Cee 16 05

Control, Instrumentation and Automation in the Process and Manufacturing Industries May 2016

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The Smart Factory: bridging the OT/IT gap Dynamic simulation benefits across the plant lifecycle Enhancing DP-based flow measurement with dynamic compensation

ID and vision solutions for difficult packaging applications

CONTENTS

Overcoming ‘smart factory’ challenges...

Editor Suzanne Gill suzanne.gill@imlgroup.co.uk Sales Manager Lydia Harris lydia.harris@imlgroup.co.uk Production Sara Clover sara.clover@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

I am writing this at the same time as packing my bag for the annual trip to the Hannover Messe and am wondering what Industry 4.0 project information I will be travelling home with for future issues. I will certainly be interested to find out more about the challenges that these ‘smart factory’ projects have posed and how they have been overcome as well as finding out what benefits it is offering.

Until then, this issue includes a feature section looking at the subject of ‘the smart factory’ and offers advice from an Industrial IT expert, who highlights the need for closer collaboration between the OT and IT worlds. (pg 12) Key to any smart factory project is the need for connectivity and communication across the plant floor. Recent analysis

has identified the industrial movers and shakers among the various Industrial Ethernet offerings available today. It found that, while transition towards Industrial Ethernet is increasing, we will still be talking about the more traditional fieldbus communication technologies for some time to come. (pg 4) Another article in this issue highlights the role of simulation technologies within the industrial sectors and suggests that it can help increase plant efficiencies as well as speeding up project schedules and cutting costs. (pg 16) Suzanne Gill – Editor suzanne.gill@imlgroup.co.uk

INDUSTRY REPORTS

WIRELESS

4

18 A real-time monitoring solution is squeezing more efficiency out of a semiconductor manufacturing process.

Recent analysis has identified the upcoming industrial network technologies and looks at the drivers behind their adoption.

EDITOR’S CHOICE

FLOW & LEVEL CONTROL

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22 Henk van der Bent describes how a multivariable pressure transmitter with built-in dynamic compensation can correct many of the errors and inaccuracies that occur in differential pressure based flow measurements.

Planning and simulation tool for Profinet networks; Magnetostrictive sensor with IO-Link functionality.

MACHINE VISION 10 Many materials processing applications now incorporate cameras and software solutions to support the positioning of workpieces and tools, and to perform inspection tasks.

26 Suzanne Gill reports on the development of a new pressure regulation device.

INDUSTRIAL COMMUNICATIONS 32 A partnership agreement between PI and CLPA aims to broaden the use of open industrial Ethernet-based networks.

THE SMART FACTORY 12 Jeff Lund comments on the challenges of implementing an IoT initiative and offers tips for ensuring project success.

14 Anja Moldehn believes that the basis for success of Industry 4.0 is the creation of plant-wide secure and consistent digitisation.

SIMULATION 16 Dynamic simulation can help maximise plant performance and deliver cost savings on new plant projects.

Control Engineering Europe is a controlled circulation journal published six times per year by IML Group plc under license from CFE Media LLC. Copyright in the contents of Control Engineering Europe is the property of the publisher.

ISSN 1741-4237 IML Group plc Blair House, High Street, Tonbridge, Kent TN9 1BQ UK Tel: +44 (0) 1732 359990 Fax: +44 (0) 1732 770049

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FINAL WORD 35 Brian Foster Foster, head of Industry Finance at Siemens Financial Services in the UK explains why it is important that companies keep up with technological advances and suggests how this can be achieved in a challenging financial environment.

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May 2016

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INDUSTRY REPORTS

Industrial network movers and shakers Recent analysis of the industrial network market has identified the upcoming network technologies and offers suggestions for the drivers behind their adoption.

However, industrial automation is a conservative market and it will take time before industrial Ethernet outgrows fieldbuses.”

Wireless is coming

Image courtesy of HMS Networks.

A

s an independent supplier of products and services for industrial communication and the Internet of Things, HMS Industrial Networks is able to offer insight into the industrial network market with its industrial network analysis. The company has identified a recent growth in the pace of adoption of Industrial Ethernet technologies. The company says that, currently it accounts for 38% of the market with EtherNet/ IP being the dominant choice globally, followed PROFINET. However, HMS also found that classic fieldbuses still dominate the fragmented world of industrial networks, accounting for 58% of networks. The Internet of Things is also now starting to make some impact and is driving the use of wireless technologies.

Looking at new installed nodes within factory automation globally, HMS’s analysis found again that fieldbuses are still the most widely used type of networks and are still growing – by

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May 2016

approximately 7% per year – because they are able to meet users demands for simplicity, tradition and reliability.

The dominant fieldbus is PROFIBUS which accounts for 17% of the total world market including industrial Ethernet, followed by Modbus with 7% of the market and and CC-Link with 6% of the market.

However, Industrial Ethernet is said to be growing at a faster pace than in previous years. At a growth rate of 20%, Ethernet now makes up 38% of the global market, compared to 34% in the previous year. EtherNet/IP is the number one Ethernet network with 9% of the market followed by PROFINET with 8% of the market. Other notable networks include EtherCAT, Modbus-TCP and Ethernet POWERLINK. Commenting on the figures, Anders Hansson, marketing director at HMS, said: “We see evidence of an accelerated transition towards industrial Ethernet when it comes to new installed nodes.

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For the first time, wireless technologies featured in the analysis findings, with 4% of the worldwide industrial network market. WLAN was found to be the most popular choice, followed

by Bluetooth. “We see the Internet of Things as a big driver for wireless technologies,” said Hansson. “Wireless opens up new automation architectures and is increasingly being considered for machine connectivity and control, including Bring Your Own Device (BYOD) solutions via tablets or smartphones.”

In Europe and the Middle East, PROFIBUS is the leading network while PROFINET has seen the fastest growth rate. Runners up are EtherCAT, ModbusTCP and POWERLINK. The US market is dominated by the Common Industrial Protocol networks, where EtherNet/IP is starting to overtake DeviceNet in terms of market share.

In Asia, no network currently stands out as being truly market-leading – with PROFIBUS, PROFINET, Ethernet/IP, Modbus and CC-Link all being widely used. EtherCAT continues to establish itself as a significant network in the region, and there are early signs of CC-Link IE Field being adopted.

The Industrial Internet of Things (IIoT) has resulted in more industrial devices being connected. “It is interesting to see that industrial Ethernet is now growing faster and that wireless technologies are gaining a foothold,” continued Hansson. “What is clear, however, is that the network market remains fragmented as customers continue to ask for connectivity to fieldbus, industrial Ethernet as well as wireless networks.

Industrial devices are becoming increasingly connected, boosted by trends such as Industrial Internet of Things and Industry 4.0.”

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EDITOR’S CHOICE

Delta robot offers fast lightweight pick-and-place solution The MELFA range of compact SCARA and articulated arm robots from Mitsubishi Electric has been extended by the introduction of new Delta style robots from Codian Robotics.

Employing high precision servo motion technology and Mitsubishi Electric software the new range is said to be fast, precise and user friendly. It is suited to use for lightweight pick-andplace tasks. Each robot is able to work autonomously using servo control or be integrated seamlessly into a Mitsubishi Electric automation environment.

This solution has been developed as a result of the e-F@ctory Alliance partnership, an initiative of Mitsubishi Electric where companies work together to create best in class automation solutions. As members of the alliance,

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Codian Robotics and Mitsubishi Electric are providing a more extensive combination of robot technology and control options to machine builders and robot integrators within the group and to the market in general.

Manufacturing and packaging industries are very competitive and this translates into demands for higher speeds and high reliability to combat tight margins on machinery and production lines. When low weight items are being assembled, processed and packaged the construction of the production lines is often equally lightweight. When introducing a robot to this environment it is an advantage to be able to save weight in construction and also reduce moving mass in the manipulator.

Codian Robotics’ Delta robot is constructed using materials such as carbon fibre, titanium, anodised aluminium, 316 stainless steel and plastics to ensure it is lightweight. In combination with advanced servo driven movement this makes it suitable for typical three-axis top-loading packaging applications and push-fit assembly.

A waterproof model is available for wash-down environments such as food & beverage, cosmetic and pharmaceutical applications.

Planning and simulation tool for Profinet networks

Magnetostrictive sensor with IO-Link functionality

A new software tool from Siemens has been developed for the design and simulation of Profinet automation networks.

The Sinetplan network planner is aimed at plant designers, constructors and operators and offers support from the planning stage, through commissioning, to the operation of a Profinet communication network.

In order to ensure subsequent operational reliability and to avoid problems during commissioning, the network is already designed with a suitable topological structure at the planning stage and any possible bottlenecks caused by peak loads, for example, are simulated. In the operating phase, Sinetplan offers transparency about the network capacity up to the port level of the individual stations by means of online

MTS Sensors has expanded its linear position sensor range with the introduction of new versions of the E-Series that support the IO-Link communication protocol.

Available in a variety of housing formats, the E-Series IO-Link offering is optimised to address spaceconstrained applications.

The IO-Link protocol offers simple bi-directional point-topoint communication with both signal transmission (at rates of up to 230.4 kbps) and power delivery being handled. It enables consistent communication between sensors and the controller, as well as providing access to diagnostic data.

The sensors have a maximum stroke length reaching up to 2540mm. They are able to keep deviation to within a margin of less than 0.02% (full scale).

May 2016

scans, traffic shapers or reporting functions. This prevents unnecessary downtimes due to network overload.

Sinetplan is used in particular for the planning and operation of Profinet networks that use acyclic data services such as TCP/IP in addition to cyclic realtime communication. Projects already planned in Step 7 are easy to import, and existing systems are scanned online, verified and simulated.

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PREVENTION IS THE BEST MEDICINE

Improving operational efficiency is crucial to maintaining the health of company-wide assets. With an integrated platform that combines rugged CompactRIO hardware with intuitive NI InsightCM™ software, NI provides systems that monitor critical equipment. With advanced I/O, complex signal processing and data analytics and visualisation capabilities, NI puts you on the cutting edge of the Industrial Internet of Things and connects equipment, people and technology like never before.

S e e h ow a t n i . c o m / m c m

CompactRIO Platform and NI InsightCM

©2016 National Instruments. All rights reserved. CompactRIO, National Instruments, NI and ni.com are trademarks of National Instruments.

Other product and company names listed are trademarks or trade names of their respective companies. 24687

COVER STORY

ID and vision solutions for contact lens packaging Janina Guptill and Jan Grootjans discuss a joint project to develop an ID and vision solution for a packaging machine for contact lenses. during and after packaging thanks to Cognex ID technology and an SQL database.

Identification for accurate filling

NKL’s new lens packaging machine from Stevens Engineering offers a high throughput on a small footprint (picture rights: Stevens Engineering).

I

ndustrial automation is mostly about handling robust products. Within the manufacturing and/or packaging process and integrated vision and ID solutions need to be fast and highly productive. However, there are some applications which are more challenging, such as identifying a delicate, seethrough product in a clear liquid while reading a translucent code. For NKL Contactlenzen, a manufacturer of hard and soft lenses, the Dutch company Stevens Engineering has equipped a packaging machine with vision and ID systems from Cognex which see what is almost invisible.

NKL Contactlenzen is a subsidiary of Menicon, the Japan-based supplier of lens materials, lens design and lens care solutions. At its production facilities in the Netherlands, NKL has installed a compact packaging machine with high quality and hygiene requirements in which customer-specific lenses are

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packaged efficiently and carefully.

The turnkey solution, which combines mechanical design with electrical automation, was developed and installed by Stevens Engineering. The vision and ID solutions employed in this packaging machine were delivered by Cognex.

After a final manual lens inspection, the operator places the lens in the lens holder and places this in the newly developed product carrier.

The machine takes the product carrier with the lens holder and adds the special preservation liquid, seals it with aluminum foil and closes the lens holder’s cover – ready for shipping.

The machine has a remarkably small footprint and requires almost no manpower. The seal quality is extremely high and the fluid dosing is highly accurate. The cycle time is currently just 10 seconds and each product and lens holder can be tracked at all times both

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The packaging machine is equipped with a rotary table with 10 positions for operating and controlling the lens, lens holder and the product carrier.

One of the first jobs in the packaging machine involves being processed by the DataMan 200 from Cognex. The DataMan 200 is a small, fixed-mounted industrial high-performance barcode reader with a resolution of 752 x 480 pixels and a global shutter ideal for 1-D applications.

Within NKL’s packaging machine, the reader scans the 1-D barcode label on the product carrier. Based on this identification, the lens holder is then accurately filled with one of two

Control Engineering Europe

COVER STORY

One of three Cognex vision systems in the packaging process: The DataMan 200 reads 1-D and 2-D barcodes on product carrier and lens cover (picture rights: Stevens Engineering).

available liquids for preservation.

Next, another vision system from Cognex, the In-Sight 7050, detects the lens. This is a challenging application because the lens is not only transparent, but also has different colours and is covered in liquid. However, the fully integrated In-Sight system is perfectly equipped for such sophisticated applications thanks to its autofocus and fast image capture functions. The smart camera also checks whether the lens is covered by enough fluid and whether there is any spoilage, such as drops outside the lens storage section.

The camera system was configured with In-Vision’s standard software and inspection tools, so no additional scripting or manual configuration was required.

Cognex’ In-Sight series and DataMan fixed-mount barcode readers ensure quality and traceability even of delicate products (picture rights: Cognex).

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End of process verification Finally, the lens holder is sealed with aluminum foil and the plastic lid is closed. The lens holder lid is then printed with a UV ink 2-D matrix code to clearly identify the lens. The 1-D barcode on the product carrier and the 2-D matrix code on the lens cover outside are now read by another DataMan 200. Here, the reader’s integrated bright field is complemented by special UV lighting to detect the UV ink printed code. The product and packaging data acquired

helps to verify the completion of the process in the SQL database and NKL’s management information system.

It took Stevens Engineering less than half a year to develop and install this customer-specific solution for NKL Contactlenzen. Following a further six months of usage within a ‘clean room’ production environment, the customer is satisfied with the packaging solution which offers multiple functionalities on a very small footprint. The new machine is faster and requires less manpower, which leads to constantly high packaging quality. Compared to the previous solution, the quality checks and the packaging quality have been enhanced, fulfilling the high requirements for this delicate product. Currently, NKL and Stevens are discussing further improvements for the next generation of this packaging machine. The optimum quality check and traceability will again, be ensured

by Cognex systems.

Janina Guptill is marketing specialist at Cognex Germany Inc. Jan Grootjans is project manager manufacturing & machinery at Stevens Engineering

New vision sensor powered by In-sight Cognex has recently introduced the In-Sight 2000 series, a product line that combines the power of its In-Sight vision systems with the simplicity and affordability of a vision sensor.

Said to be ideal for solving simple errorproofing applications, these vision sensors set new standards for value, ease of use and flexibility thanks to the combination of In-Sight vision tools, a simple setup, and a modular design with interchangeable lighting and optics.

Commenting on the range, Joerg Kuechen, vice president and business manager for Vision Products at Cognex, said: “Manufacturers want a cost-effective way to expand the use of vision technology down to the simplest applications – using the same setup software they use to solve more challenging vision tasks. The In-Sight 2000 series can easily be applied to simple vision

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applications out of the box, while delivering the reliable performance expected from In-Sight vision systems.”

