Cee 17 05 by Modiconlv

Control, Instrumentation and Automation in the Process and Manufacturing Industries May 2017

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The new easy â&#x20AC;&#x201C;

digitalisation down to the field level

Special feature section: Focus on the smart factory Intelligent wiring makes control solution smarter The flow meter role in Industry 4.0 success

The Art of Manufacturing cloud

Supply Chain

Sales and distribution

Procurement Production

Engineering chain

Product design

Operation and maintenance

Process design

Management Systems IT system

VSDs

Data Handling

Data Primary Processing / Analysis

IT Information Interface

Edge Computing

HMIs

SERVOS

Plant Level PLCs

ROBOTS

Total integration of plant and business management Today the art of successful manufacturing relies on instant access to accurate live data. Speed and clarity become the driving forces behind agile, responsive manufacturing where plant level operations seamlessly interface with management level information systems. Mitsubishi Electricâ&#x20AC;&#x2122;s e-Factory solution provides a comprehensive range of industry leading automation solutions that take organisations to the next level in manufacturing through high speed connectivity, precise control and reliable data all deployed using robust, proven technologies. Discover the art of optimal performance with e-Factory by visiting our website or emailing automation@meuk.mee.com gb3a.mitsubishielectric.com

For your journey to Industry 4.0 and Smart Manufacturing n Deeper insight through better data n Flexible and efficient manufacturing n Enhanced and more responsive

performance

CONTENTS

Taking the first steps on a smart journey

Editor Suzanne Gill suzanne.gill@imlgroup.co.uk Sales Manager Nichola Munn nichola.munn@imlgroup.co.uk Production Sara Clover sara.clover@imlgroup.co.uk Business Development Manager Iain McLean iain.mclean@imlgroup.co.uk Dan Jago David May Colin Halliday

Group Publisher Production Manager Studio Designer

So, that’s another Hannover Messe done! I found the event this year particularly busy, with lots and lots of product launches. The event organisers also certainly achieved their goal of highlighting the benefits of digitalisation. I don’t think there was a single stand that I visited where this subject didn’t come up. I will be putting together a review of the product launches and highlights from the event in the June issue, but I have sneaked some of the information into this issue too, so keep an eye out for it! An overview of the event is also available in this issue, on page 4.

19 Low and mid-frequency non-contacting radar devices are now being complemented by high frequency technology.

This year’s Hannover Messe set out to make the benefits of digitalisation tangible for visitors.

20 The role of the flow meter in Industry 4.0.

EDITOR’S CHOICE 6

Suzanne Gill - Editor suzanne.gill@imlgroup.co.uk

This issue also includes a special feature section that takes a look at the journey to a smarter factory. (starting on pg 21)

INDUSTRY REPORT 4

This is not something that can be ignored or considered as simply a fad… it is happening… and if your company wants to remain competitive in the future then it is journey that you really do need to take. It doesn’t need to be done in one fell swoop, but you do need to look at how you can start to connect up your plant floor devices and equipment to gather data, turn it into useful information and then, importantly, act on it!

Process control system adds digital-only IO; Inverter gains condition monitoring capabilities.

FOCUS ON THE SMART FACTORY 21 Suzanne Gill finds out more about the journey to becoming a smart factory. 24 The human side of the smart factory.

PANEL BUILDING 10 Intelligent wiring makes control solution smarter.

PNEUMATICS 12 Suzanne Gill finds out more about the digitalisation of pneumatics.

INDUSTRIAL COMMUNICATIONS 14 The FDT IIoT servicer (FITS) which is being developed to empower the intelligent enterprise.

26 Safety first: how Industry 4.0 can optimise safety. 28 Integrated industry and the future of smart factories. 30 When and where might Industry 4.0 happen?

FINAL WORD 39 Klaus Wammes, managing director of Wammes & Partner, has identified an ever-increasing failure rate for HMI displays.

16 We report on how the Ethernet is being costeffectively brought to edge devices.

FLOW & LEVEL CONTROL 18 A report on the use of level measurement devices which can monitor build up and automatically alert maintenance personnel when cleaning is required. 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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Control Engineering (USA) Frank Bartos, Mark Hoske, Renee Robbins, Vance VanDoren, Peter Welander Circulation Tel: +44 (0)1732 359990 Email: subscription@imlgroup.co.uk Completed print or on line registration forms will be considered for free supply of printed issues, web site access and on line services.

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Qualified applicants in Europe must complete the registration form at www.imlgrouponthenet.net/cee to receive Control Engineering Europe free of charge. Paid subscriptions for non-qualifying applicants are available for £113 (U.K.), £145 (Europe), £204 (rest of world); single copies £19.

May 2017

INDUSTRY REPORTS

Making digitalisation tangible

This year’s Hannover Messe set out to make the benefits of digitalisation tangible for visitors, with demonstrations of the potential of intelligent robots, adaptive machines and integrated energy systems.

he show’s chosen lead theme of ‘Integrated Industry – Creating Value’ shone a spotlight on the benefits of Industry 4.0 and the role that humans might play in the integrated factories for the future. Summing up the event, Thilo Brodtmann, managing director of the German Engineering Federation (VDMA), said: “Hannover Messe has served as a showcase for the mechanical engineering sector. Industry 4.0 is now well past the trial stage, and is already generating real benefits in application. The show reflected the industry’s

May 2017

buoyant mood – a mood powered by having exactly what it takes to get the job done for the benefit of people everywhere.” This year over 225,000 visitors attended the event, with over 75,000 coming from outside Germany. The largest number of foreign visitors came from China (9,000), followed by the Netherlands (6,200), India (5,300) and Poland, whose 5,000 visitors set a new partner country record. A new generation of robots – the collaborative robot, or cobot – were on display showing how they may transform the way factories work.

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Their connectivity, artificial intelligence, innovative sensors and intuitive operation allow them to communicate directly with humans, as they learn autonomously and swap instructions with other cobots. Sensors have traditionally been viewed as a solution to connect up different machines. However, this year at Hannover Messe platform solutions came very much to the fore, with cloudbased network connections for the entire production operations, including data collection and analysis. “The trend towards the ‘digital twin’ concept in the production environment is opening up entirely new vistas for industry,” said Dr Jochen Köckler, a member of the managing board at Deutsche Messe. “If testing can be carried out in virtual reality – for example, to see whether a new production line is going to work out – it is possible to bring products onto the market faster, at lower cost.” Companies continue to be optimistic about the road ahead, with more than 70% of participating exhibitors rating the overall business climate in their sector as good to excellent. Their own prospects were seen in an even more positive light, with 80% of all exhibitors stating them as ‘good’ or ‘excellent,’ while 71% anticipate a further brightening of the general economic climate in the course of 2017. Accordingly, 41% of exhibitors in Germany are planning to hire more staff. The next Hannover Messe will run from 23rd to 27th April 2018, with Mexico as the official partner country. The June issue of Control Engineering Europe will include a Hannover Messe Review, where we will focus on some of the most exciting developments from the exhibition. Control Engineering Europe

INDUSTRY REPORTS

Sensors & Test exhibition As sensors, measuring and test systems gain more importance in todays increasingly networked world the international trade fair for measuring technology – SENSOR + TEST – takes ever more importance. This year, the theme of the event, which takes place between 30th May and 1st June in Nuremberg, will be “Networked measurement technology for mobile applications.” Visitors to the forum in Hall 5 will be able to find out more about new products and developments in the area of networked, mobile measurement technology. Issues being debated in the presentations during the event will include data security and global networking, distributed and seamless data acquisition, user-friendly software for mobile applications, networking of test tasks in the Internet of Things and data management with sensors.

Over 600 exhibitors from across the globe, will be presenting their sensing and test solutions alongside the numerous congresses and conference programmes that occur at the event. The scientific AMA Conferences SENSOR and IRS, for example, are regarded as an international networking platform for experts in sensor technology and measurement

Global process instrumentation and automation market set to grow The value of the global market for process instrumentation and automation is forecast to grow at a five-year compound annual growth rate of 4% between 2016 and 2021, according to figures from

Control Engineering Europe

Global Automation Research. Control systems, field measurements, and final control devices account for 80% of the total global market, with the fastest growing product lines including contact and non-contact microwave level, ultrasonic flow, Coriolis flow, electronic/pneumatic positioners, TDL moisture measurements, optical dissolved oxygen analyzers and remote I/O. Products that appear to be losing market share include mechanical flow, mechanical level, data acquisition systems, and pneumatic positioners. Application areas such as life sciences, electric and water & wastewater utilities, chemicals, and petroleum industries are all growing above the market average, while materials production industries are growing much slower as prices and global over-capacity dominate.

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technology from all over the world. Specialists from science and industry present current research and development results and invite participants to exchange their expertise. The complete program and other useful information can be found on the SENSOR + TEST website at www.sensor-test.com.

On-demand engineering education platform CFE Media has introduced CFE Edu, an on-demand education platform designed to provide continuing education to engineers to advance their education and obtain continuing education units. CFE Edu goes further than the typical Webcast or Lunch and Learn events by creating courses that provide engineers with exclusive and unique educational information. Exclusive course material includes a combination of video, presentations, technical content, and comprehension quizzes that can be completed on any device. Students are also encouraged to engage with the course authors through discussion boards. All CFE Edu courses offer continuing education. Many students have already completed CFE Edu’s courses on critical power, data centers, and electrical safety, and more are being developed by the platforms expert team. For more information visit CFEedu.cfemedia.com

May 2017

EDITOR’S CHOICE

Process control system adds IO to handle digital-only signals Yokogawa Electric Corporation has released an enhanced version of its CENTUM VP integrated process production control system. Enhancements to release R6.04 include a new input/output (IO) module. Because the latest control systems often primarily use digital signals, a lowcost IO module that handles only digital signals has been added to the CENTUM VP’s N-IO (Network-IO) lineup. To accommodate both analogue and digital signals it can be used in combination

Time-saving control cabinet wiring app EPLAN has introduced a new Smart Wiring Application alongside the release of EPLAN Version 2.6. The app visualises the control cabinet wiring and provides the necessary production data digitally which eliminates the need to work from schematic diagrams when wiring control panels. Research has shown that 43% of all design time is spent wiring a cabinet so the solution can offer time-savings. A key benefit of the app is that it memorises previously used control system elements, which are then available whenever they are needed for future use. This enables engineers to benefit from timesavings, especially for last-minute changes, because the software also handles the frequently complex task of project comparison.

May 2017

with the universal IO module. In this way, the cost of a plant construction or expansion project can be reduced. In addition, a signal conversion function is included in the new IO module’s adaptor. With the universal IO module, a dedicated signal conversion board is required to directly receive signals from a field instrument such as a temperature sensor. The incorporation of this function in the new IO module eliminates the need for this hardware. The CENTUM VP is a process production control platform with solutions that encompass all stages of the plant lifecycle – from design, engineering, installation, and startup to full operation, and routine and major maintenance – including the migration and upgrade to next-level technology platforms based on user needs, market dynamics, and technology advancements.

This latest CENTUM version uses Microsoft Windows 10 Enterprise. Based on its Long-Term Servicing Branch (LTSB) service model, Microsoft provides five years of extended support in addition to the standard five years of mainstream support, enabling a 10-year product lifecycle. CENTUM VP’s Vnet/IP real-time control bus uses the star topology, in which all devices are connected to a central hub. The latest CENTUM version also allows the use of a ring topology, in which devices are connected to each other in the form of a ring. With this feature, more flexible networks can be configured to satisfy customer needs.

Inverter gains advanced condition monitoring capabilities Mitsubishi Electric has extended the diagnostics capabilities of its variable speed drives by integrating smart condition monitoring (SCM) technology in a new version of the FR-A800 inverter series. With the FR-A800-E line users are able to carry out condition monitoring functions directly within the inverter. This has been achieved through the integration of the SCM Kit-1 into the inverters. The pre-configured, plugand-play solution includes the FAG SmartCheck vibration sensor from e-Factory Alliance partner Schaeffler. Combined with the PLC function, also integrated within the inverter, it is said to provide a complete drive-based solution for

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preventative maintenance. This integrated approach to monitoring the health of individual assets combines traffic-light indication of the asset through red, amber and green status lights on the sensor, plus more detailed analysis within the FR-A800-E series. Within the inverters operating temperature and vibration feedback from the SmartCheck sensor is combined with the monitoring of a full range of other external parameters, including speed, voltage and current information. Detailed diagnoses can be monitored remotely, or displayed on the FR-A800-E inverters’ integrated screen. Control Engineering Europe

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COVER STORY

The new easy – digitalisation down to the field level The digitalisation of a process will result in challenges. Higher data transfer rates will become as indispensable as more flexible architectures or the integration of wireless communication. However, with Profinet, an Ethernet-based standard is entering the process industries that masters all the challenges and impresses with its ease of use.

he process industries impose high demands on industrial communication – secure exchange of cyclical and acyclical data, integration of large quantity structures, overcoming large distances, real-time capability, operation in explosive environments etc. In the modern office environment TCP/ IP technology allows us to completely do without network cables because of wifi, and the integration procedure is simple. Either the printer is delivered with a fixed IP address, or it automatically receives one via DHCP (Dynamic Host Configuration Protocol), or a web interface permits safe integration into the network infrastructure. A comparably simple commissioning of field devices or uncomplicated set-up of flexible network architectures at the field level would be at the top of most operator/owner wish lists. Users who want to experience this at the field level today use Profinet (Process Field Network). This open standard protocol, based on Industrial Ethernet, combines the functionality of Profibus with the benefits of Ethernet-based communication technology. The Profinet standard follows the IEC Norm 802.3 to 100% and works at transfer rates of 100 Mbit/sec. The use of Ethernet also means that it is possible to profit from innovative technologies like the simple integration of web services, intelligent network management, consistent use of large data quantities far beyond the control room etc. In addition to all these benefits, Profinet stands

May 2017

out especially for use in process plants: for the simple integration of existing fieldbus technologies and thus the protection of legacy investments.

