designed to significantly reduce harmonics. It is, essentially, a series choke with a few added components tuned to trap more of the harmonics. A stronger harmonic rejection ratio is achieved, compared to the series choke, with higher losses and a more resonance prone filter network. This solution offers more effective compensation of harmonics than line-choke. It also significantly reduces current distortion and adds the protection of a rectifier. Disadvantages include the fact that it may be overloaded. It is not particularly flexible and may result in leading power factor. It needs to handle the full current of load, not only the harmonics, and it is impossible to control the inrush current. Passive Solutions – multi-phase: A special case of the passive series solution is the multi-pulse transformer. MultiControl Engineering Europe

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Siemens SIMATIC PCS 7: Building on its strengths When was SIMATIC PCS 7 introduced to the UK and how has it evolved? SIMATIC PCS 7 ﬁrst came to the UK in 1996. It has been enhanced subsequently as a result of advances in technology and the key drivers within the process industry sector such as industrial IT security, network-based communications, safety and human factors. Safety Integrated was introduced at the turn of the century based upon the concept of being able to use standard and failsafe components rated to SIL 3 over the same communications network. The Safety Matrix was then introduced just over ten years ago and remains to this day a unique offering in the process safety market, providing high levels of integration between the cause and effects based programming package and the plant operator interface.

For over 18 years, Siemens Industry’s SIMATIC PCS 7 has led the way as the distributed control system (DCS) of choice for UK process industries. As one of the world’s leading process automation platforms it is much more than a traditional DCS. It offers the combination of a unique and scalable architecture, powerful engineering tools and a wide range of additional functions including alarm management, process safety and asset management. On the eve of the release of its latest version, PCS 7 V8.1, Steve Leech, Product Manager – Process Automation at Siemens outlines how SIMATIC PCS 7 has evolved and highlights some of the key features and benefits that make it the preeminent control system of its generation.

Other industry-leading developments in the intervening years have included the availability of SIMATIC Batch, Advanced Process Control, Defence in Depth Security and Advanced Process Library. They have all been enthusiastically embraced by the current UK installer base. What are the key benefits that SIMATIC PCS 7 can deliver to users? SIMATIC PCS 7 offers a number of unique features and benefits for the process industries. It is entirely scalable so is suitable for pilot plant applications through to multiserver, fully redundant systems covering many thousands of IO. Such scalability is supported by highly flexible characteristics which see the system used in many wide-ranging applications across different sectors. Integration also forms a pivotal role for SIMATIC PCS 7. Vertically from the perspective of sensors and instrumentation in the field, right through to MES and ERP systems, as well as horizontally across a process plant to connect together key operational areas. The system’s intrinsic high level of both operator interaction and diagnostic and maintenance information has been cited by many users as among the many SIMATIC PCS 7 benefits. HMI and operator communications allow informed decisions to be made without delay, while the available diagnostics data underpins plant efficiencies, predictive maintenance strategies and overall plant optimisation. Finally, the Integrated Safety feature allows the use of standard and safety-related hardware in the same configuration using standard network protocols such as Profibus, while Integrated Advanced Process Control can take process optimisation to a whole new level. Describe some of the applications and process sectors that are typical SIMATIC PCS 7 users. We have a well established installed customer base across the UK. The key sectors include chemical, pharmaceutical & life sciences, oil & gas, power, food & beverage, pulp & paper, aggregates, biomass, utilities and glass. In terms of application, these are again wide-ranging, but currently include primary pharmaceutical production, turbine control, safety instrumented systems, S88 Batch compliant production, tank farm control, hazardous waste treatment, brewing, chemical cracking, sewage treatment, waste and clean water control and gas generation. Such diversity is testimony to the highly flexible and innovative nature of SIMATIC PCS 7. What are the future plans for SIMATIC PCS 7 and how will it continue to innovate? Innovation remains at the heart of all developments for the SIMATIC PCS 7 platform. The recent introduction of the CPU410 is a prime example of this as it now provides one scalable hardware platform. We are very excited about the forthcoming release of V8.1 which will bring with it a number of developments in key areas such as engineering and operation. In engineering, enhanced tools will help increase plant productivity and collaboration, while the digital plant tool

will drive the integration of plant design, automation engineering and quality improvements through simulation and emulation. From an operational perspective, the Advanced Process Library and Advanced Process Graphics packages will enhance the user experience through improved ergonomics and transparency, while a customisable HMI and a state-of-the-art alarm management system will support an even better user capability. Other technology leaps to be found in V8.1 will include enhancements to Profinet-based communications; a single, scalable controller platform based on the CPU410, the introduction of an ET200SP Profinet-based IO system and enhanced diagnostics which are built into Profibus PA network products. The continual development of SIMATIC PCS 7 since 1996 ensures it has remained the premier choice for the process sector in the UK. The additional features and benefits available with V8.1 only strengthen this position further. We look forward to another successful 18 years. WHAT THE MARKET SAYS ABOUT SIMATIC PCS 7 PLAXICA: “A key objective was to secure enhanced data collection capability to gather process intelligence. We can now look at trends and how our processes react to change. SIMATIC PCS 7 gives us this capability.” BIOMASS POWER: “In a rapidly changing marketplace and with power plants expected to be operational for up to 25 years, we now have the assurance that by using SIMATIC PCS 7 we are in many ways future-proofing our plants with a standardised approach to the automated control system. This will ensure consistency of technology development and access to subsequent upgrades and service support for the foreseeable future.” FUCHS LUBRICANTS: “Since the expansion of the SIMATIC PCS 7 system we have been able to see real progress in a number of key areas. We are achieving a significant first time pass rate for the finished products which has increased from 85% to 97%. This means a drop in failure rates to just 3% and that adds up to significantly lower levels of waste product having to be thrown away and substantial cost savings in terms of raw material consumption. In addition, our knowledge of the process is now far more in-depth, as the data we can extract from the control system informs us exactly of the type of key and highly accurate information we require to ensure product consistency and drive improvements to our efficiencies.” BOOTH WELSH AUTOMATION: “Booth Welsh Automation has successfully delivered Siemens SIMATIC PCS 7 projects over the last 15 years. In our experience the main benefits are the flexibility, scalability, reliability and long term support of the product from Siemens. This has allowed us to deploy SIMATIC PCS 7, with a great degree of confidence, in numerous industry sectors with varying degrees of complexity. “The relationship with Siemens has allowed us to have a solid partnership, which ensures we maximise the technology capability of the platform and are up-to-date with all the latest innovations and advances. The overall end result is that the client receives a proven solution, delivered competitively and using latest technology.” QSI: “As an integrator, having the right tools and backing is an essential part of any project. SIMATIC PCS 7 offers an unparalleled level of in-built functionality, and with the Solution Partner program, we can be confident that, for any of the challenges we encounter on a project, we will always have the full support and co-operation of Siemens. We have used SIMATIC PCS 7 on a number of complex and fast track projects, and have always found that the productivity tools within SIMATIC PCS 7 offer real benefits in the delivery of our total solution.”