The In-Sight 2000 series includes an integrated image formation system consisting of field interchangeable lenses and a patentpending LED ring light that produces even, diffuse illumination across the entire image, eliminating the need for costly external lighting. Customers can easily swap out the lens and change the colour of the integrated ring light as needed for their application.

Together with the In-Sight Explorer EasyBuilder interface, which provides a fast, step-by-step application setup, the In-Sight 2000 series allows even novice users to achieve extremely reliable inspection performance in nearly any production environment. www.cognex.com/2000 May 2016

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MACHINE VISION

Versatile vision solution

for laser marker

Many materials processing applications now incorporate cameras and suitable software solutions to support the positioning of workpieces and tools, or to perform tasks in the area of visual quality inspection.

R

OFIN is an expert in laser material processing and utilises industrial cameras in its desktop laser marking systems.

The EasyMark desktop laser marker is a particularly compact system produced by the company for the engraving of metal or plastic parts in DIN A4 format up to a height of 120 mm. The air-cooled laser beam sources, ranging in power from 10 to 50 W, are fully integrated into the system.

To ensure that the marking process is precise, while also avoiding scrap, ROFINBAASEL offers the device with a range of different camera solutions. In the basic variant, a 2 MP camera mounted laterally above the workpiece to be engraved supports manual workpiece positioning.

Customers also have the option of enhancing the basic variant with the SmartView solution, which uses a 10 MP camera. In this variant, the camera captures an image of the workpiece, which is then displayed as a background in the engraving software. Against this background image, the information

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to be engraved can be easily oriented independently of the workpiece’s position. This function is said to be particularly useful for objects where the surface to be engraved cannot be defined using a positioning rectangle or, due to the material, a test engraving is not possible. The camera’s high resolution enables easy digital zooming on the image and precise adjustment of the engraving’s layout. In addition, a relatively inexpensive lens with a fixed focal lens is sufficient, and a single optical configuration provides both an overview image and a pin-sharp detailed image.

ROFIN-BAASEL offers the additional option of Through-the-Lens (TTL) technology. With this technology, a 10 MP camera looks through the deflection mirror and focusing lens along the laser’s optical beam path. This allows the camera to capture all optical and electrical fluctuations in laser beam deflection and focusing in the system, and these are adjusted automatically when positioning the engraving layout using the camera image. This enables a high degree of precision.

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USB solution An IDS USB 2 uEye SE industrial camera is used in each of the system variants that can be selected by the customer.

These cameras are available with a range of CMOS and CCD sensors, and with a choice of housing variants. The USB interface means that data is sent and power is supplied by a single cable.

The digital inputs and outputs for controlling the trigger and flash are optically decoupled and can process signals up to 30 V. The cameras can be screw-mounted on all sides so can be installed anywhere. A specially developed sensor seal provides protection in extremely dusty environments. The camera filter is also exchangeable and easy to clean.

The most important factor in ROFINBAASEL’s decision to integrate the cameras into their systems was the software support provided by IDS. This made it easy for the company to integrate the camera into its own Visual Laser Marker (VLM) engraving software and allows for simple model changes.

ROFIN-BAASEL uses two different camera models in its EasyMark systems.

If the system needs to be equipped with different camera variants to meet new customer requirements, the cameraspecific parameters would simply have to be adjusted and the ROFIN application would not need to be re-programmed.

As a result, it is easy, time-saving and cost-efficient to switch between different cameras.

Through the Lense (TTL) technology requires the use of two cameras to capture the optical path of the laser beam.

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Vision Software

that’s hardware independent

Smart Camera

Standard computer with

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cameras

Industrial computer with

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cameras

Matrox Design Assistant 4 Lets you deploy your inspection project to the platform of your choice. Whether it’s a computer with GigE Vision® or USB3 Vision™ cameras, a Matrox smart camera, or a Matrox vision system, you’ll get the processing power you need.

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M AT R O X

I M A G I N G

SMART FACTORIES

OT and IT: bridging the gap Jeff Lund comments on the challenges of implementing an IoT initiative and offers tips for ensuring project success.

M

anufacturers are Increasingly needing to invest time and money to make their factories and processes smarter and more productive in a bid to remain competitive. The Internet of Things (IoT) is the next wave of technology that will help the industrial sector to achieve these goals. Connecting smart devices throughout a plant will allow companies to automate processes, better manage assets, and analyse real-time data from a variety of sources to make smarter business decisions and reduce costs.

Enabling multiple devices to communicate with each other and with enterprise systems in this way is only possible with Ethernet and the Internet Protocol (IP). However, the resulting flood of data that comes with this requires a new level of collaboration between Information Technology (IT), which focusses on information processing, and Operational Technology (OT), which focuses on the devices, sensors and software that keep production running.

Traditionally, these two disciplines have operated in silos. But, to ensure the success of IoT, collaboration between IT and OT is vital and control engineers, as OT professionals, have a big role to play in ensuring successful convergence.

Challenges include: Different departments, different priorities – To an OT professional, availability will always be the top priority because shutting down manufacturing

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is potentially disastrous and definitely costly. It could cause safety issues, impact production levels and damage critical machinery. Indeed, system uptime often holds a higher priority than data integrity. For example, if a network security breach causes a system to shut down unexpectedly, it is more important to recover and restart the system – saving the data is secondary.

When OT data crosses into the IT domain, and is integrated with business processes, it is important to be aware that IT also has its own priorities and procedures that are important and need to be taken into account. The top priority of an IT department is to protect the data by keeping it confidential and accurate. IT has developed its own set of policies and procedures to ensure data integrity, availability and confidentially and you will need to learn to work with this when interacting with IT systems, just as IT professionals need to learn to adapt to OT needs when working in your domain.

Standard IT practices do not work for manufacturing systems – Little to no downtime is key in any industrial setting.

Therefore, IT may need to modify some practices for manufacturing systems. For example, some procedures may not be feasible in a factory, such as ‘calling the help desk’ to fix a system issue. Recovery needs to happen quickly to avoid impacting productivity. So, the recovery process must be simple and fast with steps that plant personnel can complete

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on their own; implementing automatic software patch updates; rebooting, particularly as an early approach to fixing a problem; giving all data equal priority versus prioritising some types of data (for example robot movement instructions) over others (for example report generation).

Industrial networking systems have unique requirements that may be unfamiliar to IT – When preparing to work with IT, it is necessary to remember that they may not have experience working with high-voltage, high-current equipment; industrial ratings and policies; keeping people and processes safe; and the important differences between putting control versus information on a network.

Further, IT will not be familiar with working in the harsh environments often found in industrial settings which can impact the type of equipment needed to ensure the integrity of the data transmission vital to IoT. Without understanding this, the IT department might install commercial-grade wire and cable and commercial grade routers, switches and wireless networking devices that will not perform well in an unforgiving industrial setting.

Overcoming the obstacles To overcome these challenges an environment of collaboration needs to be fostered. Consider this advice to start bridging the gap between OT and IT. • Offer an olive branch: Find out which IT representatives would be the most likely to handle IoT projects and set up a time to meet with them. Look for projects on Control Engineering Europe

SMART FACTORIES which both functions can begin to collaborate.

• Be sure you get in on the ground floor: Executives looking to capitalise on the IoT may think, because it involves IP technology, it should be led by the IT department.

Speak to your leadership team and keep in touch with your friends in IT to let them know how including OT at the front end of IoT projects will help the process run more smoothly.

• Educate: Proactively educate IT about what is required for the manufacturing side of the business to make an IoT initiative a success. For example, make sure IT understands that, even when sitting in a control room, equipment can be exposed to extreme aspects of an industrial environment that can degrade materials, so you need products that are resistant to water, oil, torsion, vibration and shock. Give details about the types of industrial switches, routers and physical components the project requires to withstand the harsh manufacturing environment.

• Walk through standard processes: Work together to develop standard processes for undertakings that will need to be modified to accommodate the needs of both OT and IT. For example,

outline guidelines for when and how to administer software updates, how to recover from a network outage, and what steps to take before adding a new device to an existing network system.

• Listen: Collaboration is a two-way street. Both OT and IT can learn from each other and the different perspectives and expertise that each brings to the table. Begin to create this type of environment by listening to IT, asking for their input and being empathetic to their needs.

The goal of IoT is to transform data into insights for creating business efficiencies.

IP is the foundation for IoT and, once you start putting in Ethernet-based systems, IT is going to be involved with network design and access. Instead of working in silos, it is necessary to join forces with IT to create a collaborative approach that will result in a stronger industrial network to ensure your organisation can benefit from all that IoT has to offer.

Stop traveling on site for support!

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Jeff Lund is senior director of product line management for Industrial IT at Belden.

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May 2016

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SMART FACTORIES

Secure communication is the key Anja Moldehn believes that the basis for success of Industry 4.0 is the creation of plant-wide secure and consistent digitisation.

T

he manufacturing industry is facing a new challenge to optimally plan and implement complex manufacturing processes.

Production needs to proceed without interruption or rejects. When combined with high flexibility, this helps ensure competitiveness. To meet these challenges intelligent and secure communication structures are vital.

Industry 4.0 points to solutions for fulfilling these demands through the use of digital, networked system solutions and Phoenix Contact has been applying some of the abstract Industry 4.0 ideas to meet practical requirements of production. The company has defined six fields of action that focus on high flexibility, performance, quality, and economy. These include consistent digitisation, secure communication, autonomous adjustment to changed

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framework conditions, simple installation and operation, as well as the efficient use of resources.

Secure and consistent digitisation forms the foundation of the initiative. Only when all the relevant information is available in digital format and all participants of the value chain are networked can the Industry 4.0 approach be systematically implemented. Digital data is taken to maximise added value at any given time. The connection of people, objects, and systems leads to dynamic, selforganising added-value networks. These can then be improved according to various criteria, such as cost, availability, or resource consumption. Intelligent mechatronic systems exchange their data across locations and companies through public or private network infrastructures.

This communication, based on Ethernet and the Internet, ensures high

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production availability. At the same time, it forms the foundation of flexible, self-optimising manufacturing processes.

For this reason data transmission needs to be reliably protected from electrical interference and unauthorised access.

Phoenix Contact has employed Industry 4.0 ideas in its own production systems, which has led to a new production line at the Bad Pyrmont location where 6mm wide isolation amplifiers are produced for interferencefree signal transmission.

The manufacturing process has been improved in terms of how the product, worker, and machine communicate with each other. A continuous material flow in the process chain and short production retooling times for all of the 98 product variants contribute to efficient methods of operation. When ordering isolation amplifiers, customers can use an internet-based configurator to select the input or output signal type. More than 1,000 different module versions are available and, in order to allow such a wide variety of products to be manufactured in small lots of 5 to Control Engineering Europe

SMART FACTORIES 480 at mass-production costs, personnel and machines need to work quickly and economically.

Flexible processing After soldering paste has been applied and SMDs have been mounted, sets of four PCBs are checked for the correct arrangement of the individual components. Up to 154 small components, such as resistors, capacitors, and diodes, can be installed on a single PCB. After soldering, a stamping machine cuts out the PCB. It is then placed on a workpiece carrier and fed into the Industry 4.0 system cycle. Around 20 workpiece carriers circulate around the production line at the same time, allowing employees to work at capacity and the system to function economically.

First, the workpiece carrier is conveyed through a short cycle. After a laser has completed labeling and the recesses have been milled, the housing is completed. In the next step, the PCB is inserted and coupled with the housing.

Then in a soldering portal, the housing is soldered to the PCB. The module is now completely functional. During downstream programming of the respective firmware, a cylinder lifts the workpiece carrier to the test head. This is followed by high-voltage and final electrical testing.

When an order is loaded to the production line, the work plan is generated. As soon as the product is in the workpiece carrier, an RFID tag creates a connection to the information which the higher-level system provides.

That includes the indication of which tests are to be performed on the article and whether and what firmware must be implemented. The workstation machine operator comes into contact with each module three times. Each contact involves a different task. One is to read out the RFID chip to compare the finished article’s image area with the specifications displayed on the screen.

Another is to insert the PCB and package the finished module. The processing status of the individual products is communicated to the higher-level Control Engineering Europe

system via the RFID tag. That is why the screen only shows the information or options that need to be performed on the current task. In this way the communication between the article and the facility control system makes the high complexity resulting from the wide range of variants manageable for personnel. They receive assistance, allowing them to complete work quickly and without errors.

This application demonstrates that systems can already be developed to offer flexible production. However, in order to gain all the advantages of future industrial manufacturing, it is important that the actual article communicates with the processes that are based on digital data. This will require the products involved to

be just as thoroughly digitised as the individual workstations through which they pass during their manufacture. This will allow the human actor to operate the production system economically with support from assisting systems. In addition, both data exchange and the design of the communicated content must be adequate for the production systems. If operators want to ensure that their production locations will continue to be successful, they must organise standards and guidelines that are sufficiently open to allow them to adapt to changing conditions and business models.

Anja Moldehn is a marketing specialist Industrie 4.0 at Phoenix Contact Electronics GmbH

SmartFactory demonstrator progresses The third generation of the World‘s first manufacturer-independent Industry 4.0 plant was displayed at Hannover Messe this year.

The SmartFactory initative is bringing together a wide range of automation vendors such as Festo, Phoenix Contact, Mettler Toledo, Pilz, Harting, Cisco and Weidmuller to name just a few, to transfer new technologies and concepts into the environment of factory automation.

These technologies are constantly being tested on a typical industrial production plant, and then further developed and expanded.

The SmartFactory KL demonstrator on display at the exhibition showed how market-ready technologies from a variety of automation suppliers are, together, able to put Industry 4.0 concepts into practice today and to show what advantages this can offer the end user.

Topics such as Plug&Produce, Predictive Maintenance, Failure-Proof Maintenance, Scalable Automation and Supporting the Worker in the Production Environment were demonstrated throughout the event,

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with hardware modifications taking place daily.

Through its design, which demands modularity and interoperability throughout, the demonstrator was able to show the realisation of flexible and efficient production. Digital product memories control the order processing which start with the product and enable batch sizes of one to be created in an efficient manner.

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SIMULATION

Dynamic simulation benefits ACROSS THE PLANT LIFECYCLE Miquel Angel Alós explains how dynamic simulation can help maximise plant performance and deliver cost savings on new plant projects.

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he oil and gas industry has witnessed seismic downward shifts in barrel prices and uplifts in market competitiveness which has challenged owneroperators to squeeze more out of their operations. Engineering, procurement and construction companies (EPC) are also under more pressure to reduce project risk and achieve better alignment with owner-operators to ensure effective management of their client’s capital.

The use of rigorous dynamic simulation can help to maximise operating performance while achieving better quality products more quickly.

Analysing operating scenarios using dynamic process modelling gives confidence that new plants will startup safely, meet budget and perform to plan. Dynamic simulation is also vital to successful plant design and operation. Designs can be improved by incorporating a system’s dynamic response to changes within the design model. To accommodate and study scenarios such as shutdowns and emergency situations, dynamic process simulation of the ‘real world’ can deliver effective results.

Lost production overshadows installation costs in the oil & gas and refinery sector, so it is vital that plant designs are robust. Dynamic simulation can show transient responses that are not determined during traditional steady-state design methods, providing engineers with a deeper understanding of plant operational behaviour, which can be crucial in safety-related equipment sizing. As a process simulation knowledge provider, Inprocess conducts dynamic simulation studies to confirm safe and efficient

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design. The net result of this for a project is significant time and cost savings.