The new flexibility The introduction of bus systems, such as Profibus, about 25 years ago has clearly reduced the need for cable installation when compared to the analogue 4-20-mA technology and it greatly simplified the integration of field devices. However, these and the many other benefits that Profibus offers also come with limitations. For example, Profibus DP is limited to, at most, 125 connected slaves per segment, only one data channel between master and slave, and the data transfer is limited to, at most, 12 Mbit/sec. Alarms, messages, and status updates are all transferred with the same priority and only the creation of simple line structures comes as a standard. Profinet, however, offers much more: The choice of topology is completely free – Star, tree, line, or ring structures are possible – and so Profinet permits the creation of real networks. The ring topology is especially interesting for the process industries. Closing a line into a ring creates a simple structure of a redundant communication path without any additional hardware. If an error, such as a broken cable, is detected then the connection to all participants of the segment is kept secure through smooth switching from ring to line structure. The underlying Media Redundancy Protocol (MRP) is specified in accordance with IEC 62439

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and is fully supported by Profinet. It is not just the topology that is flexible. The use of diverse transfer media ensures even more flexibility. In addition to copper cables, Profinet architectures can also use fibre optic cables and Industrial WLAN or a combination of the above.

Easy device integration The new version 9.0 of the Siemens Simatic PCS 7 process control system supports this high-performance Industrial Ethernet standard without restrictions. Together with reliable Simatic automation products, the creation of Profinet networks is quick and easy. Devices are connected using switches – such as the new Scalance XF204-2BA DNA. It also offers a Y-switch functionality, with which S2 devices can be connected to a high-availability R1system. Two further switch ports ensure that S2 devices can be connected to the Scalance switch via a redundant ring. In addition, switch functionalities are already integrated into many Siemens devices, such as controllers, remote I/Os and operator devices. Thanks to functions such as auto negotiation and auto crossover, communication can be established independently: Simply connect Profinet cables and start! Where you once had to enter and document parameters by hand, it is now simply Plug&Produce. This concept is supported by the Simatic Compact Field Unit (CFU), a new distributed I/O line developed by Siemens. For example, the PA edition of the modern field distributor makes connecting Profibus PA devices easier Control Engineering Europe

COVER STORY than ever: all field devices connected to Simatic CFU are automatically addressed and integrated via standard profiles of Profibus & Profinet International (PI). Existing system components can, therefore, be comfortably retooled to Profinet and at the same time installation efforts are reduced as communication with the superimposed levels takes place directly via Profinet. This means there is no need for marshalling cabinets, multi-core master cables, terminal boxes etc. In contrast to previous Profibus installations, you can save up to 60% in cables!

Switch devices in record time In addition to cyclical process data, process systems also exchange acyclical data for alarms and messages, for example, as well as for parametrisation and diagnostics. Both communication types run next to each other without interruptions in Profinet. Diagnostic messages permit the status-based maintenance of system components. Connected Profinet components are maintained and monitored by the SNMP standard (Simple Network Management Protocol). The protocol uses diagnostic information of the network participants and reads port-specific data and information for the neighbourhood recognition of devices. Thanks to this property, changes in the

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topology can be recognised during running operation and names assigned to components automatically. What does this mean for the everyday operation of processing systems? An example: A Profibus PA device connected via Simatic CFU unexpectedly fails. Production stops. In addition to the LED diagnostic directly on the device, detailed reports are also provided in the Simatic PCS 7 Maintenance Station pursuant to NE107.* Thanks to Profinet and Plug&Produce, this is easy for the maintenance staff: due to neighbourhood recognition and standard profiles, they can use a replacement device with a different version status and even by a different manufacturer. The replacement device receives the same position and the same address in the network and automatically receives the same set of parameters as the failed device. The new device is ready to use after about one minute and production can start up again. This means it is much faster to replace defective devices compared to Profibus scenarios and even inexperienced technicians can do this.

Higher availability The I/O system Simatic ET 200SP HA also uses the benefits of Profinet optimally: redundant Profinet connections permit a connection to high-availability

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controllers via two completely separate networks, optionally per copper or fibre optic cable. The I/O system is modular and can be scaled and expanded in small steps. Due to the large number of available modules it adapts optimally to every automation task. For example, digital and analogue I/Os as well as 4-20mA and HART devices can be connected. In addition to redundancy at the Profinet interface, the peripheral modules can also be redundant themselves. A terminal block for integrated I/O redundancy permits the use of redundant I/O modules for especially highly available applications in the process industries â&#x20AC;&#x201C; without having to change any wiring. High system availability is also ensured by having the ability to pull and plug components during operation. This way it is even possible to expand stations without shutting the system down.

Start today The relatively long running times of process plants make it necessary to integrate existing field buses and the installed base during modernisation measures â&#x20AC;&#x201C; no operator wants to, or is able to, re-network his field level all at once. Profinet thus integrates seamlessly into existing architectures. Using proxy technology, existing system components can be integrated into a Profinet infrastructure, for example with the Simatic CFU or Simatic ET 200SP HA. The use of such modern remote I/Os, proxies, and switches together with Profinet protects investment in established technologies and also allows digitalisation in the field to begin. This means that, while at the same time protects their existing system components, Profinet users can profit immediately from more flexible topologies, increased data throughput, more diagnostic information, the use of one cable for all applications (e.g. the integration of failsafe communication via Profisafe), and a clearly higher system performance. * NAMUR recommendation 107: Self-monitoring and diagnosis of field devices, 12.06.2006. May 2017

PANEL BUILDING

Intelligent wiring helps make

control solution smarter An aging barrel feeding system, which forms part of a polyurethane production process, has been brought up to date with the addition of new operator panels connected back to a central PLC via an intelligent wiring system.

n aging plant plant handling system at BASF’s Lemförde plant is a crucial element in the barrel transportation chain around the facility. The barrel feeding system transports 200l drums filled with raw materials or finished products to and from the two production halls to the barrel warehouse. The 25-year-old system was recently

upgraded with the installation of SmartWire-DT and motor protection switches, supplied by Eaton, which has enabled simple power measurement of each individual drive, supporting precautionary maintenance. In the event of a fault, the drives affected can now be deactivated in a controlled manner before the motor protection switch triggers. “There is a whole chain of processes behind the system, with no buffer stock

With the use of SmartWire-DT motor protection switches become smart and communicationenabled components.

May 2017

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between the individual process steps. If the feeder system fails, the production process can run into problems,” said Claus Buhrmester, specialist in the plant’s maintenance systems team. After 25 years in operation, the barrel transportation system was no longer able to fulfil the company’s requirements. Thomas Büch, a member of Site Engineering Lemförde’s technical team, takes up the story: “The system was controlled by three PLCs that had to be replaced as spare parts were nolonger manufactured. The safety levels were not state-of-the-art and we had no plant visualisation. Manual operation to rectify faults in the event of failure was also not possible.” Within the framework of the upgrade project, it was decided to update the automation and safety technology. During this process, a total of 50 three-phase motors needed to remain operational for the feed route and the five integrated vertical feeders. As part of the modernisation project, the barrel transportation system is now controlled centrally from a PLC instead of from three autonomously controlled systems. “This simplified the structure of the automation architecture and the consolidation of the three control cabinets allowed us to save valuable panel space,” said Büch. In addition, operator panels were installed at the critical points of the system to aid visualisation. Now the operator is able to identify any barrels not removed from the transport system and can see when congestion occurs. The operator panels are also important for preventive maintenance. “The Control Engineering Europe

PANEL BUILDING

With the use of operator panels spread across the system the employees can see when and why a fault or downtime occurs.

system displays the type of error that has occurred. We can, for example, distinguish whether it is a runtime error due to an overcurrent or frequent switching on and off,” explained Buhrmester. As a result, the maintenance team is provided with valuable information in order to act early and proactively test the drives or mechanics. To enable this error detection, the BASF team paid close attention to the current measurements on the drives. “This was the main reason for us to wire the control cabinet with the SmartWire-DT intelligent wiring system,” said Büch. It connects the individual switchgear and drives not via point-to-point wiring with the control, but all devices are connected via the SmartWire-DT eight-pole flat cable. This now supplies all the devices connected with power and simultaneously takes care of data communication. “By using system tools and components, wiring errors are virtually eliminated,” said Thomas Gern, head of the Industrial Systems Technology department at Elektro-Anlagen-Technik EAT, the electro-technical service provider that built the control cabinets for the BASF plant. “Routine testing of the cabinet can therefore take place within a very short time. After a brief system introduction at our end, our control cabinet makers were able to complete wiring in half the time in comparison with conventional point-to-point wiring.” The system also saves space in the control cabinet. For the control of the contactors and the feedback from contactors and motor circuit breakers, no inputs or outputs of the PLC are needed. All input signals are collected via SmartWire-DT and transferred to the PLC. During the plant modernisation project, BASF was able to divide the plant into different security areas. In the past, if an emergency-stop button was pressed, the entire system stopped and confirmation for a re-start was only possible from a central location. To optimise this outdated condition, via the powerfeed modules that supply the switchgear with power in the SmartWire-DT system, safety zones have been created – one module supplies the power to the drives within its safety zone. In the event of an emergency stop, the relevant power-feed Control Engineering Europe

May 2017

module and the high-level, redundant group contactor are switched off. This means that the system only shuts down in this particular zone. Re-start authorisation can be given via the corresponding operator panel on site. “In general, we mainly retrofitted the safety technology we had,” said Büch. Many safety-light barriers and fence elements were installed. In addition, the system was fitted with a hand-held control panel with ‘dead-man’ function. This allows the operator to control the system manually for routine maintenance tasks. The entire safety technology communicates with the controller via PROFINET. For that reason, Büch connected the SmartWire-DT system with a corresponding PROFINET gateway. “Thanks to the upgrade of the system, we have avoided the need to call in electricians during the night time or over weekends,” said Büch. “Furthermore, the system is back up and running much faster after an overload situation. Slightly increased current levels, for example in the event of mechanical faults, can be identified more quickly and can be rectified in good time. In particular, for drives that are usually in operation for only a couple of minutes during a conveying cycle, an early identification by a conventional motor-protection switch would be virtually impossible.” Buhrmester adds: “With the information of each individual drive, the cause of a fault can be found and rectified easily.”

While you look ahead … we have an eye for the rest.

360° Network Reliability for Smart Factory Automation • Cybersecurity for your entire network infrastructure • Single point and multi-point network redundancy • PROFINET, EtherNet/IP, Modbus TCP, CC-Link, SafetyNet Moxa Solutions. Protected, easy, intelligent. www.moxa.com

PNEUMATICS

The digitalisation of pneumatics Suzanne Gill spoke to Marcio Lopes da Silva, product manager at Festo, about the latest pneumatic developments from the company.

ith software apps that replace over 50 individual components, it looks like Festo has succeeded in moving pneumatics into the era of Industry 4.0 with its new VTEM Motion Terminal. The pneumatic and digital automation platform combines all the functions necessary to enable more adaptable and economical production processes and offers a new control concept, with a fusion of mechanics, electronics and software. What are the major benefits of Festo’s latest development? A single Festo Motion Terminal valve is able to substitute up to 50 individual components. This offers a huge reduction in complexity as the use of an app makes it possible to adapt a single valve to achieve a wide variety of different pneumatic functions. Of course, this also makes spare part handling much easier. For the design engineer, function extensions or changes from an original machine design concept during the commissioning phase can now be done simply at the click of a mouse. This can offer significant reductions in the time it takes to get a product to market. For the end user the technology will make machines more flexible and it will be a key enabler to help achieve one of the Industry 4.0 goals – greater product variation and batch sizes of one! It allows users to visualise and modify a production system in real-time, providing the flexibility to meet their customer demands for greater product customisation. This is all achieved using a single programme. Due to its design as an industry 4.0 cyber-physical system, the Motion

May 2017

Terminal is also able to provide new functionality for pneumatic systems. Constant and self-adjusting speed of cylinders, complete application diagnostics and leakage testing are just some of its features. Could you talk us through the system and how it works? Basically each app-controlled valve consists of four 2/2-way membrane poppet valves which work together in a bridge and can be actuated separately. Each of these four valves are piloted proportionally by a piezo valve. The membrane poppet valves functionality is defined and driven via the simple to use apps. It is the interplay between these components and the bridge circuit design that makes the system so flexible. A host of integrated sensors form the cyber-physical system and these give it self-adjusting functionality. You talk about it being a cyberphysical system. Doesn’t this require it to be connected to the IoT? How is this achieved? There are two different approaches for communication and system modification. It can be handled cyclically, via standard fieldbus connections and the PLC attached to them, with the PLC being connected to the web/ IoT. Alternatively, it can be achieved

via an integrated web server on the Motion Terminal – directly from a laptop and its browser, or via any other IoT infrastructure that is attached to the Motion Terminal – such as a cloud visualisation solution. Does this mean that Festo will be offering its own cloud concept? Yes. At Hannover Messe this year we showed an IP65-rated IoT gateway, based around the CPX remote I/O terminal. A pilot version of a Festo cloud and dashboard was also demonstrated with cloud-based apps being able to visualise a range of Festo products and mechatronic sub-systems as smart and intuitive solutions. We have started with just three sample products and installations, and will continue to create more apps for other product ranges, as well as developing more offerings for the Motion Terminal too. So, when with the Motion Terminal be available? We are currently running several pilot projects with customers, who have reported that the use of such a modular system can offer engineering improvements, opening up a whole new world of potential solutions. If any other customers wish to try it out we would be happy to talk to them. The official launch of the Motion Terminal is scheduled for October this year. Detailed descriptions of all VTEM Motion Terminal apps can be found at www. festo.com/motionterminal

The VTEM Motion Terminal is said to make pneumatics Industry 4.0 ready.