www.siemens.com/processautomation

HARMONICS

pulse solutions entail the use of a multipulse, or multi-winding transformer with phase shift in the windings. Every secondary winding utilises its own rectifier. A 12-pulse solution uses two secondary windings and dual rectifiers. An 18-pulse solution adds one secondary winding and one rectifier. Multi-pulse systems are sensitive to voltage unbalance. Figure 1 shows total harmonic distortion (THD) as a function of loading for a fixed set of voltage unbalances. Consider a case with an 18-pulse drive under 50% load. When the unbalance is increased from 0% to 3%, the current THD increases from 10% to 35%. In a similar way, under 100% load, the current THD increases from 8% to 16%. The multi-pulse system similarly requires symmetrical loading on the secondary windings in order for the harmonic cancellation to occur. When compared to other solutions, the multiwinding transformer is physically large and heavy. In applications where space is at a premium, this is a disadvantage. Advantages of this system are that it offers more effective compensation of harmonics than a line-choke. It significantly reduces current distortion and adds protection to the rectifiers. Disadvantages include that it is sensitive to voltage unbalance and transformer asymmetry. It is not flexible and is difficult to retro-fit.

Passive solutions – shunt Passive shunt filters encompass a range of solutions with regards to compensating reactive power, they are the most common solution. They can generally be divided into the following basic types: • Fixed capacitor banks. • Contractor-based units. • Detuned contractor based units. • Thyristor-based capacitor banks. • Fine-tuned passive filters. As with all passive solutions, loading cannot be controlled. The loading of the filter will be determined by its

November 2014

impedance, the connected grid and the loading on the grid. Further, several fine-tuned filters may interact when Figure 2: A comparison of current compensation results placed in the and efficiency of several solutions – data courtesy of Danfoss. same grid. Since the tuning will depend on and interact with is a voltage boost of the DC voltage the source impedance the end results compared to a conventional six-pulse of adding fine-tuned shunt filters can drive with a diode rectifier. The higher be unpredictable. Advantages of this solution are DC voltage creates a higher ripple on that it is often a more effective the motor side, meaning that a dV/dt filter may be needed, especially in an compensation of harmonics than a line application with higher motor voltages choke and it is a retrofittable solution. (600-690VAC). However, it can be overloaded and For AFE drives with LCL-filters, special is not flexible. It is sensitive to grid conditions and will interact with grid consideration needs to be given to the switching frequency and the resonance power quality. Impact on voltage point of the line filter. Normally, the is difficult to determine and grid switch frequency is above the resonant interaction is unpredictable and, in frequency in order to benefit from the many cases, non-intuitive. higher damping. However, this puts the Active solutions – series AFE at a double disadvantage as the The active series solution is usually switching frequency already needs to be low in order to not make the active implemented in the form of an active rectifier part too bulky and lossy. front-end (AFE) variable speed drive. Due to being a series design – In a regular variable speed drive, the transmitting the full load current – the rectifier is controlled via diodes. With an AFE these are replaced with an AFE needs to have a low switching frequency in order to be more active (usually IGBT-based) controlled efficient. The high current capacity, rectifier. One of the benefits of this is the in combination with a low switching ability of the active rectifier to feed frequency, leads to large switching ripple and a higher risk of interacting electrical energy back to the grid with other loads on the grid, possibly during braking. AFE drives usually have causing harmonic resonances. very low current distortion (typically Advantages of this technique are down to 5% THD) and good power factor. that it offers very efficient suppression The effect on AFE performance will of harmonics and good power factor. be a trade off. In order to make the It is also able to feed energy back to AFE as light and compact as possible, the grid and is insensitive to network it is desirable to lower the switching unbalance. frequency of the active rectifier. This, Disadvantages include the fact that any active rectifier must transmit full however, puts stress on the line filter load power. It is large and complex and creates a higher switch ripple. and harmonics compensation is Increasing the switching frequency is done at a very high cost - the active tied to drive. It is also impossible rectifier grows physically larger and to retrofit and grid interaction is becomes more expensive. unpredictable and in many cases nonDue to the active rectifier, there intuitive.