The pillars of effective use of steadystate and dynamic simulation to support best engineering design practice are based upon good communications, efficient knowledge transfer and comprehensive support training.

Tailoring training programmes to maximise process simulation knowledge will help to ensure a better understanding of the plant lifecycle and will maximise project return on investment.

make the necessary trade-offs and optimise the design. Dynamic simulation makes it possible to simulate a realistic understanding and behaviour of the plant and to help improve decision support and safety.

Dynamic simulation benefits

Best practice

Unlike steady-state simulation, dynamic models factor time, which helps model complex transient behaviour such as changes of temperature and pressure.

This type of simulation reproduces the real behaviour of a process plant, providing values that correspond to process variables at a given time. These simulations have an interactive interface that helps the engineer understand what it would be like with a real plant and with solutions becoming more precise, fast and easy-to-use. The main benefit of dynamic simulation is the deeper knowledge it provides about the process as a result of improvements in system control design, plant operations and staff training. It enables the verification of the appropriate size of equipment used to determine design constraints covering the plant’s normal operation. As the plant goes through many modifications during its lifetime, dynamic simulation provides a means of continuous assessment of the operability of the proposed design solution.

Better design decisions through detailed analysis enable engineers to

A recent case study based in Central America required Inprocess to provide consultancy to a large owner-operator.

We were asked to verify and perform a feasibility study on engineering design models supplied by an international EPC. Verification of the EPC’s design formed the project’s first phase while its second involved verification of the multiphase pipeline behaviour, assessing plant start-up and support plant operability to reach production targets.

The project involved analysis of all operating variables, including safety analysis, process dynamics and units interactions. Applying simulation models helped the client across different phases of the facilities’ lifecycle.

For example phase one, using AspenTech’s Aspen HYSYS simulation platform, first-principle models (steady-state and dynamics) provided a significantly better understanding of the process dynamics and its interactions and enabled Inprocess engineers to evaluate and fine-tune strategies before implementation. Using dynamic simulation early in the design phase

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Control Engineering Europe

SIMULATION allowed the engineers to identify important operability and control issues, along with equipment sizing adjustments, which led us to improve the design.

Through the second phase, the simulation platform integrated everything into one simulation environment, reducing the time required for ‘what-if’ studies. During start-up operations, a holistic simulation model, incorporating both the pipelines and the structure of the platform (topside), determined the correct sequence of steps to adopt when starting up the initial wells and to reach the early production rate.

Designing pipeline systems requires complex considerations, such as the pipeline flow path, terrain profiles, expected volumes to be received and delivered over the pipeline, along with the physical properties of products to flow through the pipe. Dynamic simulation of pipelines with updated compositions from the wells was invaluable to gain crucial information about the development of liquid holdup profiles, as well as pressure and temperature data. This information determined predicted hydrate formation risk and slug sizes. Crucially, dynamic modelling results helped to keep the flow going, which consequently prevented interruptions to the plant and avoided reduced profits.

Big savings were achieved on the project through improved and faster start-up procedures with capital cost savings through the avoidance overdesign of relief systems. The topside model was tuned and calibrated by reconciling discrepancies with plant data, by adjusting certain values and parameters to ensure the model corresponded to actual unit operation before proceeding with further development.

The availability of the upgraded model helped the client to troubleshoot operability issues and to reach targets earlier. In addition, using a common platform facilitated the effective communication between all Control Engineering Europe

stakeholders, which was essential for the transfer of knowledge. Collaboration and information sharing became the lifeblood for determining accurate outcomes and analysing plant behaviour.

Inprocess also delivered a Process Trainer of the plant – a dynamic model containing real plant data, combined with a user-friendly interface, identical to the HMI of the plant which is able to facilitate the execution of preprogrammed scenarios of different operational conditions to troubleshoot detected problems. In the early field production phase, this operational support yielded a database of operational cases, which are cumulative during the plant life cycle. Consequently, new engineers at the plant are able to learn how it operates by following the simulation cases, helping to minimise the impact of personnel turnover in plant operability and safety.

Understanding An effective design and control strategy requires a comprehensive understanding of the process in order to avoid unplanned downtime. Process

simulation experts are now able to quickly create robust models that can validate EPC design and increase confidence that projects will run on time, to standard and be maintained easily to help ensure optimised operations. Dynamic models of the plant give companies the assurance that they can achieve faster and safer plant startups while maximising productivity.

Dynamic simulation helps to avoid disruptions and minimises the impact of unnecessary costs on real plant operations. For example, using a reliable dynamic model, owner-operators can ensure production goals are achieved according to already signed contracts, avoiding penalties for not meeting agreed production or product quality.

Similarly, it is possible to plan for sub-optimal plant operating points, preventing full plant shutdowns and keeping the plant in operation, when partial power failures occur in remote locations or where power supply can be unstable.

Miquel Angel Alós is services manager at Inprocess.

Bosch Rexroth adopts augmented reality for service support Augmented reality software and smart glasses from XMReality has enabled Bosch Rexroth to roll out a new service and support programme with remote assistance.

The first Rexroth solution launched for industrial hydraulics involves the client company’s own maintenance team, who carry out adjustments, troubleshooting and emergency work, with remote guidance from Bosch Rexroth’s systems specialists, using XMReality software on a smart handheld device, along with optional smart glasses.

The augmented reality smart glasses enable hands-free operation during interaction with the service experts.

However, the software can also be used with just an ordinary smartphone.

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The service expert sees on his screen what the operator sees through the lens. The software transfers video and audio streams between the service expert and the operator with perfect synchronisation, even when the bandwidth is low. Gestures, drawings or instructions can be overlaid by the instructor on the live image.

The XMReality software is compatible with Windows and Android operating systems. The optional smart glasses can be used with prescription glasses or protective smart glasses. A 40° field of vision enables the instructor to see the periphery of the image. The smart glasses are powered by the tablet or laptop computer and battery life is usually around two hours, depending on battery size.

May 2016

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WIRELESS TECHNOLOGY

Wireless sensor network streamlines SEMICONDUCTOR MANUFACTURING Ross Yu and Enrique Aceves explain how a wireless realtime monitoring solution has squeezed more efficiency out of a semiconductor manufacturing process.

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emiconductor wafer fabrication facilities (fabs) need to be carefully managed to maximise uptime, yield and throughput. Plant operations teams are constantly looking for new ways to squeeze even fractions of a percent more efficiency out of the manufacturing process.

At Linear Technology Corporation’s Silicon Valley fab, over 175 specialty gas cylinders are used in the wafer manufacturing process. These gas cylinders need to be closely monitored to ensure uninterrupted supply. To avoid downtime, technicians manually log the pressure of each gas cylinder in the fab three times every day. This process is prone to human error and is costly to maintain.

It is, typically, a manual process because communications wiring is costly and impractical in the fab. Cylinders are located throughout the facility, and there are often no AC outlets or Ethernet jacks nearby. For safety reasons the building will have concrete walls, making it cost-prohibitive and disruptive to the process to install new wires.

A better solution A better solution has been found by Linear Technology, through the use of its own low-power wireless mesh networking solution. A SmartMesh IP wireless mesh network has been deployed to monitor gas pressure in the gas bunker. Every node is powered by a pair of lithium AA L91 batteries for an approximate eight-year battery life, so no additional wiring was needed and no unnecessary downtime was required to install the network. Despite the concrete construction and prevalence of metal structures in the fab, the network has

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proven to be reliable. Since installation, the network has been up continuously for over 83 days, and has transmitted over 26 million data readings with >99.99999% reliability, which is 100 times better than the stringent ‘5 nines’ reliability expected of high availability communication and computer systems.

Real-time gas usage readings are wirelessly sent to plant software which predicts gas replenishment schedules and helps in capacity planning.

In the gas bunker, each cylinder is measured for both tank pressure and regulated pressure and these readings are communicated to a central monitoring system via the SmartMesh network. Each SmartMesh node is connected to a pair of cylinders and sends readings through the wireless mesh network to a web server across the building. In the control room, the fab’s site management software tools display real-time readings and automatically calculate run rates to establish regular schedules for cylinder replacements. In addition, low-pressure thresholds are set to alert facility technicians if cylinders reach low levels prior to the replacement schedule. Alerts are displayed on the control room monitor and via Internet messaging on a 24/7 basis.

By using real-time gas consumption rates, technicians are able to precisely predict when gas cylinders will need

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Wireless nodes need to be able to perform reliably among pervasive metal and heavy concrete construction.

to be replaced, reducing waste from unused gas due to premature cylinder changes. The benefits extend beyond efficiencies in day-to-day operations.

By centrally collecting gas usage data and making it readily available to plant management, the system enables trend analysis which further identifies opportunities to streamline plant operations by correlating readings with specific semiconductor fab processes and geometries. This helps to optimise fab capacity growth as the need arises.

“The efficiency gains have more than justified the installation of the wireless gas cylinder monitoring network. As a result, we plan to expand this system across the entire plant to gain further efficiency in our operations,” said Alex McCann, chief operating officer at Linear Technology.

For semiconductor wafer facilities, optimising uptime and increasing operational efficiency results in increased production output.

Dust networks Linear Technology’s Dust Network products are embedded chips and precertified PCB modules complete with intelligent wireless mesh networking software. When embedded into sensor and gateway products, the wireless connection achieves >99.999% data reliability and ultra-low power consumption, enabling sensors to be placed in challenging Industrial Internet of Things (IIoT) environments.

Ross Yu is product marketing manager, Dust Networks Products at Linear Technology and Enrique Aceves is remote office facilities manager at Linear Technology.

Control Engineering Europe

UK INDUSTRY REPORTS

Automatic programming makes swarm robots safer

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esearchers from Sheffield Robotics have applied an interesting method of automatically programming and controlling a swarm of up to 600 robots to complete a specified set of tasks simultaneously to reduce the effect of human error in programming. This could be particularly advantageous in areas where robot safety is a concern.

Swarm robotics is the study of how large groups of robots interact with each other in simple ways to solve complex tasks cooperatively. Previous research has used ‘trial and error’ methods to automatically program groups of robots, which can result in unpredictable, and undesirable, behaviour.

Researchers from the University of Sheffield applied an automated programming method previously used in manufacturing to experiments using up to 600 of their 900-strong robot swarm. This supervisory control theory has reduced the need for human input and therefore, error. The researchers used a graphical tool to define the tasks they wanted the robots to

achieve. A machine then automatically programmed and translated this to the robots.

This program uses a form of linguistics, comparable to using the alphabet in the English language. The robots use their own alphabet to construct words, with the ‘letters’ of these words relating to what the robots perceive and to the actions they choose to perform. The supervisory control theory helps the robots to choose only those actions that eventually result in valid ‘words’.

Hence, the behaviour of the robots is guaranteed to meet the specification.

The research required up to 600 robots to each make decisions independently to achieve the desired actions of gathering together, manipulating objects and organising themselves into logical groups. This could be used in a situation where a team is needed to tackle a problem and each individual robot is capable of contributing a particular element, which could be beneficial in a range of contexts – from manufacturing to agricultural environments.

Dr Roderich Gross, Department of Automatic Control and Systems

Engineering at Sheffield, said: “Our research poses an interesting question about how to engineer technologies we can trust – are machines more reliable programmers than humans after all? We, as humans set the boundaries of what the robots can do so we can control their behaviour, but the programming can be done by the machine, which reduces human error.”

The next stage of the research will focus on finding ways in which humans can collaborate with swarms of robots so the communication is two-way and they can learn from each other.

Manufacturing Training Centre gains an apprenticeship patron Multipix Imaging is becoming apprenticeship training centre patron for the Lloyds Bank Advanced Manufacturing Training Centre (AMTC), near Coventry.

Commenting on the news, Julie Busby, Multipix director, said: “Multipix Imaging is proud to be a patron of the AMTC. The facility features some of the most advanced manufacturing equipment in the world and that includes the machine vision equipment supplied by Multipix Imaging.

“Machine Vision is vital in many manufacturing disciplines and it is essential that we train young engineers so they understand how to use this Control Engineering UK

technology to create automated vision solutions. There is a lack of vision engineers in the UK and this must be addressed if we are to secure a position in global manufacturing.

“Multipix Imaging is delighted that the AMTC has recognised this and we look forward to supporting the training and education of the apprentices here.”

Peter Hunt, co-founder, said: “We know first-hand the value of apprenticeships and the great foundation they offer for the individual as well as the employer. We are pleased to be offering three apprenticeship positions at Multipix this year, ranging from IT to digital marketing.

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Paul Rowlett, managing director of the AMTC, added: “We are delighted to have Multipix Imaging on board as a patron. They will provide invaluable support and play a major role in helping to develop our next-generation of engineers. This partnership presents a fantastic opportunity for our apprentices to benefit from their expert training using their latest machine vision equipment, enabling them to develop skills that are much-needed by industry.

“The support from our patrons is making a tangible difference to the skills and knowledge of those who train here, as well as to the wider UK manufacturing industry.”

May 2016

UK1

TRACEABILITY

Track and trace from farm to fork Robert Brooks examines how automation in the food and beverage production supply chain can help to deliver increased visibility and traceability.

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odays consumers want to be better informed about what they consume. Sell by and use by dates are no longer sufficient.

Today there is legislation that requires information on allergens, nutritional value, producer details and country of origin, for example.

To help meet the requirements of all stakeholders within the supply chain there has been a move towards standardisation in the way information on packaging is presented, supplemented by legislation to ensure absolute traceability through the supply chain.

The European Food Information to Consumers Regulation No 1169/2011 (FIC) brings together EU rules on general food labelling and nutrition labelling into a single piece of legislation. The majority of requirements of the new legislation applied to pre-packed foods from December 2014, with mandatory nutrition declarations for most prepacked foods coming into force in December 2016. New rules on country of origin information for meat from sheep, pigs, goats and poultry have applied from April 2015. Topics covered by these regulations include dates of freezing of meat, compositional standards for minced meat, water content, caffeine content and even font sizes for labelling.

Surprisingly, once a product leaves the producer, there are no prescribed standards, in terms of information you need to share or how you share it. Here, the onus is on each individual company to have the necessary information to share with the relevant bodies if something goes wrong and manufacturers should be looking to automation for cost effective, flexible and secure solutions to these traceability issues.

GS1 standards provide a wider

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framework for supply chain visibility and are steadily being adopted by the food and beverage industry to offer a recognised framework for supply chain visibility and product traceability.

GS1 and other standards impose a requirement to print human and/or machine-readable codes on the product’s packaging, including alphanumeric as well as 1D and 2D codes. There are important differences between these printed codes, in terms of what information they can convey, what standards they meet, and where the data is intended to be used.

GS1 standards enables data to be shared between all parties in the supply chain.

eliminating the risk of human error.

Addressing inline detection

Total cost of ownership

Integrating process controllers and vision equipment directly into the realtime network can help to automate inspection tasks which, currently, are carried out by human operators. Modern production processes cannot rely on manual product inspection, so the printed alphanumeric codes need to be machine readable, to enable automated inspection systems to check that the mark is present, readable and correct.

Automated systems can now also manage shape recognition as well as handling in-factory quality measurements prior to packaging, and checking that the right pack and the right label are matched with the product itself. This can be done with a single system accessible via a single interface.