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Control Engineering Europe

Control, Instrumentation and Automation in the Process and Manufacturing Industries

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April 2017

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30/03/2017

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INDUSTRIAL COMMUNICATIONS

AN ENABLER FOR

smart operations The FDT Group is currently working on the development of an FDT IIoT server to empower the intelligent enterprise and simplify the ecosystem exchange. Control Engineering Europe finds out more.

he Industrial Internet of Things (IIoT) is one of the most significant trends in automation technology today. A melding of innovations in the fields of computing and communication, IIoT and its ‘smart’ devices look set to change the way users and machines interact as well as the way that machines engage with each other. IIoT requires standardised, open and interoperable standards to ensure that new measurement and control assets are able to communicate and work together as needed in smart industrial operations. To advance its support of IIoT and Industry 4.0, and meet the demands of the automation end user community, the FDT Group has developed a solution known as FITS (FDT IIoT Server) with the aim of making the IIoT a reality

via a broad ecosystem that spans the process, hybrid and factory automation markets, and involves controls and instrumentation suppliers, end users, and standards organisations. FITS is intended to protect legacy investments in the FDT standard through advanced business logic, well-defined interfaces and common components, while also providing the foundation for a modern, integrated automation architecture. FITS can be deployed as a cloud, fog, local server, or standalone platform, and can scale to suit the needs of a single manufacturing facility or an entire industrial enterprise. It is a solution that enables sensor-to-cloud, enterprise-wide connectivity in industrial control systems. It allows sensor, network and topology information to permeate the enterprise – including mobile devices, DCSs, PLCs,

To advance its support of IIoT and Industry 4.0, and meet the demands of the automation end user community, the FDT Group has developed FITS.

May 2017

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ERP systems, the cloud, the IIoT and Industry 4.0. For industrial organisations, FITS will be delivered as an open, standardised architecture concept to empower the intelligent enterprise and simplify the ecosystem exchange. The server’s core FRAME and DTM components are surrounded by three primary interfaces: • FDT/OPC UA information modeling enabling information to be shared between higher-level applications and the FITS architecture. • Web Services supporting operating system (OS) agnostic platforms, along with a standardised mobile access approach to the FITS architecture for browsers, apps, standalone applications or anything else capable of interfacing via web sockets. • Control capabilities allowing operational management and maintenance for industrial automation networks and attached devices. FITS’ robust layered security addresses all the aforementioned components of the server architecture. It makes use of vetted industry standards and encrypted communications, with transport layer security (TLS) utilising secure HTTPS and WSS communication protocols. FITS users will be able to switch standard protocols for any level of their backbone architecture. The technology currently supports more than 16 automation industry networks, and its open architecture makes it possible to add networks to meet changing industry demands. This includes cloud Control Engineering Europe

INDUSTRIAL COMMUNICATIONS

IO-Link Safety specification released

FITS enhancements include a Web Services portal focused on the needs of facility operations and maintenance personnel, as well as the use Microsoft’s HoloLens computing device for real-time and analytic data in a hands-free operation.

connections enabled by new IIoT/ Industry 4.0 networks such as Message Queuing Telemetry Transport (MQTT), Virtual Private Network (VPN) to firewall, and Azure Advanced Message Queueing Protocol (AMQP). Any other cloud method is simply a different FDT Communication DTM. The ability to seamlessly nest or tunnel through a myriad of networks to transparently communicate with the end device is key in a smart, connected enterprise. New features announced at the FDT Group press conference at Hannover Messe 2017 in April 2017 included enhancements to the Web Services portal focused directly on the needs of facility operations and maintenance personnel to ease troubleshooting efforts. Users can now take advantage of standard browsers to gain access to device DTMs and FRAME-enabled systems, while developers can write custom apps and programs that benefit industrial maintenance departments through cloud-based enterprise data access and mobility. This includes solutions enabling troubleshooting to be performed

With the recent release and publication of the IO-Link Safety specification by the IO-Link community and its concept assessment approval by the TÜV SÜD, the way looks paved for the implementation of IO-Link Safety enabled systems and devices. Like IO-Link, IO-Link Safety achieves its fieldbus and system-independence through conversion of the many safety protocols available on the market to IO-Link Safety in the master. Currently there are over 4,000 IO-Link masters and for these to create a new system for IO-Link Safety, all that is necessary is to develop a corresponding IO-Link Safety master. Existing IO-Link Safety devices can then be used without modification. The time and effort for configuring IO-Link Safety is minimal, with authentication being derived from the assignment to the master port, and the monitoring time is set automatically for each device. As with IO-Link, devices can be replaced without the need for any engineering tools. A replaced device is automatically assigned the stored parameters of its predecessor after startup. Open and secure parameterisation of safety devices is always a challenge. IO-Link Safety devices have an IODD device description, which contains the

remotely and monitoring of instruments’ critical operating parameters to ensure they are functioning according to specification. Additional maintenance benefits include the ability for field technicians to take pictures or scan bar codes with their secure, authenticated smart phones or tablets to provide a host of device-specific information. Programmers will have the option to write algorithms to simplify reporting. FITS also supports the use of augmented

FITS is intended to protect legacy investments in the FDT standard through advanced business logic, well-defined interfaces and common components Control Engineering Europe

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complete communication properties, identification, parameterisation, and diagnosis. However, the applicable standards require a ‘dedicated safety tool’ to rule out manipulations. A software interface therefore exists for integrating the dedicated tools associated with the devices into the IO-Link engineering tools. The Device Tool Interface (DTI) has been kept simple and ensures that integration into the existing IO-Link engineering tools does not pose a problem and that safety-related device software can be adapted and used further on the device side. In the process, it is important that the package consisting of the IO-Link Safety device, IODD, and the ‘dedicated tool’ can be used globally in all system environments without modification. In this way users can access a broad range of devices – regardless of what automation system they use or in what industry and region they work. On the basis of the existing specification, manufacturers can now begin to integrate IO-Link Safety into their systems. The test specification, the test system, and the certification are being developed in parallel. Products are expected to be available in 2018.

reality via Microsoft’s HoloLens computing device for real-time and analytic data in a hands-free operation for a virtual view of content. Devices utilising Web Services can be connected through wired media, fibre optics, or wireless networks. Plants and factories employing FDTenabled systems are already benefitting from open access to the Industrial Internet. In the future FITS will simplify the move to IIoT, providing OPC UA integration, Web Services, mobility, and control to enhance connectivity and information sharing. To learn more about FITS, watch this video: https://fdtgroup.org/fdt-iiotserver-fits-simplifying-industrialautomation-ecosystem-exchange/ May 2017

INDUSTRIAL COMMUNICATIONS

Cost-effectively bringing

Ethernet to the edge Control Engineering Europe reports on how the Ethernet interface can be reduced in size, power, and cost to allow it to be incorporated into edge devices such as sensors and actuators.

ecent advances in communication technology have changed the landscape for Ethernet and today the concept of low-complexity Ethernet is being used to bring EtherNet/ IP communication to edge devices. An Ethernet node consists of both hardware and software architecture. On the hardware side, the architecture can either be a processor-MAC-PHY (Media Access Controller) (Physical Layer Device) or a processor-MAC-switch-MAC-PHY in the case of multi-port devices. No matter what processor is used, it will be paired with an Ethernet MAC. And in many cases, the PHY is not integrated onchip due to power dissipation, chip die area, and cost considerations. Also, PHY performance in real-time applications is critical, so leaving the PHY separate allows the designer to choose the right PHY for the application. In all cases where the PHY is not integrated with the MAC, the interface to the PHY is MII (IEEE 802.3) or RMII (RMII Specification) for 10/100BASE-TX (10/100 Mb/sec) Ethernet and GMII (IEEE 802.3) or RGMII (IEEE 802.3) for 1000BASE-TX (1 Gb/sec) Ethernet. These interfaces involve many high-speed signals consuming numerous pins and additional board space due to layout considerations.

Scaling an Ethernet node To reduce the cost, size, power, and complexity of hardware in an EtherNet/ IP edge device, it is important to target small-scale single-chip processing

May 2017

solutions by reducing processor speed/ performance, flash memory size and RAM size. Other areas to focus on include a reduction in interconnect complexity from processor to network interface and a reduction in pin-count and complexity of the network interface. The addition of an Advanced MAC to the network interface (PHY/switch chip) will accomplish most of the size reduction goals. The Advanced MAC performs intelligent/dynamic frame filtering and buffering before any frames are communicated to the processor chip. This prioritises protocols, and surges in frame receipt. The intelligent filtering reduces overall buffer space and reduces the amount of data that has to be transferred to and processed by the application processor. The reduction in frame communications allows a simpler interface to be used for communication. The Serial Peripheral Interface (SPI) bus provides a common interface with low pin count and frequency based on the capabilities of the processor chip, and ease of electrical isolation between the application and the network communications. The SPI interface and frequency is unchanged, whether the device is communicating at 10 Mbit, or 1000 Mbit, just as the application communication requirements of an edge device are not changed by the network bandwidth. This interface also allows for very low power and low frequency processors that cannot manage the load required for a standard MII interface.

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The frequency and timing of the interface can be managed to avoid noise issues in critical application interfaces, whereas a MAC receive operation is asynchronous to the application operation. Additional features can be added to the Advanced MAC for common and well understood functions such as synchronisation (e.g. IEEE802.1AS), further reducing processor frame processing and RAM/Flash requirements. Functions associated with security can also be incorporated into the Advanced MAC, although this requires work to select appropriate approaches for the data and security characteristics of edge devices as opposed to standard SSL/TLS. Further reduction of Flash requirements (and the associated elimination of external ROM for the processor and reduction of cost/ complexity of the edge device) requires elimination and/or simplification of protocols that are required for more complex devices. Many protocols that make sense for a full-purpose node may be too costly for a small node. For example, LLDP transmitter is a simple protocol easily managed in a constrained device. LLDP receiver is somewhat more complex, but not generally too difficult for a node with only one or two Ethernet ports. The complexity comes with support for protocols like SNMP that are used to query LLDP receivers. Single-port devices can benefit from being connected to infrastructure switches that support an LLDP receive function, thus the single-port low cost node only needs to be an LLDP transmitter. For two-port devices in a line topology, another solution is necessary. Network management protocols are another burden for small nodes and can typically be eliminated from Control Engineering Europe

INDUSTRIAL COMMUNICATIONS two-port devices as long as the rules for setting up a network are carefully worked out. Specific work to develop widely accepted protocols for line topologies is needed. Other areas that can be excluded include security (SSL/TLS), device management (DHCP, BOOTP, ICMP) and application interfaces (Berkeley sockets). This reduces memory usage by a small amount but takes with it some convenience in system configuration and management.

The answer? The answer for EtherNet/IP to the edge lies somewhere between a current fullup device and a hardware-only device. While some advocate only a limited set of protocols to reduce footprint, it would be better to select from a wide range of protocols only those that are required by the application. In other words, if an application doesn’t need to support, say, ICMP, then it should be optimised out of the TCP/IP stack. By advancing the capabilities of an Ethernet MAC and an Ethernet Switch the processor, Flash, and RAM requirements can be significantly reduced. It also allows for a ‘reallocation’ of the Ethernet function out of the processor and into the PHY.

An example Perhaps one of the most area and power constrained devices in automation systems is the temperature transmitter which takes signals from a temperature probe and converts the information into a 4-20mA signal to transmit temperature to the automation system.