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Control Engineering Europe

HARMONICS TM

Active solutions – shunt An active filter is connected in shunt – in parallel – with the load and can be used to mitigate a number of power quality problems. The most common is the reduction of harmonics caused by variable frequency drives. The majority of active filters use IGBT technology. Active filters work by measuring the load current, analysing the harmonics and then injecting counter-phase harmonics in order to cancel out the unwanted harmonics. Because the shunt active filter only needs to handle the size of the disturbance (ie: the harmonics) – which are a fraction of the amplitude of the full current – using a higher switching frequency and a higher resonance frequency in the LCL filter is possible. This lessens the risk of grid interaction and allows the shunt active filter to compensate higher harmonic orders. Most commonly active filters work in global or selective mode. Global mode means that the active filter tries to cancel out all harmonics, irrespective of order. This can be done by removing the fundamental frequency component from the measured signal. Selective mode means that the user is given the opportunity to configure which harmonics to compensate. During selective compensation, it is possible to target a particular issue. This can enable downsizing of the active filter. For example, in the case of the 11th harmonic triggering a resonance, an active shunt filter with selective compensation can be configured to only target the 11th harmonic, in turn significantly lowering the required current rating of the active filter. The ability to downsize the active filter to only compensate the needed harmonics is a direct consequence of being a parallel device. An active filter is insensitive to network unbalance and the user may select to only partially compensate the load in order to reach a pre-determined set of criteria. The active filters will introduce switch ripple, but much less than the Control Engineering Europe

GEVA

equivalent AFE solution, due to smaller size relative to the load and due to the higher switching frequency. This technique offers the most efficient compensation and is simple to retro-fit. It is tunable to the problem at hand and allows redundancy to be designed into the system. It also results in significantly less switch ripple than AFE.

Vision System

Comparison Using as an example, a case where a 1000A variable frequency drive is to be compensated, the resulting amount of harmonics to be mitigated will be dependent upon the system impedance and the equivalent series reactance. In a weak grid, the current distortion might be as low as 20%. In a strong grid it might be up to 38%. In absolute numbers this means a harmonic current of 200 – 380 A RMS. In most cases, it will be enough to just attenuate the harmonics and to reach a certain voltage distortion (for example 5% according to IEEE-519(1992). According to the same standard there will also be a requirement on the TDD. In the worst case it will be required to be less than 5% under all conditions, meaning that if the 1000 A drive is the only system on the PCC, maximum emission of harmonic current is 5% of the demand current or 50 A RMS. In order to achieve this, the harmonic reduction in terms of current needs to be 150 – 330 A RMS. The ability to downsize the solution to fit a particular purpose is one of the biggest advantages of parallel compensation circuits compared to series circuits.

Imagine the Possibilities GEVA vision systems are designed to meet the diverse requirements of industrial inspection. Integrated with high-speed camera ports, multi-core processing and choice of application software, these systems provide the capabilities and the versatility to suit a wide range of multi-camera applications.

Performance comparison Figure 2 compares current compensation results and efficiency of a couple of solutions. (Data courtesy of Danfoss). No consideration is given to imperfections in the grid such as unbalance. As has already been demonstrated, results may be far worse for some solutions under those circumstances. November 2014

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Advertorial - MACHINE CONTROL

ABB powering machine innovations

Meeting ever changing challenges...

he machines that move today’s industrial processes require dependable, flexible and highperforming control solutions. Additionally, the demands faced by machine designers are ever changing from real-time Ethernet technologies, machine safety and energy efficiency to software standardisation and the promise of Industry 4.0. When choosing a supplier for the machine control system, these demands need to be answered, and the supplier’s ability to offer solutions and work together with the machine builder globally, becomes important.

A global leader ABB is world-renowned as a leading supplier of electrical power and automation solutions. Our HVDC (high-voltage direct current) technology continues to revolutionise electrical energy delivery and we pioneered the world’s first electrically powered robot and now, with YuMi®, have introduced a vision of robotic future. Our technologies also help customers maximise uptime in automated machinery and package the products they produce, label them reliably and

November 2014

our robots to stack and pack them smoothly and efficiently.

Powering machine innovation To achieve this we offer open automation solutions that adapt to the innovation needs of our customers’ unique requirements. ABB offers everything from highly scalable PLC technology to award-winning servo drives, motors, machine safety products and robots. We base our solutions on open network technologies, providing machine builders with freedom of choice on how they prefer to connect and build their machine control systems. Automation Builder, our software engineering platform, brings all this together providing project and system configuration, programming, set-up and commissioning via single software suite. Once a machine is delivered to the customer, our global operations ensure support and service is readily available keeping machines and business running.

Flexible choice of platform Performance is rarely the only aspect when designing new machines or upgrading existing ones. Designers need to maintain a balance between keeping

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cost down and enabling more added value for their customers. The control system must be optimally dimensioned, keeping component count and cost down, yet enabling higher machine performance and productivity. ABB offers scalable centralised and decentralised motion solutions with both industry standard IEC 61131 and PLCopen motion, as well as NextMove series motion controllers with high level programming, both featuring real-time and standard Ethernet technologies such as EtherCAT, Powerlink, Profinet and Modbus TCP. In addition, we offer award-winning intelligent drives that offer optimal solutions for single axis as well as multi-axis capability, through an adaptable drive profile in the form of application program that can be tailored to add local functions. Few suppliers offer such open choice of approach.