Adding further inspection tasks is also simplified which helps increase flexibility.

Modules within automated machines can rapidly self-configure, including the necessary automatic hardware definition, consistency checks and automatic initialisation. In this way, they have the flexibility to adapt to different inspection needs,

Price pressure in the food and beverage sector is also a hurdle. While a partcost reduction is a common approach, manufacturers are at risk of the consequences of errors, as a retailer will clear shelves and fine the perpetrator.

This highlights the need to evaluate the overall task and measure the cost improvements, taking Total Cost of Ownership (TCO) into consideration.

TCO is a management accounting concept intended to help buyers and owners determine all the direct and indirect costs of a product or system.

It goes beyond the initial manufacturing cycle time and cost to produce food or to make parts. It can include an estimate of the relative risk of alternative strategies, such as poor reliability, or the hidden costs of doing business overseas. Automation systems are key to a TCO approach, as a successfully implemented system will add to reliability and product traceability.

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Robert Brooks is european industry marketing manager, Food & Beverage at Omron Control Engineering UK

SENSOR TECHNOLOGY

Solutions for intelligent motion systems Industry 4.0 will soon start to place greater demands on sensors, which have a increasingly important role to play. This is already starting to be seen in intralogistics applications.

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odern automated shuttle transport systems reflect many of the future challenges for industry.

They offer an answer to the key trends for greater throughput, agility and flexibility as well as offering more efficient utilisation of space and the more sustainable use of resources.

However, they also highlight the growing demand being placed on sensor systems and automation components for smaller yet more powerful devices networked in line with the principles of Industry 4.0.

While seamless networking is only just starting to emerge in many business sectors, systems designed according to the principles of Industry 4.0 can already be found in the intralogistics sector where it is being employed to improve speed, precision, flexibility and availability, transparency at every process step and it is here that innovative shuttle solutions are finding applications for conveying and storage systems.

“Regardless of whether shuttles are implemented on conveyor lines or in high-bay warehouses or whether conventional high-bay storage devices, continuous conveyors, cranes or driverless transportation systems are used – up to the point of order picking – the applications are very similar, with regard to the functions that sensors are required to perform,”

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Connectivity is crucial with bar code readers.

said Wolfgang Peisker, head of industry sales Intralogistics at Leuze electronic. The presence of goods or system parts must be detected; compartment occupation checks or clearance monitoring must be carried out; volumes, fill levels, stack heights or overhangs must be detected; and various types of working areas and transportation paths must be safeguarded. Importantly data also needs to be transferred.

Growing demands “The growing demands that intralogistics applications place on sensors are particularly evident in modern shuttle solutions,” said Peisker. Shuttles are flexible, dynamic and resource-friendly with regard to space utilisation and energy consumption. They can be used in various areas of material flow or storage systems and can handle different loads. At the same time, they are able to perform a high number of storage and retrieval operations within a short period of time. For fast and flexible shuttles, reliable, spacesaving and safe sensors are needed for fine positioning, the detection of free spaces, presence monitoring and for collision prevention.

Examples of smart sensor solutions that meet the demand for dynamics, precision and flexibility but that are also compact and include the 10 series optical distance sensors

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from Leuze electronic. A high object tolerance to colour, material, surface and detection angle makes the measuring (ODS 10) and switching (HT 10) distance sensors reliable and precise. Whether working with organic surfaces such as wood, metal or plastics and whether matt, deep black or glossy, the sensors are able to maintain a constant switching point.

The working range of these distance sensors begins at 50mm and extends to 8,000mm. When used against a reflective tape, it is said to be possible to achieve scanning range limits of up to 25m. Large operating and teach buttons, as well as the OLED display, facilitate step-by-step commissioning and diagnosis of the ODS 10 at the press of a button.

The highly visible status displays on the top and front make it easy to check the status from a distance or in restricted access areas. Both models also provide an IO-Link interface ready for Industry 4.0. This allows diagnostic data to be transferred so that, by means of constant monitoring of the received signal level, the user can be alerted in good time to an impending failure.

These distance measuring sensors are used in shuttle applications, primarily for compartment occupation checks, collision protection or positioning > UK6 Control Engineering UK

Fan & Pump Control Redefined

You asked, we listened

The new F800 Variable Frequency Drive from Mitsubishi Electric has arrived, taking energy saving and motor control to the next level. Building on the unrivalled Mitsubishi Electric quality and reliability we have added several functions that will give huge benefits to the user. For maximum flexibility and adaptability the F800 features an advanced PID controller and a powerful built-in PLC. With the all new Advanced Optimum Excitation Control we have bridged the gap between dynamic motor control and maximum energy saving. The F800 is designed for fan and pump applications and the unique load curve detection feature allows early detection of leakages and blockages.

For the full facts on our new Fr-F800 Inverter visit gb3a.mitsubishielectric.com

SENSOR TECHNOLOGY applications. Other compact sensing solutions for shuttles could include the 2 and 3B series photoelectric sensors and diffuse sensors from Leuze electronic. Overhang controls very close to the outer edge of the shuttle can be simply implemented using LSR 2 throughbeam photoelectric sensors or PRK 2 retroreflective photoelectric sensors. Both devices have large operating ranges as well as high function reserves.

Measuring only 23.1 x 12 x 8mm, these sensors are smaller than a matchbox.

The 3B series sensors also have a compact design and a large selection of functions as well as high operating ranges and improved function reserves for reliable object detection, even in dusty environments or with high mounting tolerances. Technologies such as A2LS active extraneous and active ambient light suppression, brightVision for simple handling and fast commissioning are all features of the series. In shuttles, PRK 3B retro-reflective photoelectric sensors or HRT 3B diffuse sensors are often used at the end of aisles or for reference runs in order to precisely detect reference points using scanning or reflective technology.

Leuze electronic offers a range of products for every application field in intralogistics. These include automation components such as bar code readers, bar code positioning systems and data transmission photoelectric sensors. Bar code readers, such as the BCL 648i offer high resolution and simple handling.

They use blue laser light which enables 50% greater depth of field compared to conventional scanners with red laser light. This makes them less sensitive to variations in distance to the object being detected.

Often, manual focus adjustment is unnecessary in applications with varying distances. Bar code positioning systems such as BPS 348i enable precise and continuous

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May 2016

Constant temperature monitoring of electro/mechanical enclosures Addressing the need for wider electrical maintenance safety solutions on electro/mechanical enclosures, IRISS has developed a device that enables continuous monitoring – both as a stand-alone capability and as an addition to its existing window products.

Infrared imaging is able to detect thermal anomalies within panels.

However, it only provides a snapshot of the faults on the day of inspection, leaving the subject components unmonitored at any other time.

The Delta T Alert is a self-contained, wireless temperature monitoring system that can be attached to an electrical enclosure cover. It bridges the gap between infrared inspections by regularly recording and reporting critical temperatures within electro/ mechanical enclosures.

The unit comprises two temperature sensors. One monitors the interior temperature within the enclosure and the other monitors the ambient room temperature. Both are configured to collect data on a daily basis, at specific time intervals. The data is wirelessly transmitted for analysis and trending and warns the operator if the internal positioning over distances of up to 10km. Moreover, with an operating range of ±60mm they are tolerant to mechanical variations. Optical data transmission photoelectric sensors are a good choice for any application where data needs to be transmitted over long distances without cables and without interference. Devices such as the DDLS 500i enable contact-free and wear-free optical communication wherever mechanical systems are pushed to their technical limitations. With optical real-time 100 Mbit/sec, all common data protocols can be transmitted without time delay over a distance of up to 200m.

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temperature rises above pre-set thresholds.

This new technology can also be specified as an integral capability of the company’s range of polymer window products. This combination ensures the problem is verified with no operational disruption. The on-board Delta T Alert system sends a remote alarm giving the location of the problem and temperature details.

Once the repair is completed and the system re-energised, a second infrared inspection will confirm that the fault has been eliminated. The electrical enclosure can then be benchmarked and the system reset with the new baseline temperature delta.

“Communication is an Industry 4.0 buzzword that is becoming increasingly relevant in the area of intralogistics,” said Peisker. Leuze electronic has been equipping many of its sensors with industrial interfaces such as Profibus, Profinet, Ethernet IP or IO-Link to enable process information to be transferred and to provide elegant configuration possibilities and deliver diagnostic data. This data enables prefailure messages to be issued to allow weak points in the system or device to be detected early. As a result, systems can be maintained more efficiently and in a more targeted manner, and unscheduled downtimes can be avoided.

Control Engineering UK

The ultimate for small tanks!

The future is 80 GHz: a new generation of radar level sensors

When it comes to contactless level measurement of liquids in small containers, smaller is better. With the smallest antenna of its kind, VEGAPULS 64 is simply the greatest! With its excellent focusing and insensitivity to condensation or buildup, this new radar sensor is truly exceptional. Simply world-class! www.vega.com/radar

MACHINE VISION

A business case for

integrated robotic vision

reworking.

There was also a recognition of reduced material consumption when making or assembling the packaging material itself, all impacting on bottom line profitability.

However, both technology and market requirements continued to evolve. Robots, for example, quickly proved their worth in packaging lines in tasks such as picking and placing products at high speed and offered a good solution in highly repetitive processes when the same product comes along the same line, in a fixed position and with consistent dimensions.

Modern production, however, is based around much small batch sizes, often with different packaging for different customers.

There is also a trend today for low count retail packs, again something difficult to achieve with standard robotic automation as it removes the predictability and consistency of the picking operation.

New levels of sophistication

Steve Capon explains how integrated vision technology can help businesses respond to evolving market requirements more easily and package more complexly shaped products.

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he last decade has seen a rapidly growing acceptance of robotic automation in the packaging industry, and most particularly within the food packaging sector, with food and drink industry robot sales growing by 15% in the UK in 2015. In the early days the business case for robot integration was based largely on labour reduction, but it quickly became clear that robots had so much more to offer.

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With increased throughput potential, and constant rate production, robots brought both greater output and greater predictability to packaging lines, enabling businesses to boost production capacity and also benefit from more accurate forecasting. Reducing the reliance on operator precision in repetitive tasks also helped to eliminate mistakes – such as individual products missing from multi-packs – leading to reductions in waste or the need for

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So how can businesses marry up the benefits of robotic automation with these rapidly evolving market requirements? The key is the integration of vision technology onto the packaging line. Giving the robot visual information about where the product is on the line, what its orientation is, what its height is, what order to pick and what orientation to place can bring a whole new level of sophistication to packaging lines.

Vision technology enables the robot to recognise the product or package, verify its placement, and change from one product variant to another completely automatically, giving businesses increased flexibility in meeting current packaging trends and requirements.

While robots without vision technology are able to perform exacting picking and placing operations at high speed where the placement and orientation are known, robots with integrated vision technology can perform those operations on much smaller production runs and with increased flexibility within > UK10 Control Engineering UK

The new definition of bin picking.

Learn more about FANUC 3D Area Sensor

FANUC 3D Area Sensor – up to 50 % faster!

*under best conditions

Find out for yourself how bin picking works today: The revolutionary FANUC 3D Area Sensor delivers fast, 3D recognition of unsorted parts in a box with cycle times as low as 1,5 seconds*. Even if they are dirty, rusty or oily! Easy to set up, totally integrated in the robot controls, and offering collision-proof placement of the sensor above the bin picking cell. Typical FANUC!

marketing@fanuc.co.uk reference CEE0616

MACHINE VISION those production runs, responding to changes based on camera feedback.

The big argument for integrating vision technology into packaging applications, then, has become based not simply on increased speed, but on increased ability to deal with a greater number of variations within a smaller size of batch. But even further than this, increasingly vision technology can help packaging businesses cope with a greater number of unknowns. And this has become the driver behind the rise of 3D vision.

3D vision brings additional processing capabilities to the visual feedback, providing a new level of insight into the product height and orientation. If products are of a known or consistent size, then 2D vision can provide all of the necessary accuracy, monitoring the X and Y axes and even rotation around the Z axis, to enable the robot to pick the products with absolute precision and reliability. But for products where the size, shape, height or orientation are not fully known from one product to the next, 3D vision is increasingly being accepted as offering a solution that can significantly boost a company’s ability to increase productivity and improve quality.

Consider, for example, the relatively simple yet quite common scenario of different package heights on a conveyor, being picked and placed by a robot. 2D vision will give the X and Y coordinates of the package, as well as any rotation around the Z axis. But with no information about the height of the package, the robot cannot pick the package up without the potential for damaging it.

Simple height sensor arrangements on the conveyor working in conjunction with a 2D vision camera might be one solution, but this increases the complexity of the control system set-up.

Packaging operations, however, and food packaging applications in particular, frequently work with even more complex product and package shapes, with objects that are nonidentical, not just from one batch to the next but from one product to the next.

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Bags of crisps or sacks of grain are typical examples. Loose food items not only have random shapes, but can end up in random positions and orientations.

This is where 3D vision technology comes into play, with the ability to monitor X, Y and Z axes as well as processing information on roll, pitch and yaw. However the product is presented to the robot, it will be picked accurately and placed with precision. The ability to locate products three dimensionally brings a high degree of flexibility and reliability to even the most complex picking and placing operations, and enables the automation of procedures that previously only human operators could have accomplished.

Not only does 3D vision improve picking and placing accuracy with demanding objects, and improve flexibility for working with different products and low retail packs, but it can also simplify other aspects of the packaging line. A good example is the integration of quality assurance operations into the picking and placing process. In the packing of cakes or confectionery, the robot with integrated vision might accurately pick a product based on accurate feedback of height information, but at the same time verify that the height, colour and overall size

were within tolerance.

Along with the simplification (or even removal) of end of line quality assurance operations, robots with more effective vision technology might also mean there is no need for separate sections of the packaging line such as a collator, with the robot able to perform this operation as part of the packaging process.

So, the business case for the integration of vision technology on robotic packaging lines is rapidly growing, enabling companies not only to increase flexibility in response to evolving market requirements, but also to make improvements to the packaging line itself. Vision technology across the board – whether 2D or 3D – has become affordable, and the integration of this technology is no longer the preserve of specialists, with associated costs of set-up and support.

Regardless of product variants and package types, vision technology is increasingly enabling faster picking, shorter cycle times and quicker setup, for packaging lines that are easily adaptable to multiple product variants, and which simplify or eliminate downstream operations.

Steve Capon is technical manager of FANUC UK.

Using a sequencer to vary image acquisition settings A new TechTip, ‘Using the sequencer’, is available for download from IDS (Imaging Development Systems). This new technical tip explains how the sequencer function can be used to vary image acquisition parameters of successive frames in IDS UI-124x/ UI-324x/UI-524x and UI-125x/UI-325x/UI525x industrial cameras featuring e2v CMOS sensors.

The sequencer function is particularly useful in applications where it is necessary to capture images of the same object with different camera acquisition parameters, for example to produce images with high dynamic

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range in applications with unknown light or brightness conditions.

Setting up the camera to perform a sequence of image acquisitions saves time by avoiding the need to adjust camera parameters after each image.

In sequencer mode, the user can define a particular area of interest (AOI) to acquire an image with a particular master gain and exposure time. Up to three further AOIs of the same size can then be specified, where different values for gain, exposure time, number of readout cycles and even AOI position can be specified. https://en.ids-imaging.com/techtipp.html Control Engineering UK

Now offering Direct Lead Generation webinar opportunities

For more information contact Lydia Harris

+44 (0)1732 359990 or email lydia.harris@imlgroup.co.uk

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MACHINE VISION

Machine vision solutions Control Engineering UK looks at some interesting machine vision applications from UK Industrial Vision Association members.