HART can also be overlaid onto the 4-20mA signal to control set points or change calibration variables as well as receive diagnostic information. The temperature transmitter could also do this via Ethernet, but there are issues putting Ethernet in such a constrained environment. Assuming there will be a means to get Ethernet to a temperature transmitter, we still need a low power, reduced area, cost-effective way to put Ethernet inside the transmitter. The architecture of a temperature transmitter currently uses a microcontroller for temperature calibration, control, and diagnostics and a microcontroller for communication. The microcontroller on the communication side interfaces to the 4.20mA interface through a Digital-toAnalogue Converter (DAC). If HART is used, a HART modem is also connected to the microcontroller and DAC. The microcontroller used for communication is also connected to the microcontroller performing the temperature calibration, control, and diagnostics. This communication path is isolated to keep the two sides electrically independent. It is possible to replace the microcontroller used for communication, the DAC, the HART modem, and EEPROM with a low-complexity Ethernet Device (LED) with PHY. This can either be a one-port or a two-port device depending on the topology of the Ethernet network. Given the low-complexity of the temperature transmitter communication variables, it is possible to scale the EtherNet/IP

Ethernet – function versus capability.

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communication down to one implicit message and three explicit messages. By using a space optimised version of the EtherNet/IP stack along with a minimum TCP/IP stack implementation executing on the microcontroller, it is possible to have a software footprint for the communication software on the order of 128Kbytes of Flash and 64 Kbytes of RAM. The concept of low-complexity Ethernet holds the promise of cost-effective, low power, reduced area connectivity for simple EtherNet/IP devices. Such a concept can be realised in an open manner coupled with advanced features in next generation Ethernet MACs and Ethernet switches. By scaling a device’s communication software it is possible to fulfill the connectivity requirements of EtherNet/IP systems while minimising the software footprint. This scaling, in turn, reduces the Flash and RAM hardware requirements to the point where a single chip processor with memory can be utilised in the design of a field device. Further, by taking advantage of features in next generation Ethernet MACs and Ethernet Switches, it is possible to reallocate the Ethernet function from the processor into the PHY creating a low-complexity Ethernet device. Such a device provides the processor with a simple SPI interface to the Ethernet network. Not only does this SPI interface have the advantage that it is easier to electrically isolate from the other circuitry in the design, but it also eases the processing requirements since the controller no longer has to process every Ethernet message from the network. Rather than needing an A-class ARM processor to execute application and network software, a single chip processor with memory can be a simple, low-cost M-class controller. It is through this combination of hardware partitioning and software tailoring that we can achieve the concept of bringing EtherNet/IP to the edge. This article was created from a presentation given by Innovasic at the 2017 ODVA Industry Conference. A copy of the original presentation paper can be downloaded from www.odva.org May 2017

FLOW & LEVEL CONTROL

Self diagnostics: an enabler for predictive maintenance Control Engineering Europe reports on the use of level measurement devices which are able to monitor build up and automatically alert maintenance personnel when cleaning is required.

magine a production process where devices can diagnose themselves: They would know when something is wrong and send an alarm. If, for example, excessive build-up occurred in a silo or tank measurement sensors would be able to signal the need to clean a process. The Kanmantoo Copper Mine in Australia has already started to experience the advantages of selfdiagnostics following its trial of smart sensing solutions. The company had two clear objectives for which it required a smarter level measurement solution – to increase production by being able to fill its ROM bins as close to capacity as is safely possible and to reduce maintenance costs. The company wanted to use the maximum fill heights of a ROM bin used to store unprocessed copper ore. To accommodate this increase in fill heights, the existing radar level sensor needed to be relocated to a new position, where it would unavoidably get covered in dirt. This posed a problem because it meant that the strength of the measuring signal emitted and received by radar level transmitters – a critical factor for precise measurements – would diminish. Under these conditions conventional radar and ultrasonic level transmitters would need to be regularly cleaned, sometimes as often as every hour. This would be timeconsuming for the maintenance personnel and the ROM bin would be stopped, which would lead to costly downtime.

Avoiding mechanical changes The copper mine also wanted to avoid expensive mechanical changes so made the decision to trial the Endress+Hauser

May 2017

Micropilot FMR57 radar level transmitter with Heartbeat Technology. This function monitors the extent of dirt build-up, and reports it back to the control room to alert the personnel of the need to clean the transmitter. The FMR57 also features a PTFE horn protector that helps reduce the rate of build-up. This means cleaning is required less frequently. Self-diagnostics has been standard in a variety of Endress+Hauser flow devices since 2012 and its portfolio has recently been expanded to include level devices. Instruments incorporating its Heartbeat Technology can offer permanent process diagnostics and in-situ diagnostic functions. The Micropilot FMR5x radar level transmitter is made for continuous, non-contact level measurement in powdery to granular bulk solids. Dust, filling noises, temperature layers and gas layers do not affect measurement. For challenging bulk solids measurement applications, for example, extremely narrow or multi-chamber silos, the transmitter is offered with a 3.5° microwave beam angle, which enables measurement to the bottom of the silos. Endress + Hauser’s Heartbeat Technology tracks the performance of a device to ensure it is not adversely affected by abrasion, corrosion or sticky build-up. Standardised and clear diagnostic messages are sent regarding what needs to be done in order to maintain the plant economically and as a matter of priority. As the devices run their own diagnostics, proof tests are only necessary in maximum extended cycles. Furthermore, the automatically generated protocols provided by

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The Micropilot FMR5x family.

Heartbeat Technology occur without process interruption and support documentation relating to international standards. For future-orientated predictive maintenance the instruments offer parameters to monitor the performance for process optimisation.

Self diagnostics Instruments which incorporate selfdiagnostics allow plants to run more cost-effectively and safely with no interruptions. A simple, predefined procedure will guide the maintenance team through the verification procedure and, at the end, the verification results are documented. The SIL test, according to the safety manual and documentation, saves time and reduces costs and an automatically generated verification protocol supports the evidence demanded by regulations, laws or plant standards. The data acquired through selfdiagnostics facilitates trend recognition for the implementation of predictive maintenance programmes. A combination of instrument and process parameters provides the information needed to undertake the next steps in maintenance, or for targeted process optimisation. Control Engineering Europe

FLOW & LEVEL CONTROL

Getting the frequency right Low and mid frequency non-contacting radar devices can now be complemented by high frequency technology says Per Skogberg.

adar is currently the preferred technology for accurate and reliable level measurement. Low (6-11 GHz) and mid frequency (24-29 GHz) noncontacting radar devices have been installed in a range of challenging applications. The availability of high frequency (75-85 GHz) technology now increases the options available to end users. However, the different frequency bands all have strengths and weaknesses. Radar instruments emit microwaves to measure the distance to a liquid (or solid) surface. The wavelength is inversely proportional to the microwave frequency – the shorter the wavelength, the higher the frequency. Wavelength and frequency are fundamental attributes of a radar, and the physical properties of low, mid, and high frequency radar signals have a big impact on the suitability of each frequency when exposed to typical level measurement applications. High frequency microwave signals, for example, suffer more attenuation when propagating through a medium, resulting in a weaker signal return. Process liquid turbulence can adversely affect the accuracy of radar level measurement. The short wavelength of high frequency devices means that the signal reflection will be scattered and dispersed by surface movements, rather than reflected to the antenna, which can cause up to 90% of the signal strength to be lost. Low and mid frequencies emit longer wavelengths, enabling them to perform better. Dirt and contamination on the antenna affects the radar signal’s strength and direction. Low and mid frequency signals can pass through such build-up virtually unaffected, but with high frequency signals, more of the Control Engineering Europe

energy is absorbed by the dirt, and the beam’s direction could also be diverted. For a radar with a narrow beam angle, this can result in the return echo not being directed straight back at the antenna, causing loss of signal strength. Low and mid frequency technology is, therefore, more suitable. For dense and thick foam, low frequency works best. For lighter foam, mid frequency performs well. For condensation, the design of the antenna is also important. Antennas with flat, horizontal surfaces should be avoided in these applications.

Vessel size Frequency also affects the beam width and angle from a radar device’s antenna. Here higher frequency signals enable smaller beam angles using smaller antennas, which is beneficial as it helps the beam to avoid obstructions such as agitators found inside many tanks and vessels. However, if there is an obstruction directly below the nozzle a narrow beam is likely to be completely blocked while a wider beam can still measure accurately. In very small tanks – typically about 0.5-1.5m high – the size and placement of nozzles can be a limitation. The short measuring range and the requirement for small antennas means that high and mid-frequency technology are attractive options here. However, the challenges posed by process conditions such as condensation, contamination, turbulence and foam do need to be considered. Bulk storage vessels often have floating roof tanks which require level measurement to be performed via stillpipes. Low frequency radars offer better choice here as they are less sensitive to build-up on pipe walls, slots, and pipes that are not completely straight. High

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frequency radars have difficulties in such situations. When measuring solids, the best frequency choice will depend on the application in question. Low and mid frequencies can handle dust, condensation and coarse solids, while high frequency works well with very fine powders. Typically, condensation is challenging for high frequency radars, but with solids a further problem arises, as condensation, combined with some solids, will produce material build-up which will quickly clog small nozzle openings and cover the small antennas of high frequency radars. For industrial level measurement applications, radar has become the technology of choice. The introduction of high frequency devices has expanded the options available, especially for installations in small vessels and those with very small process connections. Process conditions need to be considered, along with the strengths and weakness of each frequency before selecting a solution. Per Skogberg is product marketing engineer for Rosemount Process Level Radar Instrumentation at Emerson in Gothenburg, Sweden.

Microwaves with short wavelength are more easily scattered by small waves on the liquid surface, leading to weaker signal return.

May 2017

FLOW & LEVEL CONTROL

Flow meters: a role in Industry 4.0 success

JosĂŠ Leonett discusses the changing flow metering needs of the process industry to allow it to meet current and future challenges.

he challenges facing the process industry, and its use of flow meters, can be summarised as increasing complexity; breadth of choice and product selection; maintaining accuracy of flow meters across their life-cycle; sifting the important information from the noise generated by the growing number of alerts and alarms produced; and how to control the huge number of flow meters and sensors across the plant. Many of the challenges outlined could be overcome with the adoption of smart flow meters which support the user during the entire product life cycle and can be smoothly integrated in the plant control environment.

Minimising risk Until industry decides what it can to do minimise to an acceptable level the risks involved with Industry 4.0, process plant managers need to consider products that can be deployed today, while at the same time are ready to exploit Industry 4.0 benefits in the future. As innovation drives new products, the complexity in the production process is increasing with input lines being added as more components are used and, in turn, these all need to be accurately measured. The challenge is not only to ensure that the precise amount is introduced consistently to deliver the required quality output. Processing plants are no longer built to produce one product. They need the flexibility to meet rapidly changing market demands. This requires flow meters that can quickly be reconfigured or updated with new features when required with minimum down-time. As process complexity increases, so

May 2017

has the choice of flow and level meters, requiring a growing engineering expertise to choose the right product to deliver the right performance. The different types of meters and different performance profiles means that engineers can no longer select the right product simply from data tables. They need to consider many parameters like measuring technology, mass or volume throughput, temperature, pressure loss, and line size. In many instances external help is required to guide engineers through the selection process.

Life-time accuracy Planned maintenance and calibration of meters is no longer sufficient. Meters need to be able to alert staff when they experience issues that affect their performance before it creates a product quality issue or process shutdown. This requires on-board diagnostics capable of continual monitoring of the unit and flow tubes without interfering with the measuring process. Introducing intelligence into flow meters provides the opportunity to access performance data. However, poorly configured meters increase the quantity of alert notifications and alarms that need to be processed by the DCS or the plant staff. To overcome this modern flow meters must also have the ability to configure the types and amount of alarms and warnings at any time. The flow meter must also be able to provide data from both before and after an event. The flow meter should also be able to indicate abrasion, corrosion, viscosity in a certain range, flow velocity and many more. These data should be available and logged in real-time to give total insight into a process.

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The Total Insight concept utilises Coriolis Rotamass transmitters and provides enhanced settings capability for custom setups, predefined trend views, and storage of multiple configuration sets.

Remote meter control With batch production it is likely that the process will need to change regularly. Traditionally this has meant plants faced considerable downtime and set-up to switch between processes. Flow meters now need to be capable of storing many sets of process parameters and concentration sets in a single unit which allows a straightforward switch over. Having worked with these challenges for over ten years Yokogawa believes its recently introduced ROTAMASS TI (Total Insight) range offers a solution to these mass flow metering needs. They are future-proofed to operate within existing regulatory frameworks, yet offer wider integration with the DCS and Industry 4.0 initiatives. The Total Insight concept utilises the latest generation Coriolis Rotamass transmitters and provides enhanced settings capability for custom setups, predefined trend views, and storage of multiple configuration sets for fast change overs involved in batch production scenarios. The range covers all the standard application areas, batching, balancing, blending, feeding, dosing, etc. In addition, they also include common functions for trending and recording, in-line verification, dynamic pressure compensation, tube integrity and leak detection, basically, each has a total healthcheck function inside the flow meter. JosĂŠ Leonett, is director marketing and business development for ROTA Yokogawa GmBH. Control Engineering Europe

UK INDUSTRY REPORT

Report finds that the UK is not prepared for Industry 4.0

A recent report has identified that the UK manufacturing industry is not yet ready to embrace Industry 4.0.

he ERIKS report, ‘Is the UK ready for Industry 4.0? Industrial maintenance in a connected world of Big Data’, found that that 61% of UK engineers are not currently undertaking any form of Industry 4.0 initiatives, despite the fact that 80% of those surveyed believe it will have a positive effect on production and maintenance practices. The report highlights several major barriers to the implementation of Industry 4.0 in the UK, including security concerns, a lack of understanding of its potential benefits, particularly among senior managers, and an unwillingness to share data with thirdparty maintenance suppliers or OEMs, which could facilitate more progressive maintenance practices, such as remote condition monitoring. In fact, the results suggest that 79% of organisations would offer limited or no disclosure of their data, despite 56%

admitting that they needed support from an OEM or third-party to use their data for machine diagnosis. Commenting on the report findings, Gary Price, international product Manager, Automation and Services at ERIKS Group, said: “These results suggest that UK industry is badly underprepared. Seemingly industry is fully aware that it has a data collection and analysis deficit, but is unwilling or unable to engage with its industrial supply chain in order to get help. In effect, the experts – who could help design the sensing systems, collect and analyse data which could revolutionise industrial maintenance and bring forward tactics, such as predictive maintenance and condition monitoring – are being kept at arms-length.”