Power, flexibility and dependability Adding to our award winning MicroFlex e150 EtherCAT servo drive range, the new MotiFlex e180 range offers solutions for higher power single and multiaxis applications, featuring multiple integrated Ethernet technologies. The range can function as adaptable programmable drives for distributed control approaches, or self-contained single axis controllers. In addition, our new MotiFlex e180 motion drives feature safety and feedback options which included a combined single cable solution for motor power and feedback. Machine designers looking for automation with the highest performance can benefit from the new capabilities offered by our extended EtherCAT range which includes a new ‘Machine controller’ based on the AC500 PLC Platform offering four Ethernet networks, safety option and powerful CPU. The AC500 range offers PLCopen motion libraries, pre-written drive interface control libraries for ABB servo and machinery drives. Control Engineering Europe

To find out more contact your local ABB sales office or visit us at PackExpo USA Chicago

SPS IPC Drives Nuremberg

November 2nd to 5th Booth 5936

November 25th to 27th Booth 4-420/4-520

MOTION CONTROL

Centralised or decentralised?

WHICH WAY TO GOâ&#x20AC;Ś If servo drives are used right next to motors, the wiring from a central control cabinet can be dispensed with.

Arne Linder, r product manager at KOLLMORGEN, looks at the benefits and barriers to the use of centralised and decentralised servo technologies.

ecentralising servo technology can offer machine and plant construction savings during installation. Additional advantages could include reduced cabinet heat loads and more straightforward drive architecture. However, when deciding between an integrated motor/drive solution or a detached motor and drive there are many things that first need to be considered.

In contrast to horizontal conveying, where decentralised servo drives are a common sight, centrally located servo drives still dominate the market for highly dynamic and precise motion control. Servo drives, along with other control components - sometimes with a full blown IPC - reside together in a control cabinet protected from the outside world. Connection to the motors is achieved via a star shaped structure, each having control and power cables.

Because heat loss is centrally generated, effective air conditioning is needed in the cabinet. Decentralised servo technology follows the basic principal of shifting the individual motor control from the central control cabinet and more closely locating them to the process. This architecture requires a robust design that can provide a high degree of environmental protection. Its main advantage lies in a reduction in cabling. Other advantages include improved EMC-behaviour and the widespread distribution of heat loss, which reduces the need for a centralised cabinet climate control system and the costs associated with this. Packaging machinery and machines for the food and beverage industry are moving away from long cabinet walls towards the installation of small, highly self-protected units within the machine frame. Against this backdrop, practical experience shows that a decentralised structure can be advantageous, especially with spatially distributed single axes. In contrast, machine modules for synchronised axis, physically close together and centrally located drives in a cabinet, are generally the preferred structure.

Typical example The potential of decentralised technology can be seen in an

New functionality makes motion control easier Siemens has updated its Simotion Motion Control System to version 4.4, which offers new functions designed to make the engineering of motion control projects easier and more efficient. It does this with the help of the TIA Portal. The link between the new Simatic HMI panels and Simotion has also been implemented. With the new version of Simotion and the integration of the easyProject project generator in Simotion Scout, users are able to configure even complex production

November 2014

machines in an easy to handle and standardised way. Users can now benefit from fully graphic configuration of hardware and networks, with the Simotion visually imaged in the TIA Portal together with all its interfaces and properties. In the network view, further automation components, such as the HMI or the drives, can be connected to Simotion. For the first time, the new Simatic HMI panels can also be operated with Simotion. Complex Motion Control applications

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can be created quickly through the use of standardised software modules that Siemens has stored in the easyProject project generator. The project generator is also integrated into the Simotion Scout Engineering System, from which it can be called directly. Modules can be integrated quickly and easily into existing projects, or can be put together for new projects. This means that a large part of the application just has to be configured, and no longer requires time-consuming programming. Control Engineering Europe

MOTION CONTROL

eight-axis metal forming machine. The first axis is located 5m away from the control cabinet with each additional axes located 3m further. A centralised control system would be characterised by a central control cabinet housing the drives with each motor having separate shielded power and feedback cables adding up to 248m of cable. Instead, a combination of a single KOLLMORGEN AKD-C power supply module and eight decentralised servo controllers would reduce the cable requirement to 34m. The calculation is as follows: a single 5m hybrid cable supplying power and field bus for axis control is connected between the power supply module and the first decentralised controller. A single hybrid cable 3m long connects each additional drive for a total of 21m. Because we assume that each motor is located 1m away from each decentralised AKD-N drive

KOLLMORGEN provides a one-cable motor connection technology, only 8m of additional cable is required. Overall, the decentralised system reduces the cable requirements from 248m to 34m - a saving of 86%. Another benefit of the relocation of drives is the reduction of power dissipated in the control cabinet. This effectively reduces the requirements for air conditioning. The control cabinet air conditioner can be reduced in size or completely eliminated.

Increased design freedom Sample calculations show that decentralised servo technology can save space in combination with the singlecable connection technology between motor and controller. This results in smaller cable trays, lighter drag chains, and more compactness giving greater design freedom. A way to decentralise is with the use of a hybrid integrated solution.

Disadvantages of this â&#x20AC;&#x2DC;piggybackâ&#x20AC;&#x2122; solution can include drive derating with increased ambient temperature. The higher the ambient temperature the more performance reduction occurs in order for the drive to self-protect from overheating. This relationship ensures that the motors must be larger than otherwise would be necessary, to give the required performance within acceptable temperature limits. Typical servo tasks, such as rapid acceleration and deceleration during positioning, can be especially difficult in the design of hybrid solutions due to heat dissipation problems. Separating the motor and drive at this point, however, prevents inherent design-related derating. This solution provides the basis for smaller motors in combination with better energy efficiency. In addition, integrated combinations are usually focused on a single motor type, limiting flexibility in the machine design.