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rax JH, is a manufacturer of automotive wheel weights.

To ensure the accuracy of its products the company relies on the use of an Acrovision vision system within its manufacturing process to prevent any product defects or quality failures reaching its customers.

The vision solution incorporates two Cognex In-Sight 7050 cameras which operate on each of two lines and are required to inspect the correct orientation and size of the part, of which there are approximately 30 variants. Placed initially in a bowl feeder, the wheel weights are automatically positioned on a conveyor, which are then flipped onto their side before being presented to the camera to check for the correct orientation and size. One camera is placed above the line and inspects the length and width of each part, to ensure that it falls within pre-determined parameters. In this way all the same sized parts are contained within a single batch ready to be shipped.

The second camera is positioned on the side of the conveyor to check the orientation of the part. This inspection process is vital to ensure that the adhesive tape applied at the next stage of production is positioned correctly.

Once the adhesive tape is applied the parts are collected in a box ready for dispatch. The reporting for each part inspection is collated and is available for operators, via Cognex’s VisionView visualisation tool, which is used for analysis and managing the production processes for the purposes of ongoing quality control.

Installation of this inspection system has helped to significantly increase process repeatability and has decreased parts-per-minute (PPM) failures from the two production lines.

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Altec has developed an inspection solution for the windscreen assembly of Toyota cars.

3D pallet picking Scorpion Vision has developed a 3D robot picking system to pick track shoes for armoured vehicles and bulldozers. Using the company’s 3D Stinger technology, a dense 3D points cloud is generated together with a high-resolution 2D image set. Since most 3D point clouds contain much less information than a 2D image set, 3D data is extracted from the 2D images allowing the required 3D location to be identified before making measurements using the 2D data.

The system was required to locate the shoes in pallets 1200 x 800 x 800 in size and verify the final picking position. It has to accommodate more than 20 user configurable shoe variants – including single, double or triple grouser types with an automatic product change.

The system also features a Scorpion 3D Stinger stereovision camera mounted on the robot and equipped with an IR laser random pattern projector (RPP) to ensure that the object has sufficient texture for robust stereovision calculations.

Initially all features are located in 2D and are then converted into 3D using the RPP and stereo images to generate

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a dense 3D image. Multiple objects are located and segmented in the dense 3D image and the pose of the objects are calculated. This is used to extract the most accurate 3D coordinates from the accurate edges in the 2D images – the basis for 3D in 2D. Using the object pose, a 3D reference is created for each object plane. Once the object plane is located in the 3D image, measurements are switched to the 3D calibrated 2D image object plane. This is because the 2D image contains a lot more information than the 3D image, because the 3D resolution is limited by the RPP dot number and size.

Assembly inspection A pair of special purpose systems have been designed by Altec, in conjunction with CARV Design, to perform a series of assembly and inspection operations on the windscreens of Toyota cars.

The system is designed to produce a range of component variants and uses interchangeable fixturing, which is coded to allow automatic selection of the correct machine programme and sequences. The individual components, which include rain sensors, perimeter trim, brackets and clips, are manually loaded to the assembly fixtures by the operator.

The glass is then also loaded and the automated sequences begin when the operator presses a two-handed start system. The machine uses a series of sensors and a Keyence vision system to check alignment and the presence of all required components before servo systems position the brackets to match the glass orientation. With everything checked and in position, the system initiates the ultrasonic welding sequence.

More vision case studies can be found in the Spring 2016 issue of the UK Industrial Vision Association’s ‘Vision in Action’ newsletter which can be viewed at www.ukiva.org/publications/visionin-action/2016_Spring.html Control Engineering UK

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TECHNOLOGY IN ACTION

Updating the process control technology for the supply of drinking water The Lake Constance Water Supply Association provides a reliable supply of drinking water to four million inhabitants by taking water from Lake Constance in Germany.

The drinking water is produced at Sipplinger Berg and then transported via a pipeline network 1700 km long to the 181 members of the association.

Updating of the process control system to a PMSX pro, in order to enable the distribution of 125 million cubic metres of drinking water per annum as well as the demand-led storage of nearly 500,000 cubic metres of drinking water in the 29 elevated tanks, is being carried out

by ME-Automation Projects from Fuldabrück near Kassel, part of the Mitsubishi Electric Group.

Because of the large geographical distances involved, the existing telecontrol stations – which number more than 300 – are linked to a total of 12 server locations with redundant process servers via IEC protocols (101/104).

Spread across wide distances, the process servers are connected to the existing corporate network of the Lake Constance Water Supply Association, providing a distributed system architecture for the PMSX pro process control system.

A large-screen video wall as well as multiple operating and monitoring stations are to be installed for the operating personnel in the central control room located at the head office in Stuttgart. Two engineering stations, an archive server and one or more application servers for connecting to the offices are also to be provided in the control room.

Each of the six control substations, which are manned during the day will be equipped with an operating and monitoring station, enabling it to operate in so-called isolated mode too. The remaining sites will purely be process server locations.

The PMSX pro process control system has been configured by MEAutomation Projects to operate with

the existing additional programs that have been used for Lake Constance water supply to date, and will be integrated into the process control system during the course of the project, making them part of PMSX pro.

An in-house development department with experienced employees from ME-Automation Projects is currently working on the implementation of these additional programs with a graphical user interface. Examples include balance archive evaluation as well as leak monitoring programs.

Remote control power management solution for oil rigs Siemens UK & Ireland has helped develop an integrated power management system, specified for use on a collection of five oil rigs in the Caspian Sea. Extreme operating conditions and limited space on each rig required the use of a power management system with generator and control room functionality stationed on one rig which needed to be able to remotely manage and control the turbine and switchgear power and process automation

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requirements of all five rigs’ plants as a single integrated solution.

Siemens SIMATIC PCS 7 Power Control was selected as the primary system to create what is effectively a ‘power island’, making it possible for all operators to be trained on a single system, eliminating the need for a number of separate systems, and reducing multiple hardware needs.

The creation of the power island to control all aspects of electrical and power distribution across the five rigs is

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industry’s first use of PCS 7 technology in this way.

Siemens Solution Partner, Industrial Control Systems (ICS) worked alongside Siemens to develop the integrated solution. Commenting on the project, Steve McDermott, director at ICS, said: “The challenge was to implement a fast-acting load management system, together with the process automation system, as a single integrated answer.

We selected the SIMATIC PCS 7 Power Control system because it allows for Control Engineering UK

TECHNOLOGY IN ACTION

Drive system helps maximise oil and gas field productivity A bespoke variable speed drive system has been designed by WEG to help with extraction from some of Oman’s older oil fields, where the natural pressure is beginning to fade.

Boosting extraction from depleting reserves is part of a project that aims to enhance Oman’s hydrocarbon production capabilities and help the country broaden its economic base. It is expected that Oman will unlock about one trillion cubic metres of natural gas over the next 25 years. There are also plans to develop downstream industries such as the production of ethylene dichloride (EDC), caustic soda and other chemicals.

As part of this major effort, the PDO Saih Rawl Field Depletion Project, Phase 2, aims to develop a daily gas production capacity of 30 million cubic metres, which will be fed to the existing Saih Rawl central processing facility. Extra compressors will be installed to increase the pressure so that gas continues to flow, enabling the field to feed the liquefied natural gas (LNG) industry while offering a back-up when other

plants are shut down for maintenance.

Electric motors will play a key role in ensuring that compressors run efficiently, smoothly and reliably, as they will be responsible for driving their suction and discharge cooler fans. Because electric motor-driven systems (EMDS) are the largest individual source of energy use, and over half of this energy demand originates from motors used in fans and compressors, Indian company Larsen & Toubro decided to partner with WEG to equip the main gas compressor with an efficient drive system, that could endure demanding applications.

WEG developed a bespoke solution comprising 30kW variable speed drives and motors and 15kW drives and motors, which will be supplied as systems and mounted in control cabinets, which also includes a high capacity circuit breaker for emergency cut outs and a by-pass system for DOL (direct on line) starting.

WEG has also fitted its equipment with a passive input harmonic filter to reduce problems relating to mains borne corruption of the power supply, while

the in-depth degree of integration we were seeking and it offered a complete process and discrete equipment control solution as one package.

“The system ensures power is shared equally, and at the right frequency and voltage, across the five oil rigs, with all controllers linked together and supervision undertaken from a single control room featuring the ability to communicate remotely with the different platforms. The Caspian Sea is a very challenging operating environment with extreme temperatures and weather conditions.

It means the software at the heart of the system has to be durable and proven. This is the case with PCS 7.

“The integrated power management

system now controls everything on the five rigs from one source, including electrical distribution, voltage, heat recovery and process automation. The system also includes PCS 7 standard

Control Engineering UK

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an output filter will be used to protect the drive.

WEG has also supplied Larsen & Toubro with all of the overloads, switchgear, relays and pushbuttons used within the drive cabinets to help ensure component compatibility and trouble free system building and commissioning as well as efficient ordering and delivery. Other elements in the cabinet include a control power transformer and auxiliary contactors and circuit breakers. Additionally, a door mounted control panel incorporates a backlit LCD keypad, while a redundant serial link provides communication to the wider control system. Finally, the control cabinets include space heaters, which are essential to withstand the extreme temperature differentials between day and night in the Oman desert, which can cause potentially damaging condensation.

alarm management which vastly reduces instances of alarm overloading for operators. The overall system is designed to deliver real operational efficiencies and cost effectiveness.”

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NEW PRODUCTS

Durable ultrasonic flow meter Titan Enterprises has introduced the Process Atrato, a low-volume, high performance ultrasonic flow meter which has been developed to address the challenges of the process and control environment.

The compact Process Atrato flow meter is said to provide all the advantages of the Atrato ultrasonic technology – such as high linearity, high sensitivity, wide flow range linearity no moving parts, and fast response time – with a new durable construction. Built from 316 stainless steel and PEEK the

Process Atrato is supplied sealed to the IP65 standard.

Rated for use up to 65°C and 20 Bar the flow meter is available in four models operating over flow ranges from 2 to 15 litres per minute. Accuracy is ±1% over the whole flow range.

Every unit is calibrated with a pre-set ‘K’ factor so all meters of the same flow range are interchangeable which helps to simplify assembly and set-up procedures. The unit comes, as standard, with two frequency outputs (PNP and NPN).

Compact drive offers extreme IP66 environmental protection up to 90kW Parker Hannifin has extended the power range of its IP66/NEMA 4x protected, variable frequency AC10 Compact Drive series up to 90 kW. One of the smallest compact drives available, the AC10

Space-saving safety light curtain The Datalogic SLIM safety light curtain, available from OEM Automatic, offers a solution to protect machines where space saving and simplicity of use are important considerations.

The choice of available lengths and resolutions and three different types of brackets make it vertsatile for installation. Up to three units can be connected to protect the sides of a single dangerous area without losing resolution in the corners. The configuration of basic functions – automatic or manual restart and external device monitoring – is achieved by wiring, making maintenance a quick and easy task.

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IP66 delivers motor control in applications requiring speed or torque control within the power range of 0.4 to 90 kW. The extension up to 90 kW for the IP66 comes in response to market demand for a high power compact drive able to resist harsher environmental conditions.

Offering features typically associated with higher specification drives, AC10 IP66 provides sensorless vector mode, an output frequency of up to 590 Hz, three-

phase 230 V and 400 V supplies in all five frame sizes, and a full 150% overload for 1 minute.

Rugged set point station for panels in hazardous areas A new ATEX & IECEx certified intrinsically safe rugged panel mounting set point station from BEKA is said to enable current flowing in a 4/20mA loop to be manually adjusted from within a hazardous area.

Housed in a 316 stainless steel enclosure, the instrument can be safely installed in an Ex e, Ex p, Ex n or Ex t

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panel enclosure without invalidating enclosure certification allowing easy integration with plant control equipment.

The instrument is loop powered and displays the process variable represented by the 4/20mA signal in engineering units on an 11mm high display. Frequently used values can be entered as pre-sets.

Control Engineering UK

RESEARCH

2015 SYSTEM INTEGRATION STUDY:

In-house system integrators

T

hirty-eight percent of respondents to the Control Engineering 2015 System Integration Study perform all system integration work themselves, as opposed to hiring a third-party system integrator or providing system integration services to other companies. Below are five additional findings from this study as they relate to in-house system integrators:

human machine interface hardware or equipment, operator interface, control panels, alarms, annunciators, data acquisition equipment, or data recorders or plotters (64%); and process control wired networking hardware, Ethernet switches, cord sets, connectors, wire or cable analytical instruments, or test or calibration equipment (63%).

3. Project effectiveness: Fiftyfour percent of in-house system integrators have found automation system integration to be highly effective in their projects, compared to 38% moderately effective, 6% somewhat ineffective, and 2% not effective.

1. System integration projects: An average of 16 system integration projects are worked on in house per year; and the average project size is $248,000.

2. Devices integrated: The top devices these companies integrate in-house are programmable logic controllers or programmable automation controllers (72%);

4. Project effectiveness: More than half of in-house system integrators

measure project success by the effect on productivity, if the project was on budget, and if the project was completed on time.

5. Challenges: The top five challenged faced by these system integrators are trouble with hiring engineering talent for system integration (46%) as well as industry expertise (40%); lack of communication (31%); keeping up with changing regulations, codes, and standards (30%); and making time for continuing education (26%).

View more information at www.controleng. com/2015SystemIntegration.

Amanda Pelliccione is the research director at CFE Media, apelliccione@cfemedia.com.

Most recent system integration project Sc hedul e Not on time 11% Not on time but delay was small and insignificant 5% Not on time but delay was agreed upon

Bud g et Don't know

Don't know

Not on budget 9%

6% 54% 24%

Not on budget but deviance was small and insignificant 4%

On time

8%

15%

Not on budget but new budget was agreed upon

64%

On budget

Looking at their most recently completed system integration project, 54% of respondents indicated an on-time delivery, and 64% were able to adhere to the budget initially settled upon. Courtesy: Control Engineering Control Engineering Europe

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VIRTUALISATION

Distillery saves time and money with virtualisation Midwest Grain Products (MGP) saved an estimated $3 million with an upgrade using virtualisation, compared to a rip-and-replace alternative.

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hose who have worked with a virtualised system would not want to go back to conventional control because of cost savings, increased quality, consistency of process, and more efficient use of time.

The automation vendor involved in this project helped create a three-step migration path using virtualisation that would ultimately save more than $3 million over the rip-and-replace option with another vendor.

Midwest Grain Products (MGP) rye whiskey distillery produces the bulk straight rye whiskey with a 95% mash bill, popular with bottlers and consumers. There is not time for interruptions in the plant’s continuous, 24/7 operation. The facility produces 40,000 to 50,000 proof gallons a day of brown goods and an additional 16,000 per day in grain neutral spirits, all parts of nationally recognised whiskeys, bourbons, gins, and vodkas.

The control system at the distillery has been upgraded several times to keep up with demand. The system needed an upgrade to continue growth as the distributed control system (DCS) lifecycle was ending, and the human-machine interface (HMI) program was no longer available or supported. Considering that downtime costs five figures per hour, keeping the plant running was a top priority.