Age gap The report also highlighted concerns about an age gap in UK manufacturing,

with senior managers less likely than their younger counterparts to have a full understanding of the benefits of Industry 4.0 and a willingness to share their data. Only 15% of over 55s would allow full disclosure of machinery or production with OEMs compared to 34% of 25-33 year olds. Further, 72% of 25-34 year olds believe they need the support of the OEM manufacturer to use data for machine diagnosis or fault-finding, compared to only 35% of over 55s. “There is a real age gap developing because the older generation of engineers, many of whom hold senior positions in UK industry, appear to be more sceptical and more risk averse. Conversely, the younger generation of engineers understand that it needs the support of external suppliers and is much more willing to share data,” said Price. “We are also concerned with the age gap demonstrated by this report. Industry 4.0 is moving quickly, but the senior generation appears to be more sceptical and risk averse. Industry 4.0 offers opportunities for industry to connect with its supply chain and use its capabilities. We must take this opportunity to connect industry and the industrial supply chain in order for UK manufacturing to become more productive, more efficient and more competitive.”

Tell your food industry story at Appetite for Engineering To inspire and educate delegates about the benefits of implementing automation technologies, this year’s annual Appetite for Engineering event will be taking place on 19th October at the Manufacturing Technology Centre (MTC) in Coventry, a UK Catapult Centre for high value manufacturing, where many innovative manufacturing concepts are first validated and implemented from primary research. Appetite for Engineering provides an informal educational forum for engineers working in the food and beverage processing sectors. This year the event will be looking at how the industry

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needs to prepare for the future, for example through the use of automated solutions. It will also be addressing environmental issues with speakers talking about the benefits of implementing energy-saving and waste management solutions and will be looking at the important issues of food safety and hygiene and addressing how the sector is addressing the skills shortage. If you would like to join us at this event, or if you have a success story in any of these areas that you wish to share with a wider audience, please do contact me for further details. suzanne.gill@imlgroup.co.uk

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May 2017

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MACHINE VISION

IS 3D RIGHT FOR YOU? The third dimension is playing an increasingly important role in image processing applications. Jana Bartels describes the strengths and weaknesses of the different 3D technologies available today

D image processing is currently the most widely used image processing technology and is particularly suitable when the application offers high contrast or if the structure and colour of the object are decisive for the end result. Applications for 2D cameras can generally be found in all areas of image processing – positioning, detection, measuring and reading. 2D camera technologies include area scan and line scan. Area scan cameras capture the scene to be analysed with a single image, while the line scan camera uses a scanning process where the image is recorded line by line. Depending on the selected camera model, the scene is represented either in a monochrome or colour image. Several technologies are also available for capturing the third dimension of objects and scenes. A distinguishing characteristic of 2D and 3D technologies is that, in addition to making the Xand Y-values visible in an object, the depth values of the recorded scene or object are provided. This opens up new possibilities to solve complex tasks, particularly in robotics, factory automation and the medical sector. 3D image processing is used whenever volumes, shapes or the 3D position of objects will be analysed. Depth information can also be used to handle tasks in the examination of objects and images of defects that do not have enough contrast for 2D but do show a recognisable difference in heights. Typical application areas for a 3D camera include: • Detection of obstacles and ‘human’ navigation of autonomously driving vehicles in an industrial environment, such as fork lifts.

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• Robot-controlled gripping jobs on conveyor belts or bin picking. • Presence detection, checking and counting objects in a bin / box, even if they exhibit no contrast at all against the background. • Examination of position and presence of components on a circuit board. • Volume measurements of a wide range of objects. • Portioning of food, such as meat separation. The trend towards 3D solutions is growing and should be expected to play an increasingly significant role due to the growth of automation and to meet Industry 4.0 requirements.

2D or 3D?

complement each other to satisfy the needs of the different applications, 3D image processing also offers various technologies. Those that are used most frequently right now are: • Stereovision and structured light. • Laser triangulation. • Time-of-flight. Each is based on a different principle to record the third-dimension and they each have various advantages and disadvantages. The most suitable one will depend on the requirements of the respective application.

Stereovision and structured light Stereovision works according to the principle of human eyes. Two cameras are used to record two 2D images of one object. The same scene is recorded from two different positions and the depth information is assembled into a threedimensional image with the aid of the triangulation principle. Stereovision uses image data from two regular 2D area scan cameras to provide depth values for the scene. The images are rectified based on the camera positions and knowledge about the geometry of the application. After the rectification, a matching algorithm is used to search for corresponding points in the right and left image and a depth

The decision about whether 2D or 3D camera technology should be used to handle a respective inspection task has to be made at the very beginning of a project. With some applications, the question can be answered easily, since the demands are very clear. However, either 2D or 3D technologies could be used for some other applications, so the technologies do need to be understood so that they can be used appropriately and so that the best solution can be chosen. To check whether a 2D or 3D solution is suitable for the intended task, it helps to proceed according to a list of criteria. (Figure 1) Just as it is possible in 2D image processing Figure 1: To decide whether 2D or 3D is right for an to use area scan and application it helps to create a list of criteria. line scan cameras that

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MACHINE VISION

Time-of-flight cameras employed in a smart forklift for storage automation.

image of the scene is created. One option for improving the performance of a stereo system is to add structured light to the stereo solution. With a light source that projects the geometric brightness patterns on the scene, the measurement results become more precise and the disadvantages of the stereoscopy, due to homogeneous surfaces and low light, are significantly reduced. Calibrating the projector with the camera even makes it possible to dispense with the use of a second camera. Stereovison and structure of light techniques can achieve high accuracy at short range, 2D area scan cameras can be used and exposure to sunlight is not a problem, nor is there an issue with highly reflective surfaces. However, it will not work on homonogenous surfaces or in low light conditions and computing load makes real-time capability difficult.

Laser triangulation Laser triangulation uses a combination of a 2D camera and laser light sources. The laser projects lines or dots onto the scene in front of the camera. These lines or dots appear on the objects in front of the camera and are recorded by a 2D camera. If the distance of the measured object to the sensor changes due to camera movement across the object or to movement by the object â&#x20AC;&#x201C; for example through a conveyor belt â&#x20AC;&#x201C; the angle at which the laser lines or dots are observed will change along with their position in the camera image. The distance of the object from the light source is calculated from the position coordinates in the image with the aid of mathematics.

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Volume measurements in logistics, palletising and de-palletising tasks, as well as autonomously driving vehicles in a logistics environment are suitable applications for time-offlight cameras.

Laser triangulation offers very high accuracies and it can cope with difficult lighting conditions and with mirroring or highly reflective surfaces. However, it can be slow, due to the required laser scanning of the object and its high accuracy requires the use of very costly components and complex set up processes.

Time-of-flight The time-of-flight method is an efficient solution to get depth data and to measure distances. A time-of-flight camera provides two kinds of information for each pixel: the intensity value, stated as the grey value, and the distance of the object to the camera, namely the depth value. There are two different methods to use the time-of-flight technology â&#x20AC;&#x201C; continuous wave or pulsed time-offlight. The continuous method is based on measurements of the phase length for a brightness modulated light source. The method is mature and works with standard electronics. The sensors used in this method are relatively large and work only at low resolutions. Pulsed time-of-flight measures distances based on the travel time for many individual pulses of light. This requires very fast and precise electronics to reach accuracy in the +/- 1cm range. The technology has now developed to allow for the creation of precise light pulses and their exact measurement at high resolution at justifiable costs. A time-of-flight camera is a compact system with no movable parts. It consists of an integrated light source, an integrated lens and a time-of-flight sensor. The light source sends out pulses

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of light or continuous light. This light strikes an object and is reflected back towards the camera. The integrated lens ensures that the reflected light reaches the sensor. In a simplified explanation, the distance and thus the depth value of each individual pixel is calculated on the basis of the time travelled by the light until it reaches the sensor again. This process enables a simple and real-timecapable depiction of scatter diagrams / depth maps and also provides an image of intensity and confidence, recorded at the same time. With time-of-flight technology the scene is recorded all at once and does not need to be scanned. It is high speed, producing both 2D and 3D information in a multi-part image. The system works well in low lights and no structure or contrast is needed. However, the technology does have problems with mirroring and highly reflective surfaces. It is sensitive to scattered light so will also have difficulties with sunlight. Time-of-flight cameras are suitable for applications that require a large working distance, high speed and low complexity. If these properties are desired and a low budget is more important than accuracy down to the millimeter, the pulsed timeof-flight technology is a good choice. Volume measurements in logistics, palletising and de-palletising tasks, as well as autonomously driving vehicles in a logistics environment are suitable applications for time-of-flight cameras. Time-of-flight cameras are suited to generalised tasks such as pick-and-place applications of larger objects. They can also be used for robot control systems or the measuring and position detection of Control Engineering UK

MACHINE VISION large objects. There is no one perfect solution for an application. That is why each application has to be evaluated in terms of its requirements and the appropriate technology. First it must be decided whether 2D or 3D should be used. If a solution requiring the third dimension is selected, the suitable technology has to be chosen according to the application requirements and the advantages and disadvantages of the respective 3D technology. It is important to outline the criteria and basic conditions for the application again. Listing the basic conditions and requirements makes it easier to determine which technologies should be considered. The following points need to be clarified: • How much accuracy does my application require? (sub-mm, mm or cm) • What is the surface condition of the objects? (cooperative / uncooperative) • What kinds of working distance does

the system have to fulfill? • What is the required speed of the system? • Does the system have to be real-time capable? • What are my requirements for the installation and the setup? Can the setup be complex or does it have to be very easy to implement and integrate? • What is the total budget for the application? (Total cost of ownership) • What is the maximum cost for the 3D solution as an individual component? • Will the application be used indoors or outdoors with direct exposure to sunlight? After the most important requirements are listed, they have to be prioritised. This works best by asking yourself what are the absolute must-haves and what is more a B priority? Which advantages of another technology would be worth the omission of one requirement? When it comes to the choice of

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technologies for image processing, there is no 100% certainty, even between the choice of 2D and 3D technology. The image processing and the applications behind them are often so complex that individual decisions have to be made depending on the application. Choosing between 2D or 3D is the first decision that needs to be made. It is important to consider the total costs of the investment, which can accumulate over the entire lifecycle, not just the individual components. The installation of the system and the software solution may result in high costs, even if an individual component appears cheap. In the development of image processing solutions, the demand for 3D looks set to continue to rise. This increase is caused particularly by Industry 4.0 and the growing use of automation in all areas of industry. Jana Bartels is a product manager for Basler.

MACHINE VISION

Artificial intelligence and its impact on MACHINE VISION Artificial intelligence (AI) for machine vision will allow AI to think more like humans by employing deep learning techniques and other functions that humans use to develop their brains, says Winn Hardin.

hen the concept of ‘thinking machines’ emerged in the 1950s, alarmist warnings about this new field of artificial intelligence (AI) soon followed. The fear of the rise of the machines has played out in pop culture ever since, from the iconic 1968 film ‘2001: A Space Odyssey’ to ‘Ex Machina’. While AI still has not taken over society, improvements in data storage and processing power have enabled the development of cognitive systems, like IBM Watson, that are designed to take the guesswork out of decision-making human. Most current iterations of AI tackle more modest tasks like object recognition. The promise of AI looks to enable machine vision to take on challenging applications beyond the capabilities of today’s solutions. But is the technology ready for use in industrial applications?