80% or better overall equipment effectiveness achieved by top performers*

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FLOW & LEVEL

Improving flowmeter CALIBRATION ACCURACY Dr Norman Glen, principal consultant at NEL, explains how the use of synthetic reference fluids can help improve flowmeter calibration accuracy.

iquid-measuring devices are used in a huge variety of commercial applications. There is currently a debate within the flow measurement community regarding the merits of using real fluids for the development, testing and calibration of multiphase flow meters. However, a consideration of th thermophysical h i l properties ti off fluids id and d basic metrological principles indicates that the use of stable, well-characterised substitute fluids, can offer a better solution.

Proponents of the use of live fluids such as natural gas, crude oil and brine, argue that flow loops using such fluids are more representative of the conditions that meters will encounter in service. However, the measurement of multiphase flow in oil & gas poses particular difficulties when calibrating and testing flowmeters as it has many variabl variables that require complex measuremen nts. For example, the nature of live fluids mean that their properties and the depe endence of these properties on temperatu ure and pressure may be different each time they are used. This meanss that there is less confidence in n the properties of these fluids, ultima ately resulting in higher uncertainty in n the reference flow rate for a device u under test. Conversely, reference fluids are stable and predictable, tthereby delivering consistent and reliable m measurements, resulting in lower unce ertainty in the reference measuremen nts before the flowmeter goes into the e field. Once in the field, overall measu urement uncertainties can be derived ussing PVT data along with fluid samplin ng and physical properties modelling, ass well as testing against test separator systtems.

Testing ass assumptions Multiphase fl flow loops typically consist of a three-phase e separator, reference flow meters for ea ach of the three phases, a test section and various pumps and other equipment for circulation of the fluids. Each liquid phase of Dr Norman Glen, is principal consultant at NEL.

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a typical multiphase loop operating with reference fluids will be metered through its own reference flow meter and fresh nitrogen is added and metered through its own flow meter. On-line density measurement of the liquid phases, combined with off-line measurements of the pure liquids, enables the mass flow rates of the liquid phases to be determined and hence the volumetric flow rates at the device under test. The temperature and pressure of the gas phase at its reference meter are also measured, allowing the mass flow rate to be calculated. The volumetric flow rate of the gas at the device under test can then be calculated from its local temperature and pressure at that point. This does make the assumption that all the gas (nitrogen in this example) remains in the gas phase and does not absorb any of the oil or water. To test this assumption, NEL has undertaken a series of calculations, which confirms that the nitrogen remains in the gas phase and doesnâ&#x20AC;&#x2122;t absorb liquids. Now consider a multiphase facility using real fluids. It can no longer be assumed that there is no partitioning between the phases as the operating conditions (temperature and pressure) change from the reference meters to the device under test. To test this assumption and determine the extent of this partitioning, a similar set of calculations was performed with fluids representative of a live crude and natural gas. In this case, the density difference was 7% due to partitioning of the hydrocarbon components between the vapour and liquid phases. Additional calculations were undertaken for a high-pressure multiphase flow loop using live fluids and similar differences were found in the calculated densities of the gas phase. Unless this partitioning is taken into account the density difference calculated translates directly to an error in the calibration. The calculations undertaken above are only possible with knowledge about the fluid compositions. While it may be possible to determine the gas phase composition in real time by gas Control Engineering Europe

FLOW & LEVEL

chromatography, the liquid phase composition can generally only be determined by sampling and off-line analysis. Even if this approach is used, there still remains inherent uncertainties that arise from the equations of state – all equations of state require additional parameters (binary interaction parameters) to account for non-ideal behaviour of real mixtures. These uncertainties can be of the order of several percent, potentially of the same order as the required measurement uncertainty for the device under test.

Accounting for the effects The effects of temperature and pressure on fluid properties must also be accounted for. For a single-phase facility this can most easily be achieved by using a pure fluid, for example, water, or a fluid of known, and stable, composition. For a facility testing meters under multiphase conditions, this approach will also yield the lowest uncertainties in fluid properties, since the effects of temperature and pressure on the reference fluids will be low. However, this will not be the case if real fluids are used, since they are, by their nature, much less stable with time, and the temperature and pressure dependence of their fluid properties will be less well known. In addition, differences in temperature and pressure between the reference device and the device under test will cause changes in partitioning of components between the gas and liquid phases, leading to increased uncertainties in the fluid properties.

measurement and control

Mass flow meters from the mini CORI-FLOW series by Bronkhorst Cori-Tech B.V. are based on the coriolis measuring principle covering the needs of very low flow applications. There are a variety of models to overlap flow ranges from 5 g/hr up to 600 kg/hr (full scale values), each offering ‘multirange’ functionality. Factory calibrated ranges can be rescaled by the user, maintaining the original accuracy specs. The instruments are equipped with a robust IP65 weatherproof housing and are available with ATEX approval for use in Zone 2 hazardous areas. The Mini CORI-FLOW mass flow controllers feature integrated, adaptable PID control for fast and smooth control of electronically driven control valves. Depending on the application this could be an integrated direct acting valve or a separately mounted valve. Integrated control valves for liquid applications have a purge connection on top of the sleeve that enables easy elimination of air or gas when starting up the system. For liquid dosing applications the company can offer Cori-Tech, an alternative way to control the flow. Instead of using a control valve, the coriolis flow meter can be combined with a gear pump, eliminating the need to pressurise the liquid source. November 2014

NEL is a provider of technical consultancy, research, measurement, testing and flow measurement services to the energy and oil & gas industries, as well as government and offers a centre of excellence for flow measurement and fluid flow systems.