Virtualised migration Virtualisation, possibly the most important part of migration, is often overlooked. Virtualisation approaches control from the information technology (IT) side. Operations, engineers, and

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maintenance deal with physical clients and are comfortable working with physical wires. Virtualisation eliminates the need to control through physical elements and emulates the hardware, operating systems, data storage, and networks through virtual operating systems within a host operating system.

The virtualisation system uses software that runs on the main host server with process control system.

Virtualisation allows multiple operating systems to share one host server. The client-based virtualisation controls the host processor and efficiently allocates server resources, while allowing each system, or virtual machine, to operate independently in its own shell while communicating with each other. Virtualisation software allows users to aggregate separate physical components into a pool of sharable resources that can be dynamically delivered to applications when and where needed. The virtual machine sits on top of the hypervisor, is independent, and focuses only on its own needs.

Multiple virtual machines run on top of the physical host.

migration focused first on areas of highest vulnerability to the least, starting with HMI and ending with input/output (I/O) connections. Boiler/utilities and dryers are migrated. 2016 will address the fermenter and yeast rooms, and next year cooker and stills will get an upgrade.

Migration began in 2014 and includes upgrading 200 HMI screens.

Now underway is replacement of eight prior DCS controller nodes with redundant process control system controllers.

The migration will end with Ethernet or device communications to 7,300 I/O points, replacing more than 260 I/O cards. A process historian and an information server will support longterm archiving and reporting needs this year. Virtualising the plant has reduced costs because of fewer computers to manage and repair. A central location administers control systems.

The instrumentation and controls specialist can take care of anything in the plant from the office, and about 20% less time is spent working on hardware. It has helped to improve control-system longevity; life span increased from five to seven years to 10 to 15 years before software needs to be modified.

Jason Singleton is instrumentation and controls specialist at MGP Inc., Lawrenceburg, Ind.

Migration pays off The migration strategy using virtualisation is well underway and on track for completion in 2020. The

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Control Engineering Europe

VIRTUALISATION

BENEFITS OF A VIRTUALISED power management strategy Power monitoring and management are complex and essential to maintaining continuous uptime at engineering facilities; a virtualisation management system and a specialised power monitoring and management solution can help.

I

n today’s virtualised industrial landscape, more services are running on less hardware, which means that ensuring those services stay up and running is more vital than ever. Generally speaking, no one solution offers all the features needed to keep critical power components and backup devices operating at peak efficiency. Ensuring uptime of critical power systems requires combining virtualisation management technology with a strategic power management strategy.

Deploying the right power management and monitoring solutions can help expand the capabilities of a virtual platform while also creating a cohesive, maximised asset. Implementing a virtualised power management strategy offers key benefits and opportunities.

down virtual machines and consolidating them onto fewer host devices.

“Live migration” programmes also let data centers move virtual machines from host servers running on battery power to unaffected servers elsewhere on the network or in a colocation data center in the cloud.

No other type of information technology (IT) and facilities management solution can perform these types of critical functions.

Integration, virtualisation

Real-time remote monitoring

Major virtualisation platforms enable users to view and control many physical and virtual machines while adding power management capabilities.

Many of today’s power management solutions can seamlessly integrate with virtualisation management technology, enabling users to administer backup power and power distribution assets, which include uninterruptible power supplies (UPSs) and power distribution units (PDUs), in sophisticated ways on one virtual management console.

Better command, control Virtualisation management solutions allow technicians to extend UPS battery life during utility outages by shutting Control Engineering Europe

In a perfect world, someone would be able to monitor system IT infrastructure equipment constantly, ensuring critical applications are continuously powered and running efficiently. But that’s not realistic, as teams have more to tend to than just the IT environment. That’s where a comprehensive monitoring and management platform can make a big difference, helping to act as a second set of eyes on vital equipment.

these tasks effectively, a virtualisation management system, along with a specialised power monitoring and management solution, are needed.

Operators seeking to prevent utility outages and power system malfunctions from disabling mission-critical IT applications should ensure they have the right set of onsite technologies and remote monitoring services for their environment.

More uptime

Arthur Mulligan is a product line manager for Eaton’s U.S. power quality service organisation.

Jim Tessier is an Eaton product manager for IT hardware and software products.

Power monitoring and management are complex tasks, but they are essential to maintaining continuous uptime at engineering facilities. To perform

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May 2016

21

FLOW & LEVEL SENSING

Enhancing DP-based flow measurement

WITH DYNAMIC COMPENSATION Henk van der Bent describes how a multivariable pressure transmitter with built-in dynamic compensation can correct many of the errors and inaccuracies that occur in differential pressure based flow measurements. He also explains how modern flowmeters can ensure ease of integration with FDT technology based tools.

D

ifferential pressure (DP) transmitters form the core of many field instrumentation systems, and are widely used to measure the flow rate, pressure and density of liquids, gases and steam, as well as the level of liquid in a tank.

DP transmitters have evolved in response to the demands for increasing accuracy and reliability, as well as enhanced computing and communication facilities to ease their integration into plant-wide monitoring, control and in particular, plant asset management systems.

Advances from Yokogawa have included the DPharp digital resonance sensor which eliminated the error-prone A/D convertor required by analogue sensors, and provided stability and precision, accuracy, response and repeatability. The combination of a digital sensor with integrated processing circuitry provides sensor diagnostics and high integrity, and allows full digital integration in a fieldbus based control system.

DPharp is a micro-electro-mechanicalsystem (MEMS) based silicon-resonant sensor that helps ensure precision and long-term stability. The technology is inherently fail-safe. Moreover, its design allows differential pressure and static pressure to be transmitted from a single sensor, allowing basic pressure measurements to be used as the basis of flow and level metering.

The result is a multivariable transmitter that is able to act as an ‘all-in-one’ instrument, integrating

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May 2016

Effects of orifice plate on flow.

the functions of a DP transmitter, a pressure gauge, a thermometer and a flow computer. It employs a flowrate calculation method to achieve a mass-flow calculation cycle of 100ms.

By adopting a Reynolds number compensation algorithm, all flow calculation parameters are optimised and a mass flow accuracy rate as good as 1% of actual flow rate is achieved.

The multivariable transmitter is compatible with a range of primary devices, including orifice plates, nozzles, averaging pitot and venturi tubes, and can be used with a wide range of fluids, including general fluids, steam and natural gas. Application information, such as the primary devices and fluid data required for mass flow calculation, is input using a mass flow parameter configuration tool that runs on a PC and is downloaded to the transmitter.

In operation, the flowmeter computes standard volumetric or mass flow from measured DP and flowing density using actual measured pressure and temperature, unlike standard DP

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transmitters which assume pressure and temperature – and therefore flowing density – to be constant.

Error sources The basic mass flow equation performed is: In DP flow measurements, the variation in flowing density is only one of a number of potential sources of error.

One source of error is the primary element. The accuracy of orifice plates, for example, can degrade over time as the plate loses its sharpness. A typical accuracy figure might be 1% of rate.

Another source of error is the DP transmitter. This accuracy is expressed as a percentage of upper range value (URV), and is magnified by the squarelaw relationship between flow and differential pressure.

Traditional DP flowmeters Traditionally, DP-based flowmeters have featured a 3:1 ‘turndown’. This figure expresses the range over which the accuracy is perceived to be acceptable Control Engineering Europe

> p24

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FLOW & LEVEL SENSING theory and real life. However, the discharge coefficient is flow profile (Reynolds) dependant and varies with the flow velocity, pipe internal diameter, flowing density and flowing viscosity.

In turn, the latter three parameters are affected by flowing temperature.

When a gas or steam flow passes the orifice plate it is compressed upstream of the plate due to the obstruction caused by the plate. Downstream of the plate it expands again. The gas expansion factor corrects for density differences between the pressure taps, and it depends on the ß-ratio, the isentropic coefficient (correcting for theoretical versus real-life expansion), differential pressure and static pressure. Again, temperature has an effect as well. Finally, the velocity of approach factor is dependent on the ß-ratio (d/D), which in turn is dependent on temperature. The pipe and orifice plate material expands or contracts as temperature changes, and the velocity of approach factor corrects for changes in ß-ratio due to temperature fluctuation.

Interaction between device DTM, FlowNavigator and field device.

– 30-100% of flow for a 3:1 turndown.

If the accuracy of the DP transmitter is assumed to be ±0.2% URV, at 100% flow the accuracy is ±0.2% plus the error of the plate. At 70% flow (49% DP due to the square-law relationship), the accuracy would be ±0.4%; at 50% flow (25% DP) it would be ±0.8%; and at 25% flow (6.25% DP) it would be ±3.2%. The plate adds ±1% over the full range and, when ±2.5% total accuracy is perceived to be acceptable, that accuracy is reached at around 30% flow – hence the 3:1 turn down. Turndown is often increased to 9:1 by using two DP transmitters over the same plate with different ranges, a switching mechanism and a flow computing function.

Although today’s DP transmitters are more accurate than ±0.2%, accuracy is still expressed as a percentage of URV, and the square-law relationship between flow and DP is still applicable.

It could be argued that a turndown of

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May 2016

better than 5:1 is not normally achieved.

The error due to pressure (±0.5 bar) and temperature fluctuations (±10°C) in gas or steam flows can easily be of the order of magnitude of ±2%.

The flow factor k in the basic formula above is a constant compensating for the differences between theory and real life. It is calculated as part of the orifice calculation, and is valid only for one particular set of operating conditions – making it another potential source of error. It is dependent on the discharge coefficient, the gas expansion factor and velocity of approach factor.

The result of an orifice calculation is the diameter of the hole in relation to the pipe diameter – the ß-ratio. When a fluid is flowing through a pipe with an orifice plate, the flowing area reduction is abrupt, causing the smallest flowing area (Vena contracta) to be downstream of the plate. The discharge coefficient compensates for the difference between

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Dynamic compensation The error in flow factor k increases with decreasing flow rate, contributing to overall flowmeter accuracy. A primary element of a DP based flowmeter is sized for one particular set of operating conditions. When in real life the conditions change – lower pressure, higher temperature, lower flow rate – the user would like to re-calculate the flow-rate/DP relationship for every new set of conditions. The multivariable transmitter is able to correct for pressure and temperature variations and can compensate continuously for the effects of changing operating conditions on the flow factor. Using a flow configuration wizard, it can be set up to act as a flow computing device.

There are two options – basic mode and auto compensation mode. In basic mode, the transmitter only compensates for pressure and temperature fluctuations with a constant flow factor, similar to a standard DP transmitter with a separate flow computer, Control Engineering Europe

FLOW & LEVEL SENSING resulting in a turndown of say 5:1.

However, in the auto compensation mode, it dynamically compensates for fluctuating conditions and their effects on the flow factor, reducing the error basically to the uncertainty intrinsic to the primary element. Consequently, the accuracy specification of Âą1% of flow rate (assuming the primary element to be ideal) over a 10:1 turndown in flow terms (equivalent to 100:1 turndown in DP terms) is only valid in the auto compensation mode. So, with its 10:1 turndown, the multivariable transmitter eliminates the need for a separate flow computer, and can replace one or two DP transmitters and a pressure transmitter over the same plate, while achieving good performance over a wide flow range.

The flow computer is configured using a portable software application, FlowNavigator, which is based on FDT technology that is able to interrogate a DIPRR (AIChE) physical properties database for 126 fluids and gases as well as pipe and plate material property databases. Its compressibility equations meet international standards including the AGA 8 and ISO12213 natural gas equations (either simplified or using the full molecular weight composition method), IAPWS-IF97 formulation for water and steam, or custom compensation based on user-defined density and viscosity data.

DTM configuration An important benefit of the transmitter is provided by its communication capabilities, which allows it to interface

with other elements of an integrated plant-wide operation. As a result, it is possible to carry out remote configuration and diagnosis using industry standard tools such as FDT technology. FDT is a proven industrial open interface specification. A key component of FDT (Field Device Tool) is the device Device Type Manager (DTM), a portable software application.

Through DTMs FDT technology facilitates the management and configuration of sensors, actuators, flowmeters, transmitters and other field devices connected to process automation and plant asset management systems as well as PC-based device configuration and management tools, regardless of the communications protocol used.

The DTM for the multivariable transmitter features an add-on flow configuration wizard which can be integrated in any FDT frame application.

The add-on module features the flow configuration wizard configuring the transmitter for a specific flow application and, enabled by FDT

The Yokogawa FieldMate field device engineering and maintenance tool offers easy configuration and diagnosis of field transmitters.

capabilities, can also access the fluid and material property databases and features the ‘obtain flow coefficient’ function where the transmitter calculates the flow rate, flowing density and discharge coefficient, on the basis of manually entered values for differential pressure, pressure and temperature to verify the correctness of the flow configuration. This reduces the commissioning effort for this type of device. FDT technology frees users from the need to learn configuration methods from different manufacturers and eliminates the constraint of having to install devices from the same manufacturer so that more efficient plant operations to be realised.

Henk van der Bent is marketing manager Field Networks at Yokogawa Europe B.V.

FLOW & LEVEL MEASUREMENT

Taking the weight out of pressure regulation Suzanne Gill reports on the development of an innovative new design for pressure regulation devices which results in a longer life, lightweight solution with a smaller footprint.

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he knowledge gained in the research and development of turbines, jet engines and scramjets has been harnessed to create an innovative pressure regulation/pressure reducing valve (PRV) technology by Oxford Flow, a technology business originating from Oxford University.

Professor Tom Povey was behind the development, which aimed to create a regulator solution capable of handling the very high pressure and flows typically found when conducting research and development into applications for gas turbines, jet engines and scramjets.

The majority of traditional pressure regulation and control products on the market today utilise a diaphragm as the measuring element. This modulates with the changing pressure and so needs to remain flexible to provide accurate control. Loss of flexibility of the diaphragm is one common route cause of pressure regulator failure through fatigue, erosion or embrittlement, and so the devices require frequent inspection and regular replacement.

Prof Povey and his team have developed a compact, high precision regulator with only one moving part which eliminates the need for the more complex and failure prone diaphragm arrangements found in most regulator designs.

Prof Povey explained: “Our design is not based on any current regulator design. We went back to the drawing board to look at new design concepts

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May 2016

having identified the minimum requirements for a device and went on to create something from first principles which would offer a device able to provide advanced and accurate pressure control.” The design features just one moving part and has only one deformable part – a seal – so the wear life is anticipated to be very long, making it suitable for use in applications where the cost of failure is greatest – for example in subsea oil and gas applications.

The resulting PRV is based around a direct sensing piston regulator which has simplified pressure regulator design and removes the need for a diaphragm.

The design of the Oxford Flow PRVs enables them to be manufactured from a variety of different materials to suit a wide range of applications including corrosive atmospheres and extremes of temperature.

Being designed to fit between standard flanges in a pipeline the original IHF series Oxford regulator is a very compact device. One side of the piston is exposed to downstream pipeline pressure; the other is balanced against a pressure cavity controlled by a pilot regulator. The sleeved piston actuator operates over an optimised feed hole configuration to provide precise, stable control across the entire operating range.

During operation, the piston moves inward, reducing the size of the cavity when the downstream pipeline pressure exceeds that within the pressure cavity set by the pilot regulator.

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The IHF series offers a compact solution for in pipe pressure regulation.