Testing the AI waters AI’s applicability in machine vision relies on the affiliated branches of machine learning and, more so, deep learning. At its broadest level, AI is a computer’s ability to simulate human intelligence. Diving deeper, machine learning gives computers the ability to act without being explicitly programmed. Deep learning, a subfield of machine learning, enables computers to learn from experience. Several developments over the past decade have made deep learning a reality, not just a possibility, for machine vision. “Based on new techniques in neural networks, sufficient

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computational power in GPUs [graphics processing unit], and an abundance of data, only now can we use artificial intelligence for image processing,” said Olivier Despont, business development at ViDi Systems, a Swiss maker of deep learning-based vision software. Deep learning holds promise over traditional machine vision because, unlike traditional image processing software that uses a rules-based approach. “AI is the next step where we take things that are not easily characterised or non-linear and give them to the machines to create that next level of repeatability,” said Wallace Latimer, sales director, customised optical systems at FISBA LLC. “Whereas linear algorithms create a very narrow bucket, AI/deep learning creates bigger buckets that can accept more variation,” Latimer continues. “It’s widening the acceptance band of what is good or bad, and why it’s good or bad. By having the bigger bucket, you can focus on what offers the biggest bang and reduces changes to inputs.” At least one deep learning system is on the market for machine vision users today. ViDi Suite from ViDi Systems is the first commercially available deep learning-based industrial image analysis software. The software, which integrates with standard image processing libraries, learns like a child does. “You don’t teach a child using a rulesbased approach by explaining what a house is,” said Despont. “Based on few examples, our brains, even at a young age, are able to extract what makes a house. Our system works the same as the human brain.”

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ViDi Suite is comprised of three different tools. ViDi Blue finds and detects single or multiple features within an image. The tool localizes and identifies complex features and objects by learning from annotated images. ViDi Red detects anomalies by learning the normal appearance of an object, including its variations. The Red tool also segments specific regions in images. ViDi Green learns to separate different classes based on a collection of labeled images to classify an object. Another advantage of deep learning over traditional machine vision solutions is that it can reduce the time necessary to develop a machine vision program. “With the classic vision approach, many applications need 60-plus days of software development and feasibility,” continued Despont. “ViDi can complete development in half a day.” Unlike AI systems that use server farms to power their software, such as ones that have been developed by Facebook, Google, and IBM, ViDi uses a single highend NVIDIA GPU to train the system in a matter of minutes, rather than the days or months it takes to program and parameterize with IBM Watson, according to Despont. “And instead of using millions or billions of images, we recommend starting with 30 to 50 representative Control Engineering UK

MACHINE VISION good images to teach the system,” Despont said. “We’re not sending images to a cloud-based server farm to do the processing or training. Customers are happy they can run everything on a single PC with one GPU and keep ownership of their images.”

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Deep learning shows particular promise in applications that present challenges to traditional vision systems. “AI is really suitable in food inspection among others where you want to inspect donuts or a piece of meat that shows significant difference from one instance to another,” said Bruno Ménard, software program manager at Teledyne Dalsa. But it’s not just organic inspection applications that will benefit. Ménard cites traditional defect detection applications as another example. “It’s difficult to program a computer with traditional algorithms to define the defect without having to redo the settings every time there is a new defect,” he said. “But by using artificial intelligence with a lot of samples, you can end up with a really good definition of what is a good part and what isn’t.” As AI emerges in machine vision, the technology will find a place in additional inspection tasks and eventually extend beyond the realm of industrial automation. According to Latimer, deep learning will be advantageous in markets such as medical, life sciences, food, counterfeit inspection, and lumber grading. “These are areas that all have very gray decision points,” said Latimer. “Is that apple good enough or not? That’s hard to make a linear rule to say it is. Deep learning should enable a lot of applications to become much more efficient and repeatable.” For his part, ViDi Systems’ Despont foresees that deep learning will include medical diagnostics, surveillance, autonomous vehicles, and smart agriculture for inspection or map analysis. “AI is the future and will be helping people solve some complex tasks very quickly as computational capabilities are doubling almost every one-and-a-half years,” said Despont. Many machine vision professionals recognize the promise that AI and deep learning offer to the vision industry, but they say AI’s full potential won’t be realized for at least another three to five years. What’s more, AI isn’t necessarily the solution for everything that ails traditional vision and image processing. Ménard noted two major drawbacks in AI systems. “First, you need a lot of training ... and you need to create the expert to reach the next level of classification,” he said. “The second drawback is once it’s trained and the classification fails, it’s difficult to fix the problem. You have no choice of retraining with a new sample.” Before artificial intelligence becomes commonplace in machine vision, industry experts believe the industry will have to let much bigger players do the heavy lifting. “From our niche segment, we’re getting to watch the Googles of the world drive this technology to incredible levels of investment and refinement,” Latimer said. “Our industry cannot invest the time and money at the necessary scale. We’re going to have to leverage it.” Winn Hardin is contributing editor at AIA, part of the Association for Advancing Automation (A3). This article originally appeared in www.controleng.com

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ASSET MANAGEMENT

Connecting controls helps

MANAGE ASSETS According to Rob McKeel, a winning industrial internet strategy starts with connected controls to help systems use more asset data, dynamically adapt in realtime to changing business conditions, and automatically upgrade as needed for better cybersecurity. Advantages have included productivity gains of 22% and a maintenance cost reduction of 40%.

ith the rise of the industrial internet, the pace of technological advances has accelerated significantly, and initial tests of more interconnected controls show productivity gains of 22% and a maintenance cost reduction of 40%, among other benefits. So, why the hesitation? Advances are now outpacing control system upgrade cycles. Today, the average traditional control system only can use about 3% of data from industrial assets and is unable to dynamically adapt in real-time to changing business conditions. Out-of-date systems also often cannot automatically upgrade

internal software and security patches. Risks include productivity loss, security, and system integrity. To gain and maintain a competitive edge in this new era of software-defined machines, it is no longer enough for a control system to keep a machine running reliably. Machine-level controls need to be smart enough to collect and process data locally and be connected. Connected controllers, like connected people, can take more intelligent actions.

Predictive models, optimisation The good news is that the industry is beginning to see a new era in controls, where instead of one application

Apps now allow wind turbines to talk to each other and coordinate the way they change blade pitch as the wind changes to maximise wind farm power output.

running on a controller, dozens of apps all can run simultaneously. These could be machine apps like digital twins, that embed detailed engineering knowledge into predictive models, and real-time optimisers that determine the optimal way to run assets. Such apps require more horsepower, more flexibility, and more connectivity than traditional control systems can provide. To enable these advanced capabilities, control systems are being developed for the age of the industrial internet.

Piloting internet-based controls For example, a recent pilot program for the new internet-based control system connected machines such as gas turbines and MRI machines to cloud-computing capabilities. This has dramatically increased the amount of data captured and can deliver 1,000 times more computing power than standard control systems. By combining the power of data analytics and real-time control at scale, GE’s Industrial Internet Control Systems (IICS) have helped improve asset performance by 7% and productivity by 22%, reduce maintenance costs by 40%, and increase network and asset security.

Connectivity apps For example, a secure health cloud platform uses advanced controls technology from an automation and controls company. The platform collects data from anesthesia machines, analyses

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Control Engineering UK

ASSET MANAGEMENT trends, and uncovers insights that improve patient care and boost operating room efficiency. Among customers using the system is the Department of Anesthesia at the Canterbury District Health Board in New Zealand. Benefits include reduction of fresh gas flow rates, which has a myriad of positive benefits including financial, ecological, and clinical. This new era of controls brings an emergence of the industrial app economy. Because industrial internet-enabled controllers can run multiple apps simultaneously, benefits are increased. The industrial app economy will spur innovation by enabling a more seamless environment for people and machines to work smarter and more efficiently together. As machines and people become more interconnected, machines will begin to use apps the same way as consumers do, to improve health, boost productivity, learn from each other, and more. Existing apps: • Allow wind turbines to talk to each other and coordinate the way they change blade pitch as the wind changes to maximise wind farm power output. • Tell jet engines how to reduce fuel consumption. • Check the health of gas turbines and predict when a fault is likely to happen to allow intervention with preventive maintenance. • Allow doctors and nurses to schedule medical procedures more efficiently and collaborate in real-time on patients’ diagnoses, curing people better and faster. With industrial internet-enabled controllers, intelligence can interface safely and securely with the brains of industrial equipment, control systems, enabling equipment and processes to act more intelligently and dynamically in response to changing conditions. Unlocking the value of the industrial internet begins at the machine level with a connected control system. Rob McKeel is CEO of GE Automation & Controls. This article originally appeared in www.controleng.com

GE’s Field Agent Technology is being deployed by GE Healthcare to boost operating room efficiency. A recent pilot program for the new GE Industrial Internet Control System (IICS) connected machines, such as gas turbines and MRI machines, to GE Predix Edge and Cloud computing capabilities. GE Healthcare developed a secure health cloud platform using advanced controls technology from GE Automation and Controls. The platform, named Carestation Insights, collects data from anesthesia machines, analyses trends, and uncovers insights that improve patient care and boost operating room efficiency.

Control Engineering UK

May 2017

UK9

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INDUSTRY FOCUS – WATER & WASTEWATER

Controlling water supply measurement Effective management of water metering networks is crucial to ensure that the required accuracy is attained, says Alick MacGillivray.

he need for the water industry to understand and control its distribution networks has never been more pressing, with regulatory authorities such as OFWAT in the UK, and environmental pressures demanding better measurement accuracy. As a result, flow metering is increasingly being seen as an important factor in monitoring of leakage and other types of abstraction in the water industry.

Network analysis Flow meters are subject to a range of conditions within the water network and can be subject to electromagnetic or acoustical interference as well as mechanical damage. To manage this, the industry has developed analytical methods to detect when this happens. The water industry has, for example, made use of mass balances techniques to estimate the level of leakage in a system. Recently, this has been augmented by the development and application of powerful data analysis that takes this process a stage further by helping to identify the individual instrumentation that is mainly responsible for the imbalance. There are also more sophisticated techniques – originally designed for

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use in such diverse areas as missile tracking and computer vision – which can extract underlying trends from very noisy signals. These techniques can offer benefits in the water industry too.

Data validation The first and most basic of these tools is a technique known as data validation. This is effectively a collection of tools used to assess the quality of the acquired data. Part of this suite of tools applies numerical filters to acquired data to ensure that it ‘makes sense’. It is, for example, possible to set upper and lower limits on measured flows and to reject data that are outside this range. This is, in effect, a way of detecting cross-errors in the system. Another component of this technique is to set limits on the rate of change of measured quantities to detect spikes and other transient behaviour in the network. This allows the operator to base further analyses on data that lie within the normal operating parameters of the network. Often analyses are not based on individually acquired points, but on data that have been smoothed or averaged over a period of time, which allows the operators to determine longer term trends in the data and assist in demand forecasting. This can be taken further by the application of neural networks or generic algorithms where a computerbased neural network ‘learns’ the behaviour of a metering network and then highlights anomalous behaviour.

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Uncertainty analysis Uncertainty is the degree of doubt about a measurement. Undertaking an analysis of uncertainty involves identifying the main influences that affect the result of the measurement. This will result in a number which represents the ‘margin of error’ in the measurement. Applying this to the network gives an uncertainty in the water balance; that is a margin of error within which the mass balance should lie. Identifying the main contributors to this figure can ensure that capital expenditure is targeted to areas in the network where it will produce the most benefit.

Data reconciliation Data reconciliation is basically a self-consistency check designed to complement the existing metering infrastructure. It applies corrections to individual flows, to remove imbalances from pipe intersections in the distribution network. The size of each correction is compared with the expected uncertainty of the measurement to assign a measurement index to each value. If this index exceeds a given threshold, it is likely that the meter measuring this flow is a major contributor to the imbalance in the system. Alternatively, it may indicate that there is a leak in the pipe section containing the meter. By trending the index over time, it is possible to detect meter drift or leak development before significant operational problems arise. Going forward, optimising data use is an operational imperative, especially to water companies under environmental, regulatory and resource pressure. Failure to protect significant metering investments, by not complementing it with modern, cost-effective, data analysis techniques, risks increased capital and operational expenditure through poor targeting of effort. Alick MacGillivray is a senior consultant at NEL, part of the TÜV SÜD Group. Control Engineering UK

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ROBOTICS

Designing hygienic robots to suit the

food industry

Fast orientation, or fast picking, of raw materials is a complicated operation, frequently undertaken using non-hygienic equipment. A state-of-the-art robot designed to meet European Hygienic Engineering & Design Group (EHEDG) guidelines enables complete hygienic control of the process line, says Arnaud Derrien.

obots are increasingly being adopted by the food industry to help increase productivity and efficiency. Three types of robots are, typically specified. Delta, 4-axis and 6-axis. Staubli set out to determine which technology is best suited, from a microbiological standpoint, for bacteria control and to show how EHEDG hygienic guidelines can be used to improve the engineering of these technologies. The resulting Humid Environment (HE) project was a cooperative study between EHEDG, ECOLAB and Stäubli Robotics. EHEDG design principles refer to both open and closed equipment so can be employed when designing easy-to-clean robots. The EHEDG guidelines – specifically Documents 2, 7, 8 and 10 – have been used to assess Robotic cheese handling in a hygienically sensitive area.