Mass Flow

Coriolis flow meters and controllers for low flows

Control Engineering Europe

As research shows, the use of ‘real’ fluids such as natural gas, crude oil and brine, increases uncertainty on the calculated fluid phase properties. This is due to the issues of dealing with essentially unknown partitioning of hydrocarbon components between the vapour and liquid phases. In order to achieve the lowest overall uncertainty, it is necessary to control all of the parameters as accurately as possible. This would, therefore, justify that the best metrological approach is to eliminate this issue by the use of suitable stable, well-characterised reference fluids. For this reason NEL has recently switched from using crude oil to refined oil as part of its multiphase flow loop meter testing. This is consistent with the approach recommended in the current issue of Department of Energy and Climate Change’s Guidance Notes for Petroleum Measurement, Issue 9, July 2014. (Section 9.7), which makes specific mention of the need to account for possible transfer of components between phases and a preference for ‘model’ fluids, to minimise additional uncertainties.

The most extensive product range of thermal mass flow meters and controllers Flow ranges for gases from 0-0,7 mln/min up to 0-11000 m3n/h Flow ranges for liquids from 0-75 mg/h up to 0-600 kg/h Laboratory, Industrial (IP65) or ATEX approved design Analog, RS232, FLOW-BUS, PROFIBUS DP, DeviceNetTM, Modbus, EtherCAT®

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TECHNOLOGY UPDATE

New day for wireless control Wireless control technology is becoming available to more users than previously. With this simple, secure, and reliable wireless control solution, itâ&#x20AC;&#x2122;s a new day for process operations says Terry Blevins, principal technologist for Emerson Process Management.

new day has dawned for wireless control applications. With modifications to the proportional-integral derivative (PID) algorithm, the ability to use wireless devices for most process industry applications has emerged. This new approach makes it possible to achieve control performance comparable to using traditional wired transmitters and wired valves. The movement toward wireless began with the drive to improve plant operations. Plant managers saw opportunities for significant gains by accessing information about process operating conditions in remote areas. Wireless devices were the most cost effective way to get access to remote areas, given that the cost of wireless installations is a fraction of the cost of a wired installation using traditional transmitters. Once plants gain experience using wireless measurements, the next consideration is often looking for a way to incorporate these wireless measurements in closed loop control.

a factor for wireless devices. To achieve a five-year battery life, a communication update rate of 8 or 16 seconds is typically required in wireless control applications. As a result, when using traditional PID control, the calculated reset and derivative action may not be appropriate in many applications. Two communication techniques are most appropriate when implementing control using a wireless transmitter. When continuous (periodic) update is selected, the device wakes up at a configured update period, senses the measurement, and then communicates the value. For the window technique, the device wakes up at a configured update period, senses the measurement, and then communicates the measurement if the change in value since the last communication exceeds a specified limit or if the time since the

last communication exceeds a default update time. Window communications is the preferred method since for the same update period less power is required. In spite of the technical challenge presented by a slow measurement update rate, there are a limited number of applications where the standard PID can be used with wireless transmitters. For controlling very slow processes, such as level or temperature, the standard PID available in most distributed control systems is a viable option. Closed loop control with wireless transmitters that use slow communications update rates (8 or 16 seconds) will work as long as the process response time is at least four times slower than the communication rate. The reliability of most networks is better than 99.9% when using standard PID in wireless control. However, it is prudent to add logic to switch the control to manual in case communications are lost.

Wireless control applications From the beginning of WirelessHART standard development, the vision was that someday wireless devices

Wireless technology challenge Manufacturing facilities have found that slow measurement updates and nonperiodic measurement updates present technical challenges to using wireless measurements in control applications. The underlying assumption in process control has always been that control is executed on a periodic basis and that a new measurement value is available for each execution. That approach works when power consumption is not a factor. However, power consumption is

November 2014

Fig 1: Control for wireless measurement is shown. All figures courtesy: Emerson Process Management from â&#x20AC;&#x153;Using Wireless Measurement in Control Applications,â&#x20AC;? ISA 2013

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Control Engineering Europe

TECHNOLOGY UPDATE

would be used for control as well as for monitoring. In anticipation of the issues ahead, engineers began working on solving the problem by challenging previous assumptions about control. What they discovered opens up the possibility of using wireless devices for the vast majority of applications in the process industry. The PID algorithm can be modified to correctly work with slow measurement updates, non-periodic measurement updates, and loss of communication to achieve wireless control performance that is comparable to that obtained using traditional wired transmitters and wired valves. The key is to understand that when the PID reset is implemented using a positivefeedback network, the time constant of the filter used in this network is a direct reflection of the process dynamic response. Based on this, the reset calculation of the PID may be modified for wireless control.