The movement of the piston actuator progressively covers the feed holes, reducing the flow rate to maintain a stable downstream pressure.

When demand increases the downstream pressure falls below that set by the pilot and the reverse operation occurs. The cavity expands, as the pilot feeds it, uncovering the feed holes, which increases flow and maintains a stable downstream pressure.

Extensive testing of the IHF PRV against market-leading pressure regulators was conducted in a dedicated test facility. The comparisons across all performance parameters demonstrate its benefits, including: • Maximum flow rates up.

• Increased accuracy – response times down.

• Minimum pressure drops reduced.

• Lower noise emissions.

The tests also demonstrated that the Oxford Flow device provides new levels of outlet pressure control accuracy across varying inlet pressures and flow rate demands.

“The product range continues to evolve,” said Prof Povey. “Fundamental design principles remain the same but we are developing the technology to suit the needs of other industry sectors by offering it in different configurations.”

The Oxford Flow design, for example, can result in a pressure regulator that is less than 10% of the weight of a typical pressure regulator in high pressure applications.

With its combination of compact size Control Engineering Europe

FLOW & LEVEL MEASUREMENT along with reliable precision pressure control for all gases, including natural gas and other fuel gasses such as LPG, the IM PRV is well suited to use in natural gas pipelines because it is a compact device and is completely non-venting. It could also be utilised in high-specification clean application high-pressure fluid lines – such as nuclear reactors and high pressure water and steam systems.

The IM offers ultra-high flow capacity and accuracy for gas and fluid applications. It is suited to use as a monitor regulator with active IM or an IHF series regulator. The optimised flow path has minimal restrictions reducing turbulence, noise and minimum pressure differentials. This also makes the design suitable for handling liquids and dirty fluids such as crude oil or drilling fluids.

Manufactured in 316 stainless steel and rated to 110 Bar, the IM regulator saves space and fits neatly between standard flanges in a wafer-type installation.

The IP is another variant of the original design, developed to offer a low-cost solution for the water industry. “The specification drivers in the water sector are installation cost, ongoing maintenance costs and size,” said Prof Povey. The Oxford Flow IP PRV is designed to control regional pipes of around 4-6in in diameter.

The regulators weigh around 2kg, compared to a more traditional regulator designed to do the same job at between 50kg and 70kg. This

size and weight reduction enables operators in the water sector to minimise trench access while having just one moving part helps reduce the need for maintenance and replacement. Further, the device can be manufactured from polymers that are approved for potable water use.

The team at Oxford Flow are continuing to innovate, and are developing more product variants based around the same design concept. The products are manufactured in the UK.

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CYBER SECURITY

The whitelist:

Finding the light in cyber darkness Attacks on critical infrastructure and energy organisations are becoming more frequent and a threat from a safety and financial standpoint. Application whitelisting can be an effective strategy in limiting what programs can run on a computer, which can limit the potential for a cyber security attack.

A

ttacks on critical infrastructure and energy organisations are becoming more frequent and costly from financial and shareholder perspectives.

These attacks are calculated, sophisticated, and persistent to achieve the end goal – whether they access data or damage the operational technology (OT) environment.

This has spurred energy organisations to be aware of existing cyber vulnerabilities and seek solutions to improve their security posture, maintain best practices, and prevent the next major disruption to operations.

Because these attacks are most often aimed at the industrial control system network, they have the potential to cause catastrophic damage in comparison to information technology (IT)-specific incidents.

These attacks pose risks to human safety, physical equipment, and are very expensive. In 2015, the average annual cost of cyber crime for energy and utility companies was $12.8 million, which led all industries in highest cost aside from the financial sector. It’s not exactly a competition anyone wants to win, but a reality faced in industrial environments.

The rising costs are associated with the rising number of threats. Attacks on critical infrastructure have increased dramatically in the last few years, up 20.4% in 2015 compared to 2014 according to an ICS-CERT report, but they have not been as widely reported as IT breaches because they aren’t as pervasive and remain contained within the organisation.

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In some cases they may not even be recognised as a cyber attack until months later. According to the 2015 SANS industrial control system (ICS) security report, 34% of industrial organisations surveyed believe their systems have been breached more than twice in the past year, and 44% were unable to identify the source of the infiltration.

The uncertainty and lack of transparency surrounding cyber attacks in industrial sectors have made them difficult to not only prevent and mitigate, but also to understand.

When hackers hijacked the systems of two power distribution companies in Ukraine, 80,000 customers lost power.

The illusive critical infrastructure cyber attack became a reality for everyone.

To help guide organisations, the U.S. Department of Homeland Security (DHS) recently issued its “Seven Steps to Effectively Defend Industrial

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Control Systems,” which identified the implementation of application whitelisting as the most effective strategy to mitigate potential cyber threats. Application whitelisting has traditionally been challenging to configure in ICS networks, but recent innovations and shifting business strategies toward a managed security service model have enabled much easier and cost-effective adoption.

What is application whitelisting?

In the IT environment, application whitelisting is an administrative process designed to limit what applications can run on a computer. Similarly in an OT, industrial environment, application whitelisting runs on human-machine interface (HMI) computers and designates the specific applications that are allowed to run on the ICS network.

This strong layer of protection for Control Engineering Europe

CYBER SECURITY a network that is overlaid on physical assets helps detect and prevent cyber attacks in the form of malware that could directly impact the operation of those assets. By ensuring that only genuine firmware code is capable of running on the secured controller platforms, application whitelisting protects servers from malware and zero-day attacks.

One downside to application whitelisting has been the complexity and cost surrounding implementation and maintenance within organisations. More vendors, however, are offering implementation as part of the investment in the ICS software and accompanying cyber security solutions.

The technique’s effectiveness provides value for the vendor and industrial customer by protecting the ICS layer of the network. DHS recommends that ICS operators collaborate with their vendors to baseline and calibrate application whitelist deployments to guarantee secure set-up and proven protection.

To ensure the success of a strong application whitelisting practice, training and education must be implemented throughout the organisation. To maintain the application whitelisting mechanism, operators must have an understanding of cyber vulnerabilities and what applications are safe to run on the network. As a large portion of the energy workforce is nearing retirement, operators with a background in engineering and cyber security are a scarce commodity and continue to be highly sought after.

Industrial organisations will need to become more aggressive about providing training programs and opportunities for continued education to develop the workforce it requires and help nontechnical staff understand how their actions impact security. To supplement the need many vendors offer to maintain the application whitelisting as a service. This helps alleviate the talent gap by providing the technology and expertise to support cyber security requirements and needs, Control Engineering Europe

which is particularly beneficial when an organization is not set up to manage this undertaking internally.

Light: Policy-based control A strong cyber security strategy for an ICS today includes a granular, policybased control of the application layer to enable industrial operators to eliminate the system’s attack surface size by only opening doors to trusted software and applications. Many vendors have developed whitelisting mechanisms to determine the validity of software processes running in an embedded control system and ensure that only the genuine released

software is allowed to run.

This comprehensive approach to safeguarding against attacks prevents the execution of malicious programs, malware, or other software processes deemed to be security risks. All of this is critical to safeguarding a critical infrastructure or energy organisation – and its customers – and is particularly important when these risks are more prevalent and destructive.

Dana Pasquali, product management leader, GE Oil & Gas. This article originally appeared in Control Engineering April issue (www.controleng.com)

Blacklisting’s role in cyber security Traditional firewalls and antivirus software are not enough to prevent against advanced attacks. A more predominant method in the energy space, blacklisting, has been a standard practice in virus protection and intrusion detection/prevention systems but has failed to meet the constantly evolving threats that are being manipulated and adapted to penetrate unique industrial environments.

Blacklists rely on signatures for known threats that are part of a threat-centric model in which known threats are blocked from running while all other unlisted programs are allowed to run. The downside is there is no inherent protection against zero-day threats that are not yet known to be potentially damaging, and it is impossible to keep up with the growing volume of malware today.

One of the more known malwares, BlackEnergy, has been active in the energy industry since 2007. Like the flu virus, BlackEnergy has evolved in several variants to become more effective in propagation. BlackEnergy 3 was found in the recent Ukraine hack and may have been introduced through spear phishing. The variant in this case was the inclusion of a

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KillDisk component. It is believed hackers gained access to the networks, and once on the networks, took over the operator stations to control the breakers and shut down power.

Blacklisting would not have recognised the “BlackEnergy 3” variant to prevent the initial access to the network.

Blacklisting also tends to require more server updates to keep pace with the proliferation of malware.

When ageing digital assets, such as gas turbines and compressor controls, have a life span of a decade or longer and require continuous operation, they are more vulnerable than other machines that receive regular updates and patching during frequent maintenance shutdowns.

These assets are safest when they are either completely shut down or fully operational. For this reason, frequent updates pose a greater risk of introducing cyber threats.

Rather than protect against the known threats, operators must rely on the trusted applications and block everything else through whitelisting. As additional applications are identified as safe, operators can modify the whitelist to include or remove applications when needed without taking the asset offline.

May 2016

29

MAINTENANCE

Cleaning matters Cleaning is an important consideration for many critical applications, to ensure optimum performance.

Control Engineering Europe reports.

C

leaning is an integral part of many processes and is often also critical to the continuing performance of a range of technologies.

In many industry sectors, including semiconductor production, defense, microelectromechanical systems, and biotech, an effective and efficient cleaning process is critical to the performance of equipment and systems.

‘Cleaning’ in the process industry and in research laboratories refers to the

JST Manufacturing has an applications lab equipped to test a variety of cleaning systems.

use of agents such as solvents, acids or bases to remove unwanted particulates and contaminates from products such as optics, semiconductors and electronic devices. Cleaning can be an automated process on the finished product or can entail the surface preparation of a material prior to a process.

Many applications will benefit from a secondary evaluation of the cleaning parameters or processes detailed in a request for proposal (RFP).

“The specifiers will be aware of the importance of cleaning their products,” said Louise Bertagnolli, president of JST Manufacturing, a wet processing and precision cleaning equipment company.

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“However, they may not realise that cleaning technologies have become so sophisticated that it is usually possible to improve on the initial design of a cleaning tool or process, making it more efficient, cost-effective and robust.”

Bertagnolli goes on to explain that cleaning system specialists will have a broader view and experience of all the tools and technologies available, as well as the expertise needed to select and integrate them, so it can be beneficial to work with a cleaning specialist with an applications laboratory equipped to test a variety of cleaning systems. “A facility capable of performing demonstrations will have specialised metrology equipment such as a scanning electron microscope and laser-based surface particle measurement systems in a stateof-the-art cleanroom,” said Bertagnolli.

One cleaning application undertaken

by JST Manufacturing is the design of a specialised cleaning tool for the USbased National Ignition Facility (NIF).

NIF is the world’s highest-energy laser system that consists of 192 laser beams which will focus nearly two million joules of energy and create temperatures and pressures that exist in the cores of stars and giant planets.

NIF is also a cornerstone of the National Nuclear Security Administration’s effort to maintain the United States’ nuclear deterrent without nuclear testing. Other NIF missions include finding new sources of pollution-free energy, and studying physics and other sciences.

Each of the 192 beams are supported by an array of optics – up to 50 lenses for each beam – depending on the type of experiment being performed. Ensuring that these optics remain clean is crucial to the success of the various types of laser-based experiments.

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“If the lenses were not clean then the performance of our laser would start to degrade,” explained Patrick Williams, NIF optics maintenance manager. “The cleanliness of the optics is crucial to our ability to produce maximum fluency (energy in joules) that is required to perform many tests.”

Transporting the chemistry To maintain the large inventory of its optics, LLNL partnered with JST Manufacturing in the development of a suitable cleaning tool. “The optics are heavy and large, so we don’t want to handle them a lot,” said Williams. “So, after we developed an RFP and showed it to JST, the company suggested that there might be an easier and more cost-effective way to transport, clean and inspect the optics.” One of the innovations in the NIF cleaning tool, which was a tank-like configuration, was to eliminate the need to move the optics to wash, rinse and dry them.

The engineers suggested that rather than transport the heavy optics for cleaning, it would be simpler to transport the chemistry (solutions) to the optics in a fixed location. “We also designed a sling-like device to hold the optics. This allows technicians rotate them during the inspection process,” said Bertagnolli.

To date JST has built two cleaning tools for NIF. The first tool was used for the very beginning of the facility.

“A second tool was built to provide us with dual capacity,” explained Williams.

Because NIF has become a production facility, where many scientists and companies are performing research, we also wanted to be able to clean a higher volume of optics and also get away from single-point failure.”

Precision process cleaning In some instances cleaning is an adjunct of the manufacturing process.

JST Manufacturing, also has been involved with designing cleaning systems and etching systems for the production of crystals used in aerospace guidance systems.

Control Engineering Europe

SYSTEM INTEGRATION

Industrial networks add value

to existing infrastructure Today’s web-enabled, data-centric world is full of new technology that can be used to connect things in new ways and share information across previously uncrossable boundaries.

T

he landscape of process control systems has completely changed in the last five years.

The industry has moved forward from where the state-of-the-art was integrating process data with enterprise resource planning (ERP) systems and is now pushing into the realm of completely connected, distributed, and always-on systems to devices that didn’t even exist a few years ago.

Regardless of the name – the Industrial Internet of Things (IIoT), Industry 4.0, the digital factory, or the connected enterprise – these developments are here to stay. They present many new opportunities to provide value to existing technologies, but they do require users to update work habits and style of thinking.

What worked even five years ago does not necessarily apply anymore.

When implemented correctly, though, these new technologies give the companies who use them a deeper understanding of every aspect of their world.

Tracking and analysing data The world is comfortable with the idea of tracking as much data as possible. New apps are being developed to send notifications, display the data in useful ways, and give everyone information they can use to optimise their lives. Why should the manufacturing world operate differently?

Energy usage is an example of new data streams available to users.

Web-enabled power meters, gas Control Engineering Europe

meters, and flowmeters allow access to get real-time information on water, air, gas, electricity, and steam usage.

This information can be combined with utility billing information to understand the most cost-effective times of day to run a process and provide a level of oversight for billing that previously would have required a lot of manual calculation.

Technology from outside of the manufacturing world such as beacons, geo-fencing, and smartphones with global positioning system (GPS) capability can all be implemented at a processing facility to provide a real-time view of where personnel are in the plant. The information can provide location-specific alerts and allow, with appropriate security, control of the process from mobile devices in certain physical locations.

This can have a huge impact on health and safety. The safety team can pull up a map of the plant on a phone or tablet and see where everyone is in the plant at any given time. This can save time and resources required to account for everyone in the event of a fire, natural disaster, or other event.

Integrating devices, systems One of the most difficult hurdles to integrating IIoT-enabled devices is integrating them with existing systems. Through the use of open platform communications (OPC), data distribution service (DDS), and the MQ telemetry transport (MQTT) protocol, integrating new devices is becoming as simple as adding them as a node on an existing network. MQTT is an

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Internet of Things (IoT) protocol built on a machine-to-machine (M2M) architecture, which makes it easy for a distributed array of devices to KEY CONCEPTS communicate and share status and environmental readings.

(IIoT) presents many new opportuniThe increasing number of ties to provide value to existing companies developing IoT-capable technologies, but they do require devices brings about a growing users to update work habits and style number of communication protocols. of thinking.