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robots from a microbiologically hygienic standpoint. Retention zones, corrosionfree components and non-washable parts can be checked for evidence of the presence and spread of bacteria. The project findings showed a huge increase in the presence of microorganisms on the equipment, because the robots were originally designed for non-sensitive end-of-line environments. As today’s robotic applications move further up the production line towards the food process area, adapting traditional technologies by integrating the EHEDG approach to cleanability and hygienic design is important. The primary goal of the project was to remove the oil, motors and condensation buildup from being sited above the product. During operation a robot can heat up to 70°C, when connected to fast-moving equipment. In sensitive environments operating at temperatures between 4°C and 10°C, condensation, oil expansion and cooling off can occur within a few minutes. The hotspot created by the robot is most apparent when the robot reaches the end of the production cycle.

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Bacterial growth The ideal conditions for bacterial growth inside the robot include medium temperatures between 15°C and 40°C; water presence and activity; vapour condensation drawn from the environment directly inside the robot; neutral pH; and most significantly, lack of access for cleaning the inner parts of the equipment. The problem is the same for electrical control boxes: With uncontrolled air pressurisation, bacteria and corrosion can develop within a few weeks. Pressurisation of the arm and electrical boxes is the best solution during and after production periods. The team studied a number of issues to help advance the hygienic design and suitability of robots in food production environments. Challenges which needed to be overcome included hidden retention zones, the quantity of equipment components involved, and unsuitable materials. A retention zone is the cumulative area of the robot plus the skeleton frame that holds the robot in place. A water retention area is a place on the equipment where water can stay for extended time periods. Water retention areas can be external surfaces of the equipment itself, or ‘hidden water retention areas’. The external areas are Control Engineering UK

ROBOTICS easy to remove. Hidden water retention zones, however, need a specific focus to ensure that the complete mechanical installation does not create dead ends which give bacteria a chance to grow and spread. The number of peripheral stainless steel pieces of equipment connected to a Delta-style robot also has an impact on hygienic design. The fewer pieces of production equipment attached to the robot will make it easier to clean and there will be less retention areas to harbour bacteria. Delta robots were not designed for the routing of flexible pipes and so these are almost always attached ad hoc to the moving arms. Cable ties, even detectable ones, could fall onto the food product and the friction between the moving carbon arms and cable ties can cause particle emission above the food. The problem is the same for dielectric exchanges between foaming solutions; for example, water and the various metals used in the arm construction. Corrosion honeycombing – the creation of small niches and crevices where bacteria easily grow and survive – will appear as soon as detergents are used on equipment composed of at least two different metals, due to electrolysis action.

Surface cleaning treatments While the main mechanical benefit of stainless steel is its resistance to rust, it can presents challenges for machining and drilling, as well as being trickier to assemble. Tests were made with robots designed from stainless steel, but they were not successful and the conclusion was that stainless steel is not a suitable material for a dynamic robot. The best compromise is a specific aluminum (light, rigid and mechanically approved for robotics). But even specific aluminum designed for salt-saturated ambient environments can quickly corrode in a raw food production environment, which is why it is important to design the robot so that retention zones and extra components for grippers are avoided. Control Engineering UK

AUTOMATED HAM DEBONING SOLUTION ADHERES TO EHEDG GUIDELINES Tatsuya Umino, chief of robot products at Mayekawa Manufacturing Company, explains why the company chose the Stäubli HE series of robots – which are designed to meet the particular needs of the food industry – for use as part of its integrated deboning system. “The manual process of deboning pork is a demanding operation, both physically and technically, which is why it has always been difficult for factories to maintain a stable workforce. Automation of this process has long been called for by the industry, and Mayekawa responded by handing this challenging task over to robots. “We integrated Stäubli’s HE series of robots into our automated deboning machine. After taking an X-ray of the pork thigh to create a three-dimensional image, the robot’s precision cutting is able to produce a consistently higher yield for each unit processed.” The robots are also resistant to humid environments. A closed structure and pressurised arm prevent any contact between the robot’s internal organs and the surrounding environment. Its chemicalresistant, waterproof surface also allows for regular wash downs. “By automating the deboning process, we have been able to help preserve the health of operators. Our customers can now also achieve more consistent production output and quality, regardless of the size and shape of the bone to be cut.”

The HE Project led to the development of a specific surface treatment and a 6-axis robot – A mix of specific aluminum, metal treatment and codevelopment of a surface that is resistant to detergents and sterilisation solutions. This treatment has now been in use for many years and, in many cases, allows the robot to be washed with the same chemical solution as the rest of the line. Some applications allow the robot to clean itself by manipulating the detergent foaming spray nozzle around the gripper, robot and ancillary equipment.

A CIP robot? To eliminate human mistakes and ensure the cleaning of difficult-to-reach parts a cleaning solution was developed to allow for self-washing, which is used more frequently in sensitive industries such as dairy and meat processing. One of the main concerns of the study was the structure of the

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equipment itself: Common sense dictates that mounting the robot on the side of the production line will remove the main problems – oil, condensation, and other contaminants – from above the sensitive handling area. Secondly, a vertical frame, fixed on a single mount and sometimes onto the conveyor itself, eliminates the need for a stainless steel structure to affix the robot. Ultimately, the cooperative study showed that ‘HE grade’ can be considered a general definition and shape used in the design and engineering of both 4-axis and 6-axis robots. To achieve enhanced hygienic features a HE robot should be used. Delta architecture robot design is not recommended and any delta robots used in sensitive food production areas need to be covered to prevent possible contamination. Arnaud Derrin is key account manager for the food industry at Stäubli Robotics in France. May 2017

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ENERGY EFFICIENCY

Simple changes can optimise

STEAM SYSTEMS Dave Bird explains how implementing simple efficient measures can significantly reduce energy consumption.

team plays an important role in many processes, particularly in the food and beverage sector, where a variety of different types of steam may be needed as part of the production process. To reduce energy usage, it is necessary to turn to equipment that can optimise the steam system, such as modern heat exchange technology which can deliver significant savings. Systems like these can be easily implemented, helping plant operators improve overall plant safety, reduce energy costs and usage, increase efficiency and remain competitive. Crucially, these improvements donâ&#x20AC;&#x2122;t require major overhaul. Often simple changes can be made to equipment that is already in the plant.

Steam trap facts Optimising the efficiency of steam system can be easier than many think. Take, for example, steam traps, which are the most important link in the condensate

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loop and can help to lower energy consumption, maintain product quality, and increase productivity. Effective steam trapping is, therefore, an essential process that can help users operate sustainably. Needless to say, trap selection must ensure the pressure, condensate load and air venting requirements of the process are met. From trapping stations to specific trap devices, they are considered to be one of the most effective resource-saving measures, so users must take care of them â&#x20AC;&#x201C; ideally through scheduled maintenance. A reliable and safe supply of hot water is crucial for wash-down and clean-inplace (CIP) processes. Traditionally, the food and beverage industry has relied on large shell-and-tube calorifiers that use steam to heat water. However, these are inherently inefficient and can increase the risk of Legionella. By replacing these storage tanks with instantaneous systems that use compact heat exchangers, plants can achieve energy savings of up to

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20%. These systems work by capturing and reusing heat that may otherwise be wasted and can deliver a constant supply of instantaneous hot water at a stable temperature. This reduces the amount of steam required, which in turn cuts fuel demand and the associated CO2 emissions. Plate heat exchangers are easier to maintain and simple to control, which helps keep the system running at optimum efficiency. The boiler house is the engine room that powers the whole steam system, making it a vital place to measure efficiency from. The only way to obtain true boiler efficiency is to meter all energy into the boiler (in the gas and feed water) and compare this with the useful energy out of the boiler (in the steam). Energy monitoring systems manage this process, allowing users to quickly react to data they receive. If the monitor detects that efficiency levels have dropped, for example, the cause can be identified quickly and remedial action taken in order to prevent unnecessary costs arising. The monitoring of systems also enables energy and facility managers to benchmark the efficiency of boiler settings and operating procedures, meaning energy and cost-savings can be effectively measured and implemented. All process companies must comply with legislation and some may also be driven by their impact on the environment, so energy efficiency needs to be high on the agenda. By implementing simple measures to help optimise the efficiency of the system, steam users will not only benefit from reducing their carbon footprint, but will achieve significant cost savings too. Dave Bird is food & beverage sales manager at Spirax Sarco. Control Engineering UK

P ro CI al pe M l 9 20 -2 17

ENERGY EFFICIENCY

DRIVE SYSTEMS: HELPING REDUCE THE ENERGY BILL Energy represents both an environmental challenge and a competitiveness issue for many processing operations as, on average, it is the second biggest production cost after raw materials. Because motors account for almost 70% of the electrical consumption of a production site, motorised applications are an important source of potential savings. Variable speed is the main way to achieve savings. Leroy-Somer and Control Techniques, now part of the Nidec group, have developed variable speed drive systems whose components are engineered to complement each other. These solutions are said to be able to deliver energy savings and a quick return on investment. The Leroy-Somer Dyneo range of synchronous permanent magnet drive solutions, for example, offer super premium efficiency levels exceeding IE4 classification. By reducing rotor losses, its radial magnet rotor technology improves drive efficiency and specific output power.

Putting it on trial A Belgian producer of dairy products is achieving minimum energy savings of at least 18% from its refrigeration process as a result of switching to Dyneo permanent magnet motor technology. The solution is being used in a commercial refrigeration system

Control Engineering UK

that cools milk after pasteurisation or sterilisation. Refrigeration is a key element in the company’s manufacturing process, so optimum operation and reliability is paramount. The company had acquired four new commercial refrigerator systems and had heard good reports about permanent magnet motors and wanted to install one as a trial. So, three of the compressors were supplied with standard Leroy-Somer IE2 (90kW) asynchronous AC motors, and one with a Leroy-Somer IE4 (105kW) synchronous permanent magnet motor from the Dyneo range. Using a digital energy analyser, a series of power measurements compared two refrigeration units working at the same pressure. One featured the synchronous magnet motor (105kW) running at 1500 rpm and Leroy-Somer Powerdrive, while the other housed the standard (90kW) asynchronous motor running at 1487 rpm and a competitor drive. Energy savings were achieved using the permanent magnet motor across a range of different load profiles. Depending on the type of measure – involving number of pistons, speed, evaporation temperature and condensation temperature – the calculated energy savings were between 18-21%, taking into account any losses from the drive and the motor.

May 2017

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NEW PRODUCTS

Time saving cable entry system Available from OEM Automatic, the KDSClick cable entry system consists of just three types of basic components – frames, inlays and sealing sleeves. Unlike conventional systems, where the frame needs to be opened to insert the sealing sleeve and then screwed shut, the devices CONTA-CLIP design employs a dimensionally stable solution with a one-piece lightweight frame made from fibre-glass reinforced plastic. Inlays can be simply clicked into place to achieve the required size for the frame openings, which enables different frame configurations to be constructed to meet the requirements for different

cabling requirements. The range includes 82 different sealing sleeves available for guiding multiple cables through the frame openings. After the corresponding cable is sheathed, the sleeves can be inserted – from the inside of the electrical cabinet towards the outside – into the openings that are framed by the inlays. The sealing sleeves have a conical taper so can be easily pressed into the frame openings/inlays. There, they reliably seal up the spaces around the cable. They also provide a secure strain relief mechanism for cables outside of the housing. The sealing sleeves can also be easily released

ATEX-rated digital fuel turbine meter Tuthill has introduced a new in-line digital flow meter that has +/-1% accuracy, global certifications – including UL for US and Canada, ATEX, IECEx and CE – and simple preset calibrations. It is available in the UK from Bell Flow Systems. The meter is designed for use either in-line or at the end of a pipe. It features simple, four button operation and it uses cost-effective, replaceable, AA batteries.

UK16

May 2017

The all new in-line digital meter is available in three models to handle a wide variety of fluids and in both 1in NPT and BSPP threads. The aluminium model is designed for gasoline, diesel and other fuels. The nickel plated model is for bio-diesel to B100 and ethanol blends to E85. The polymer model is for diesel exhaust fluid, anti-freeze and other chemicals.

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to add or change the cabling. This offers cabling flexibility; the cabling can be changed without completely removing the frame. This system can be extended using a locking frame inside of the electrical cabinet. The locking frame secures the sealing sleeves from within so that they cannot be tampered with. The frame uses the same arrangement of mounting holes that are already standard for industrial connectors.

Evolving control valve Routine wear and tear of traditional control valves can lead to downtime and underperformance, which can reduce process efficiently. When it designed the Spira-trol control valve ten years ago Spirax Sarco took a new approach to the transfer of steam and other industrial fluids to ensure greater durability and efficiency. This resulted in the control valve being capable of controlling pressure, temperature and flow in industrial environments, helping to achieve energy savings with minimal total cost of ownership (TCO). Spira-trol is a modular, ‘set and forget’ system. Its cage retained seat design allows maintenance procedures to be done quickly and efficiently, with no need for any special tools. The control valve can also be maintained in-situ without being removed from the line, minimising downtime and maximising productivity. Internal components of the control valve have been designed to withstand a range of industrial fluids, including steam that is highly corrosive. Electrically or pneumatically actuated, Spira-trol includes a range of smart positioners to aid accurate control valve positioning and improve efficiency. With the option of the bellows sealed bonnet, users can achieve zero emissions leakage and further reduce maintenance.