The derivative component accounts for a new measurement value not being available for each execution of the PID. Thus, there is no need to modify tuning for wireless control, that is, PIDPlus tuning is Figure 3: Response for measurement loss is shown. For the past four years, determined only PIDPlus has been a standard feature of the DeltaV distributed control system. by progress gain Emerson DeltaV users can select the PIDPlus capability as one of the control and dynamics. parameter options. Emerson is offering it free to WirelessHART users through the HART Communication Foundation. When the PIDPlus is since the PIDPlus reset and derivative used with a wireless transmitter in a control application, the performance contribution are automatically is comparable to that achieved maintained at last value on loss of using a wired transmitter. The closed communication. A field trial was conducted as part loop response of the PIDPlus was of the Separations Research Program tested for changes and unmeasured Positive feedback at the J.J. Pickle Research campus. process disturbances where the In the PIDPlus implementation, the WirelessHART transmitters were wireless transmitter used window installed for pressure and steam flow positive feedback network used to communications as illustrated in Figure create the reset contribution is modified control as part of a focus project on CO2 1. In these tests, the performance was to maintain the last calculated filter compared to a standard PI controller removal from stack gas. Using the original plant PID tuning, output until a new measurement where the wired measurement value is communicated. When a new is communicated as frequently as the the same dynamic control response was observed for setpoint changes for both measurement is received, the reset PI control algorithm executes. In the steam flow and column pressure. example, window communications contribution uses the new filter output as the positive feedback contribution. PIDPlus is available in a commercially reduced the number of communications by over 96% when compared to available distributed control system; For those processes that require the number of new measurement derivative (rate) action, the derivative users can select the PIDPlus capability as values used in control using the wired one of the control parameter options. contribution to the PID output is recomputed and updated only when transmitter. The table, Figure 2, shows From life sciences to specialty chemicals, a new measurement is received. the difference in control performance users have successfully implemented The derivative calculation uses the with integral absolute error (IAE) for reliable, realtime control with wireless devices. elapsed time since the last new periodic measurement update vs. measurement. nonperiodic. Traditional PID typically provides poor Free licenses available Using PIDPlus, the reset calculation Late in 2014, Emerson Process dynamic response; PIDPlus improves automatically compensates for setpoint Management will offer licenses for the change and measurement update rate. the dynamic response under these PIDPlus wireless PID controller at no conditions. Figure charge. The licenses will be available 3 shows that through the HART Communication PIDPlus provides Foundation to plants that use improved WirelessHART field devices, expanding dynamic response use of wireless control. With this simple, compared to secure, reliable wireless control solution, the PID for the Fig 2: Table compares communications and control comparison and same conditions itâ&#x20AC;&#x2122;s a new day for process operations. improvement using PID algorithms. Control Engineering Europe

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November 2014

EVENT PREVIEW

SPS/IPC/Drives event preview

SPS/IPS/Drives will open its doors on 25th November.

SPS/IPC/Drives 2014 will take place from 25 – 27 November in Nuremberg. The event continues to gain support as a showcase for innovation in the field of electric automation, and this years event promises to be the biggest ever.

ver 1,600 exhibitors are expected to showcase their innovations, products and solutions at this years’ SPS/IPC/Drives event and, for the first time, the event will be expanding into a newly built hall, which means it now stretches over 14 halls. The new hall will be dedicated to the topics of drive technology and sensors, expanding this area of technology to a total of three halls. Siemens will be exhibiting in a new location in Hall 11 at the event, under the banner ‘Making Things Right’. Visitors to the stand will be able to see a wide range of product innovations across every field - from industrial software, automation and drive technology to services. Key levers for productivity in this context include integrated technology platforms such as Totally Integrated Automation (TIA),

November 2014

Integrated Drive Systems (IDS) and Totally Integrated Power (TIP). The main theme running across the stand will be the interplay between automation and digitisation along the entire industrial value chain, demonstrating how innovative software and hardware can be used to merge virtual and real production processes. Commenting on the company’s presence at the event, Heinz Eisenbeiss, booth manager for Siemens, said: “Our aim is to enhance the competitive standing of our customers and to make their production processes faster, more flexible and smarter. The new location in Hall 11 offers the perfect backdrop to address the high level of interest shown by visitors to our comprehensive offering of industrial software, automation and drive technology as well as services.” Throughout the event, Siemens will be hosting a variety of product

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presentations and tutorials on the booth. The centerpiece of the stand will be an exhibit illustrating how Siemens can support companies in the creation of a cohesive workflow along the entire industrial value chain. This is illustrated using the example of various customer reference projects and Siemens’s own products. Product innovations from Siemens will include a selection of new Simatic controllers with the focus on failsafe CPUs. For the first time the company will also be featuring an S7-1500 software controller for PC-based automation and a modular open controller with PCbased software controller, visualisation and central I/Os in a single device. In the field of industrial identification, the company is expanding its Simatic RF600 RFID system with the launch of a new generation of UHF readers for production and logistics applications. There has also been an addition to the Sirius modular system featuring a mounting width of 55mm. The new switching, protection and monitoring devices are designed for currents of up to 80A and outputs of up to 37kW, and take up only minimal space in the control cabinet. Siemens will also be presenting a new addition to its Plant Data Services portfolio - the Control Performance Analytics - which is aimed at optimising process through analysis of process and status data from control loops. In the field of drive technology, Siemens will be presenting new Simotics motors conforming to efficiency class IE4. Because there are no shaft height jumps from IE1 to IE4, the motors can be easily exchanged.

Gigabit Ethernet A key message being delivered at the event by the CC-Link Partner Association (CLPA) is how CC-Link IE, which is believed to be the world’s only Control Engineering Europe

EVENT PREVIEW Profibus DP networking solutions

IO Link modules

Siemens stand will focus on the interplay between automation and digitisation along the entire industrial value chain.

open gigabit Ethernet for automation, helps deliver solutions for Industry 4.0. Independent market research has indicated that CC-Link IE is the fastest growing Ethernet-based open network technology, and the recent IEC 61158/61784 certification for CC-Link IE Field will further strengthen its position. A year on from the launch of its Gateway to Asia (G2A) programme, CLPA now has 26 partners involved in the programme and we are told that there will be an announcement at the event about an important new board member. Softing will be showing its PROFIBUS Tester BC-700-PB a diagnostic and troubleshooting tool for testing PROFIBUS segments during operation. The latest version can also be used for cable testing. The device is battery powered which offers good mobility in the field. Test results are shown clearly on a new graphic display when the device is operated in stand-alone mode, and can be exported for extended analysis in PC mode. Commenting on the new offering, Heiko Nickel, product manager at Softing, said: “Up to now, users needed to buy the diagnostic tool and the cable tester separately. The BC-700-PB is the first battery-operated tester that combines bus physics, bus communication and cable testing in one device.” Control Engineering Europe

B&R will be introducing two ne IO-Link master modules – the new X20DS438A with IP20 protection and the X2 X67DS438A with IP67 protection for use outside the control cabinet. The modules use IO-Link 1.1 to communicate digitally with up to four intelligent field devices. To achieve the Industry 4.0 goal, it is necessary to gain more meaningful data from sensors and other field devices. To achieve this, B&R relies on the IO-Link communication standard to cover the final stretch from the I/O module to individual sensors and actuators. This bidirectional digital communication interface is used in the field to exchange parameter data and diagnostic information, making it possible to intelligently integrate sensors and switching devices into the control level. This integration of end devices is greatly simplified by standardising the communication technology used, just as managing parameters centrally makes it easier to exchange them, making IO-Link a good complement to industrial realtime Ethernet POWERLINK technology.