A group of devices made by one is much manufacturer will likely be able to easier thanks to open platform comcommunicate with each other, but not munications (OPC), data distribution to devices from another company. By service (DDS), and the MQ telemetry using OPC, DDS, or MQTT as a bridge transport (MQTT) protocol. between an existing system and (IoT) is new devices, this problem is nearly cheaper than previous technological eliminated. leaps because it doesn’t require huge Many existing systems use OPC initial investments of capital expendior DDS, and many of the major tures and labor to integrate things. software vendors are releasing MQTT communication links to GO ONLINE enable compatibility betweendevices, their IIoT, integrating systems andthe IIoTright devices.

Adding this and picking team, read this information more context to article onlinebrings at www.controleng.com. process control and ERP, and other CONSIDER THIS manufacturing execution system can be (MES) data adds more value to improved through the IIoT integrating the system. Staying ahead of the with other devices? curve with technology is easier than ever. Using the IoT is much cheaper than previous technological leaps because it doesn’t require huge initial investments of capital expenditures and labor to integrate things.

ADVICE

Alex Marcy, P.E., is the owner and president of Corso Systems, a US-based system integrator.

This article originally appeared in Control Engineering April issue (www.controleng.com) May 2016

31

INDUSTRIAL COMMUNICATIONS

Gaining transparency between

PROFINET and CC-Link IE Suzanne Gill reports of the details of a partnership agreement between PI (PROFIBUS & PROFINET International) and CLPA (CC-Link Partner Association) which aims to broaden the use of open industrial Ethernet-based networks.

D

igital communication, using either a fieldbus or Industrial Ethernet, is ubiquitous in today’s production plants and is an important building block in the drive for increased productivity.

With trends such as Industry 4.0 and the IIoT the demand for intelligent communication will continue to increase.

However, today devices and machines are often unable to exchange data and this poses a barrier to the success of Industry 4.0 and the IIoT which depend on smooth information flow.

Given the heterogeneous networks used today, it makes sense that creating a solution for easy integration of networks, such as CC-Link IE and PROFINET would help to remove this barrier.

Both PI and CLPA believe that the close networking between automation components, machines and plants and IT systems – which is required for Industry 4.0 an the IIoT – can only function if standardised cross-network communications becomes the focus of greater attention.

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This has resulted in a partnership to develop transparent gateways between CC-Link IE and PROFINET networks through the use of standardised interfaces.

Achieving such a goal has always presented difficulties when advanced tasks, such as diagnostics or integration of uncommon devices and components are involved. Experts from both CLPA and PI are now working on the standarisation of a solution to this and various use cases will provide users with a solution from a single source that covers all eventualities.

To date two standardised technical gateway solutions are being developed – a coupler solution and a link solution.

Coupler solution The coupler solution covers communication between machines or systems. Traditionally developers would need to devote considerable effort during engineering and installation as well as certification and commissioning in order to design the interfaces in such a way as to make seamless communication between CC-Link IE and PROFINET possible.

In the future the two controllers will communicate seamlessly. The machine with one network will be connected to another network as a quasi-black box via a coupler. Cyclic data exchange will function as usual. Machine or system data aggregation will be achieved by acyclic/SLMP methods. The configuration of this coupler, the basic engineering, the handling of device profiles (CSP+/ GSDML) and the network management will be carried out as usual.

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Link solution A link solution will also be available for easy integration of devices – such as a drive on one network that is to be connected to a controller on another network. In this case users will be able to rely on seamless functioning of the cyclic data exchange. Device information will be collected by acyclic/SLMP methods.

The configuration, the basic engineering, the handling of device profiles and the network management will function as usual as will the addressing of devices.

Subsequent device replacement will also be possible without problems. While the solution is not yet suitable for motion control or safety applications there are plans for developments in this area too.

The coupler and link solutions will make it easier to integrate machines of different systems into existing networks.

Through standardisation of the interfaces it is expected that future exchange of data between the systems – whether devices or process information – will become easier. This will be of particular interest if, in the context of network production, there is a need for detailed information about the plant to be made available faster and easier.

Automation systems will be able to easily exchange information about the machine status and product.

The PI/CLPA collaboration was first announced at sps/ipc/drives 2015. When work is complete it will be available to members of both organisations for implementation. Significant work on the specification is intended to be completed before the end of 2016 so that joint projects can begin to be implemented in 2017.

Control Engineering Europe

INDUSTRIAL COMMUNICATION

Field device information anytime and anywhere Control Engineering Europe finds out more about the benefits of HART-IP, the HART protocol rendered over Ethernet.

E

thernet is a simple and well understood communication interface. It makes access to the measurement devices simple, convenient and immediate.

Users can access HART measurement devices using a Windows-based laptop or tablet from anywhere – in the field or from a remote location. The Windows device accesses the HART Multiplexer or WirelessHART Gateway through its web interface or IP address.

The HART Protocol now includes a specification for the transmission of HART data over the Common Internet Protocol using either Transmission Communication Protocol (TCP) or User Datagram Protocol (UDP). HART-IP offers a straightforward way to access all the HART information available in a HART device and allows that information to be brought up to the enterprise level without the need to go through any translation processes and with no loss of information.

Put simply, HART-IP is the HART protocol rendered over Ethernet.

The addition of HART-IP to HART applications provides a quick and easy way to configure, monitor and diagnose HART devices on WirelessHART networks or HART-IP compatible multiplexes from wherever you have Ethernet access.

The industry standard plant Ethernet network supports many protocols to eliminate the need for a dedicated network. Devices can pick out the messages meant for them and disregard all the rest. When different devices communicate the same protocol, they set up seamless communication using this industry standard.

Because the application layer is the same for HART field devices as HART-IP, Control Engineering Europe

time consuming and error-prone data mapping (using Modbus RTU or TCP/IP) is eliminated.

Because it is independent of the underlying media, it is able to utilise system designs using redundant Ethernet media as well as mesh or ring topologies. Similarly, HART-IP can run over Power over Ethernet (PoE) for such infrastructure and devices. Various speeds like 10 Mbit/s, 100 Mbit/s, and 1 Gbit/s etc. are supported.

A HART-enabled system can also use standard HART commands to access HART information from devices connected to it using a HART- IP enabled multiplexer, I/O or WirelessHART Gateway. This is done by connecting the system and the HART-IP-enabled device using the installed plant IP infrastructure.

Again, mapping of Modbus registers and other tasks are eliminated.

Once connected to the HART enabled gateway, the network topology will be displayed by the HART-IP capable host. The user then selects the device of interest. For Device Descriptor (DD) enabled HART Communicators, the

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proper DD is then automatically loaded.

The user is then able to view all the HART device parameters, make edits, and get device status information.

This can also be done wirelessly if the plant has a Wi-Fi network in place.

HART-IP device access removes the need to go onto the plant floor to view or change the configuration of a device.

This provides significant time and cost savings and improved safety.

Another benefit of using HART-IP is that no HART modem is required – just standard Ethernet access from standard switches to the WirelessHART Gateway or HART enabled multiplexer – also saving more money.

The HART-IP enabled DevCom2000 Smart Device Communicator application available from ProComSol, makes it possible to perform complete HART device configuration and diagnostics from a PC from anywhere with an Ethernet connection to a gateway or other HART-data concentrator.

ProComSol has been providing HART communication products for over 10 years, and is an active member of the FieldComm Group. It provides full DD based HART Communicators for both Windows and Android devices.

HART-IP support is included for the Windows products with Android support coming soon.

Process companies will certainly be using more network-related products, multiplexers and multidrop connections, for on-line interaction with their HART devices in the future. The digital communication capability of HART ensures that device information can be linked remotely to other digital networks to become part of the Industrial Internet of Things.

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PRODUCT FORUM • OCEAN OPTICS DEVELOPS MINIATURE FLAME-NIR SPECTROMETER FOR FOOD PRODUCTION Ocean Optics has expanded its Flame spectrometer family. Flame-NIR delivers powerful near infrared spectroscopy in a compact, affordable instrument. Costing around 75 per cent less than a traditional NIR system, Flame-NIR pairs a high-performance uncooled InGaAs array detector with a small optical bench for spectral response from 950-1650 nm. Flame-NIR’s spectral sensing can be used in agricultural to gauge crop readiness and characterisation, and in food production to ensure quality and ingredient integrity. The compact Flame-NIR can be used in quality labs or integrated on production lines.

Ocean Optics Geograaf 24, 6921 EW Duiven, Netherlands Tel: +31 (0)26 319 05 00 Email: info@oceanoptics.com i More info - Enter Link code 114306 Web: www.oceanoptics.com

FORTRESS UNVEILING STAINLESS STEEL INTERLOCK SWITCHES FOR HIGH PURITY APPLICATIONS AT AUTOMATICA Industrial safety specialist Fortress Interlocks is unveiling its amGardS40 stainless steel interlock switches for high purity applications at this year’s Automatica trade fair in Munich. The company will be in Hall B5, Booth 105.

Automatica is the leading trade fair for industrial automation and mechatronics.

The amGardS40 is designed specifically for the food, beverage, pharmaceutical and chemical processing industries; it is also suitable for outdoor use. Manufactured from 316 stainless steel and modular in design, the amGardS40 range can be configured to suit many other industrial applications.

Tel: +44 (0)1902 349000 Web: www.fortressinterlocks.com

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SENIX CORPORATION Senix Corporation, manufacturer of ToughSonic® ultrasonic level and distance sensors, introduces the ToughSonic REMOTE 14, the first in a series of ultrasonic liquid level sensors designed for remote monitoring applications.

The ToughSonic REMOTE 14 ultrasonic liquid level sensor is designed to withstand the harshest climates and conditions for outdoor tank level monitoring, irrigation and flood warning systems.

It provides serial data communications, enhanced surge protection and energy efficiency in a rugged, IP68-rated, 316 stainless steel housing. “Water management and process industries are investing heavily in automation.” says Doug Boehm, founder and CTO of Senix. “Monitoring remote liquid assets requires rugged, energy efficient, networked sensors. We developed the ToughSonic REMOTE product line for those unique demands.” Learn more…

Senix Corporation T: +1 802 489 7300 E: Customer.Service@senix.com W: www.Senix.com

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80 GHZ : A NEW GENERATION OF RADAR LIQUID LEVEL SENSOR VEGA introduce VEGAPULS 64, a revolutionary 80 GHz frequency contactless radar level sensor for liquids. The smallest antenna diameter is less than a one pound coin, so it can be installed in the smallest of vessels. Its narrow, focused radar beam enables mounting closer to vessel walls, in long nozzles - even through isolation valves. It can handle foaming, turbulent surfaces, condensation or antenna build up, and also a great solution for level measurement of low dielectric products like LPG, without requiring stilling tubes. It has an accuracy of +/-2 mm, range up to 30m and ATEX approvals.

New 80GHz radar level sensor VEGAPULS 64 for liquids: The smallest antenna is no bigger than a 1 pound coin, an ideal solution for measurement in small containers.

More information available at: www.vega.com/radar

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RUGGED SET POINT STATION CAN BE INSTALLED IN AN EX E, EX N, EX P OR EX T PANEL ENCLOSURE A new BEKA ATEX & IECEx certified intrinsically safe rugged panel mounting Set Point Station [set point generator], enables the current flowing in a 4/20mA loop to be manually adjusted from within a hazardous area. Housed in a 316 stainless steel enclosure, this new instrument may be safely installed in an Ex e, Ex p, Ex n or Ex t panel enclosure without invalidating the enclosure’s certification allowing easy integration with plant control equipment. The instrument is loop powered and displays the process variable represented by the 4/20mA signal in engineering units on an 11mm high display. Frequently used values may be entered as pre-sets. A display backlight, which may be loop or separately powered is available as a factory fitted option. For general purpose applications, the complementary BA647E-SS is a noncertified version, the stainless steel enclosure and impact-resistant armoured glass window make it ideal for installation in severe environments.

For further information including datasheets and certificates please visit http://www.beka.co.uk/rugged_setpoint_stations.html or phone the BEKA sales i More info - Enter Link code 114965 office on 01462 438301

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FINAL WORD

Spreading the cost of technology Brian Foster Foster, head of Industry Finance at Siemens Financial Services in the UK, explains why it is important that companies keep up with technological advances. He also suggests ways that this can be achieved even at a time when many manufacturers are financially challenged.

D

igitalisation is standardising manufacturing processes across the sector, changing the way manufacturers produce, export and communicate on a global scale.

This change is being driven by the emergence of the latest software, smart materials such as carbon fibre, a new generation of robots, process innovations such as 3D-printing and a multitude of web-based services. These changes place greater pressure on the supply chain to adapt quickly and respond to a technologically advanced and increasingly demanding market.

Industrial manufacturing systems are fundamental to such developments, allowing manufacturers to address the continually changing demands of their customers and suppliers.

Manufacturing is one of the most important industries in the UK, contributing 10% of gross value added, so it should come as no surprise that a majority of manufacturing companies are investing in technology and innovation. The UK constitutes the 11th largest manufacturing nation in the world. In order to compete at such a level, it is essential for UK companies to be at the forefront of industrial capabilities. Efficiency and productivity are decisive success factors, particularly for machine tool manufacturers which tend to comprise SMEs.(Reference 1) Industry software, such as Enterprise Resource Planning (ERP) and Manufacturing Execution Systems (MES), enables manufacturers to digitalise the entire

industrial value chain leading to faster, more flexible and more intelligent production.

Top priorities Recent research found that one-in-four manufacturing companies in the UK see the implementation of ERP systems as a top priority, while 16% believe that general IT infrastructure is a top priority.

Harnessing technological innovations is crucial for the development of the highly specialist machine tools supply chain.

A recent report from HM Government found that building capability in SMEs would constitute one of the industry’s key challenges in the coming years. The same report, however, found that access to finance would represent a further key challenge for manufacturers to overcome. Given that increasing SME production capacities relies directly on access to finance, SMEs wanting to make a change might feel unable to do so. It follows, therefore, that SME machine tool manufacturing firms need a range of flexible and appropriate financing techniques in order to make further investments to enable growth, competitive positioning and productivity in a financially sustainable way.

Against this backdrop, asset financing techniques such as leasing and renting are coming to the fore as effective, alternative methods of funding technology and software investments and upgrades.

Such financing techniques spread the cost of the technology and software over an agreed financing period, with

monthly finance payments arranged to align with expected benefits gained over time from new/upgraded software, such as improved productivity, operating cost savings, energy efficiency and access to new markets. This removes the need for a large initial outlay, increasing funds available for other expenditures.

Asset finance gives manufacturers access to the latest technologies, without having to commit scarce capital or use traditional lines of credit. Financing arrangements can also cover other costs such as installation as well as providing the flexibility to upgrade in line with technology developments.

While access to finance remains a challenge, industry trends suggest that deferring investment in performanceenhancing technologies and software could leave SMEs struggling to compete.

Industrial software helps manufacturers to meet growing demands and anticipate future needs. Today it is not simply enough to keep up with competitors, manufacturers need to be at the front of technological advances in order to ensure they are working at maximum efficiency. Asset finance is becoming an increasingly important facilitator for businesses who wish to face up to the pressures of today’s fastpaced manufacturing environment.

Reference 1 Luis M. Camarinha-Matos, Hamideh Afsarmanesh, Balanced Automation Systems: Architectures and Design Methods (2013), p. 14.

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