New w products being shown by PRO OCENTEC will include new additions to its ProfiHub range. add The two new additions to the ProfiHub family are designed to offer solutions for spur lines and star-shaped structures in PROFIBUS DP networks. The ProfiHub B5+RD is the first ProfiHub to be provided with a built-in PROFIBUS DP slave for transferring diagnostic data to a PLC. Engineers can now access detailed diagnostic information about communication failures and current details of retries. Diagnostic information about redundancy of the PROFIBUS channels and supply status can also be identified using this function. The ProfiHub B2+R enables wideranging RS 485 star/tree/bus segments and long spur lines for PROFIBUS DP installations in IP 20 environments. When redundancy is enabled, it is transformed into a low-cost reliable redundant repeater solution. The ProfiHub B2+R is equipped with 2 galvanic isolated transparent repeaters (offering three segments). Each segment can handle 31 devices and a cable length equal to the main bus. To save costs on plugs and offer flexibility, it contains screw terminals as well as DB9 connectors.

B&R will be introducing two new IO-Link master modules.

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November 2014

NETWORK SECURITY

Setting a standard for SECURE REMOTE SERVICES Using remote services can assist technicians when rectifying malfunctions. However, many remote service solutions are technically complex and inflexible, or confront operators with additional security risks. For this reason, global automotive supplier ArvinMeritor, part of Interva Products, stipulates a secure remote service connectivity solution for all of its automation contractors.

high level of plant availability and uninterrupted deliverability are vital to this automotive supplier and for several years its production plants have been administered and serviced online remotely. Facilities, including final test stands with increasingly complex software programs, always require fast data connections. Therefore, the age of modems in remote services is coming to its end. For five years, the remote service at Inteva Products has been implemented as a TCP/IP connection via DSL. In addition to higher data throughput, the connection is also established faster and more reliably. A broadband data connection is now the standard, because frequently an entire group of control computers are linked to a single plant. Transmitting monitor images, larger software updates or database inquiries is becoming increasingly data-intensive. Because today’s production plants are strongly networked, a greater safety risk exists for unprotected TCP/IP Internet connections. “We have taken precautions to ensure security in production and stipulate a secure VPN connection for the remote service with every contractor. In addition, we use an industrial firewall to meticulously seal off any access from the remaining network,” said Stephan Stottmeister, IS system manager at Inteva

November 2014

Products. The automotive supplier has had positive experiences with mGuard, the remote service connectivity solution from Innominate, a Phoenix Contact Company.

Secure VPN technology The security of the remote service connection is ensured through the use of VPN (virtual private network) technology. In the process, VPNs allow secure ‘tunnels’ to be formed in the public transmission network. These tunnels cannot be viewed or listened to from the outside and all network packets are encrypted. Alternatively, hardwareaccelerated 3DES or AES encryption and the standard IPsec protocol are used. For Inteva Products, the complete control of internal and external plant access is important. Using mGuard technology, the activation of VPN tunnels can be controlled by the operator and approved communication can be systematically limited by firewall rules to precisely the desired level. An uncontrolled external connection is not possible in the network. Additionally, each IP/VPN connection must first be actively switched on using a key switch. By using the remote service solution, the company was able to increase its plant availability and also save costs. “It has been our experience that the contractors’ technicians no longer have to work here on-site thanks to

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An mGuard Industrial firewall in-situ.

the remote service solution. If there is a dysfunction in a plant, a specialist is able to intervene much faster, and we also save on travel and local deployment costs for the service technician,” said Stottmeister. The remote service solution is used for 10 plants, six test stands and one server. The online service of the contractors comes into play during the start-up phase of a plant, at the start of serial production, for ongoing optimisations or if any problems arise. A traceability system for production data, which runs on a database server, is also supported via remote service. An external partner provides programming support through this channel. The in-house production planners also use a protected network access to log onto a system and monitor a final test stand, for example. The mGuard solution has proven to be flexible. The online connection is used in different ways, depending on the contractor and plant. Normal service deployments are carried out by remote desktop and database queries via SQL. A Siemens SPS application in a small systems network with two test PCs and peripheral devices is controlled directly by TCP/IP. Inteva Products had defined several requirements when changing from modem technology to TCP/IP Internet connections. It wanted the new solution to be DSL-based and all plants / final test stands were to be sealed off by firewall from the outside network. Operating the system without additional software installations was also important, in order to avoid impairing the plants from the very start. “Today, contractors that want to access our plants do not have to worry about complicated VPN configurations. They receive the IP address of the final test stand, and that’s all there is to it,” said Stottmeister. Control Engineering Europe

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The GEVA 3000 includes six Gigabit Ethernet (GigE) ports that support a wide range of expandable camera configurations. Optional USB based companion modules offer I/O expansion and easy integration of Teledyne DALSA Genie™ cameras. Email: sales.ipd@teledynedalsa.com Web: www.teledynedalsa.com