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FOCUS ON THE SMART FACTORY

Starting the journey to THE SMART FACTORY Every journey starts with a single step. Suzanne Gill finds out what organisations need to consider when starting their journey to becoming a smart factory.

here is agreement that data is the key to achieving the goals of a smart factory – a reliable and secure data connection and acquisition infrastructure is a prerequisite to increasing production efficiencies and reducing system downtimes. This means that sensors, and other plant floor devices are a very important element in the success of a smart factory as they are the producers of the raw data. A smart factory will need to have the ability to connect to all of these plant floor devices, including those that did not form part of the traditional factory architecture. Protocol interoperability among different devices, maximum protection against cyber attacks, and an architecture that can maximise overall equipment effectiveness (OEE) are other requirements. “The evolution of industry 4.0 is about much more than communication between machines and the cloud. It enables the manufacturing world to change the traditional business models. More than two decades ago, automotive manufacturing leaders had the vision to lease complete parts of their manufacturing process and pay the owner by delivering the output of that part of the line in a good quality,” said Thomas Heuwinkel, head of business development for Moxa Europe. “Today, with industry 4.0, the required process data can easily be made available for all involved stakeholders. The data needed to judge whether machine output meets customer specification can be made available in a neutral place to document the evidence.”

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Based on the technological evolution that guides us towards industry 4.0, Heuwinkel believes that entire markets will be able to start to focus on their core competencies, outsourcing their production stepwise. “A few decades ago, we were impressed by the idea of an automotive manufacturer being able to produce different types of cars on one production line. Looking forward, I believe we will be seeing different car brands produced on one production line! This will give us a very different view on plant effectiveness or the term OEE,” he said. Utilising cloud-based monitoring will enable process engineers to achieve smarter operation and receive realtime performance data to increase the productivity and useful life of existing machines. “Live dashboards will support engineers with alerts based on historical and target performance metrics, and they do not even require the investment or expertise in specialised IT infrastructure, servers, or software. Process engineers

will be the masters of OEE – yet they will remain heavily dependent on accurate data,” concludes Heuwinkel.

Positioned to compete According to Nicholas Temple, marketing & global accounts manager, UK & Ireland, for B&R Automation, Industry 4.0 is happening right now and he says it is vital that organisations start to consider how they are positioned to compete and how the role of the control engineer may change as a result. “Industry 4.0 will not occur overnight, but it is important that control engineers become more IT literate and they must be prepared to work across the traditionally separate lines of IT/OT,” said Temple. “They also need to start to develop new skills in data management and security.” B&R positions the automation and control engineer’s influence into a group of potential use cases. These include human-robot collaboration; predictive maintenance; data > p22 collection and storage; visualisation Industry is facing a number of key challenges as it strives to achieve more flexible manufacturing.

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May 2017

FOCUS ON THE SMART FACTORY and presentation of manufacturing information in real-time; and simulation (digital twins, for example). “These use cases require the skills and creativity of control engineers in order to be recognised,” said Temple. For example, with data collection and storage, plant managers are focused on bringing existing machines and factories up to speed for Industry 4.0. In the majority of production environments, paper documentation is still the preferred method of data storage as there are so many existing assets on the shop floor that have not been digitised. However, there are now solutions available to achieve this – for example B&R’s Orange Box, which enables machine operators to collect and analyse data from previously isolated machines and lines with minimal effort. It consists of a controller and preconfigured software blocks. The controller collects operating data from any machine via its I/O channels or a fieldbus connection. From this data, the software is able to generate and display OEE ratings and other KPIs, and can share this information with higher-level systems via OPC UA.

An ongoing process “While the exact future of the IIoT is not yet certain, it is clear that change is an ongoing process and the factory of the future will be the result of evolution,” said Mark Maas, industrial digital factory & innovation lead for TE Connectivity.

Industry is facing a number of key challenges as it strives to achieve more flexible manufacturing alongside the need for greater efficiencies. Data collection, aggregation, visualisation and analytics that enable immediate data-driven decisions can help overcome these challenges. Data driven decisions can lead to greater efficiencies in energy and raw materials use, people and money, higher product quality and thus greater flexibility. TE created its own digital factory platform to provide it with an environment that allows it to share increasingly more information, both within the plant as well as within the entire value chain. “One thing we have learned as our own factories enter the digital era is that older equipment can be expensive to upgrade or replace. We needed to find a flexible solution to connect a machine to a network, enabling pieces of equipment to communicate with each other and with users. When we looked at our older machines, for example, we identified a need for a machine independent, plugand-play connectivity device. To achieve this, we implemented an internal project to deliver such a device. The result was the IoT OmniGate, a module which connects the OT with the IT. “In my opinion the smart factory needs to be able to address a number of key industrial trends including greater customisation/differentiation of products – even in high volume production

runs; improved energy efficiency; and increasingly more interactivity. As a consequence we will see a move from ‘made to stock’ to ‘make to order’. Factories need to become more flexible and more environmentally sustainable. The ability to share information with customers – even across a range of production facilities – will lead to a better balance between offer and demand. I believe that in the factory of the future, the IIoT will connect all processes, integrating all things – from machines, controllers and drives to workpieces – into networks and IT systems. This will facilitate a leap in productivity and efficiency. It will not happen overnight, but instead will be the result of ongoing studies and developments,” said Maas.

Staying relevant Industry 4.0, combined with IIoT, big data, and machine learning all rely on the digitalisation of the industrial environment through the utilisation of IT technologies. “This is an issue that will affect all industries – machine builders, OEMs, and manufacturers – both large and small – should be looking at new business models and services to ensure they stay relevant in a possibly game-changing future,” said Paul Smith, business development manager Industrial IoT for Beckhoff. “Cloud-based platform services can include a variety of system-relevant data about an automation platform – machine details, or even plant line details including product-related information – which can be used to improve product and production,” continued Smith. “Each market stage relies on data and services from its supplier stages and – enriched with own expertise – offers a base for subsequent customers. In this way, each player can start to concentrate on its own core competencies.”

Technological challenges The technical challenges to achieve this relate to transparency and connectivity. Transparency describes the information coming from a sensor, for example, in

May 2017

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Control Engineering Europe

FOCUS ON THE SMART FACTORY the context of controller cycle times, communicated via fieldbus, controller, and multi-master bus to a cloud system for processing and analysis. Hundreds and thousands of sensors and actuators, scanned in milliseconds, form a massive data source. When this is connected to a cloud-based system it allows various vendor platform services to be utilised for data storage, aggregation and analysis. “Breaking down the technological challenges of the smart factory into industrial standards, control system concepts form the tool base for smart factory engineering in conjunction with fieldbus technology and remote IO; and scientific engineering including automation, motion and analytics, said Dr Josef Papenfort, product manager TwinCAT, at Beckhoff Automation. “Combined with connectivity protocols utilising open industrial standards such as OPC UA in conjunction with IT standards, a whole cyber-physical system scenario allowing direct cloud computing down to the detail of sensor data, can be made available.”

Providing choice Jackie Chang, president and general manager for Delta EMEA, believes that Delta is able to provide the necessary solutions for its customers looking to create a smart factory. “The most important thing for smart factory success is the ability to generate data, to collect it, collate it and analyse it to turn it into actionable information,” he said. “To achieve this there is a need for open and compatible solutions. Delta can offer smart sensors, networking solutions, HMIs, PLCs, controllers, drives, etc, which are all compatible with each other. We also collaborate with partners to ensure that the language, software and devices are able to integrate with all existing protocols and communication languages. Delta is a young company, in comparison with some of the other industrial automation vendors. This means that we do not have the problem of needing to communicate with outdated legacy equipment when we introduce new solutions.” Control Engineering Europe

adidas and Siemens collaborate in digital production adidas and Siemens have announced their intention to collaborate in the digital production of sporting goods. As part of a joint research and development program, the companies will be working to drive forward the digitalisation of the adidas SPEEDFACTORY to ultimately develop capabilities for fast, transparent and individualised production. The adidas SPEEDFACTORY opens doors for the creation of products which are more closely in touch with the consumer and are completely unique to their fit and functional needs. The manufacture of such individual sporting goods calls for flexibility in production and rapid integration of new technologies. A ‘digital twin’ of the SPEEDFACTORY will allow the entire production process to be simulated, tested and optimised up front. Merging the virtual and real worlds will help shorten the time to market. It will also bring greater flexibility and provide improved manufacturing quality and efficiency.

Delta’s own manufacturing facilities have acted as a testbed for its smart solutions. At this year’s Hannover Messe the company showed its smart manufacturing capabilities with a live demonstration of an integrated IIoT and robot workstation which employs its sixaxis articulated robot, IIoT and machine vision technology as well as a new Manufacturing Execution System (MES) to enable time and resource-efficient customised ordering and production. At the exhibition this demonstrator was put to work producing personalised business card holders for visitors. The MES system, linked to a cloud platform, allowed visitors to place orders for personalised business card holders via a laptop PC. This provides immediate confirmation via SMS including a weblink to monitor production scheduling and progress in real-time. The

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“Everything we do is focused on our consumers. They demand the highest level of individuality and quality. With SPEEDFACTORY we can completely rethink conventional processes and live up to these high expectations,” explained Gerd Manz, vice president technology innovation at adidas. “By digitalising the value chain we will be able to implement new technological innovations more quickly, make more efficient and transparent use of the resources available and so respond more flexibly to the individual needs of our consumers – to give them what they want when they want it.” “The SPEEDFACTORIES run by adidas offers a good illustration of where the production of the future is heading,” said Klaus Helmrich, a member of the management board of Siemens AG. “The social trend towards greater customisation, coupled with new technologies capable of actually fulfilling these expectations, will permanently change many production processes.”

robot then executes pick-and-place and laser carving according to the orders. Order adjustment and production rescheduling for urgent orders can be realised through the MES system for flexible and interchangeable production. Upon production process completion, customers receive confirmation via SMS.

Conclusion As we have learned, data is key. It is vital that more information from the plant floor be used to help improve production flexibility and efficiency. Even information from isolated legacy systems needs to be utilised and a variety of tools to enable this are now coming to market. It is important that we all consider the role we have to play in helping our companies become ‘smarter’ and making sure that they don’t get left behind. May 2017

FOCUS ON THE SMART FACTORY

Looking at the human side of

THE SMART FACTORY Suzanne Gill spoke to Faouzi Grebici, who believes that Industry 4.0 success will rely on the buy-in of the people on the shop floor.

or many decades the manufacturing sector has, successfully, been employing technologies and strategies such as computer-integrated manufacturing (CIM), lean manufacturing and other manufacturing models to increase productivity and efficiency. The key difference today is that, thanks to the progress in information technology, it is possible to share information much more widely. “Moving beyond the communication of operator to machine, machine to machine and machine to plant, interaction between consumer and manufacturer is now also a reality,” said Faouzi Grebici, industry solution manager for Omron EMEA. “Indeed, this closer consumer-manufacturer connection will have a big effect on how manufacturing evolves in the future.” A shift away from mass production to mass customisation has already been predicted and the results of this can be seen in the production of luxury items and products with longer manufacturing lead times, such as

May 2017

automotives. Grebici believes that, with the use of modern technology, this trend will start to spread to fast consumables too. “Manufacturing sites will get closer to their consumers. They will be nimbler and smaller, extremely agile and reconfigurable and above all rapidly responsive to consumers changing tastes,” he predicts. This is what Omron refers to as the NEAR factory – Networked, Efficient, Agile and Responsible. “Besides the traditional requirements of profitability, there will be a second mission – to embrace the aspect of people and purpose,” continues Grebici. Moving on to discuss the technological challenges for the ‘NEAR’ factory, and where humans fit into this vision, Grebici said: “Smart factories will need smarter people. Well-run companies are those which focus on people.” Indeed, the management philosophy of Omron’s company founder, Dr Kazuma Tateishi, was ‘to the machine, the work of the machine, and to man the thrill of further creation.’ Explaining why this philosophy remains relevant today, Grebici said:

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“Lean factories successfully evolved the role of worker to that of operator and now in the information era, the role of the human is evolving from operator to creator. It is a fact that badly designed production lines and inefficiently automated processes are most often a consequence of excluding the operator from the initial design. There is a false belief that more information and more data mining, crunched through ever more sophisticated cloud-based software will be the answer to the factory of the future.” While he agrees that this will play an important role, Grebici argues that before implementing any smart factory solutions questions should be asked about whom it will benefit. “Where are we closing the information feedback loop? Omron strongly believes that it should primarily serve the person in front of the machine. Operators within the plant need to own the technology they are working with and need to be involved in the evolution of production lines. Technology should be an enabler for the humans working in the plant.” As for the technological challenges of product personalisation, Grebici believes that it will, eventually, come down to perfecting the art of making standard products more special. “A concept should be applied to the product and to the production strategy, whereby the customised final product is componentised into standard elements that meet the mass production model, with more individualised consumer demands being added at the final assembly stage to offer greater product variation.” This, of course, requires greater agility and flexibility and calls for a new manufacturing paradigm which is where Control Engineering Europe

FOCUS ON THE SMART FACTORY the NEAR factory or the NEAR assembly line will come into play. “The tricky part of this is to identify the cut-off point between Make to Stock (MTS) – mass produced – and Make to Order (MTO) – personalised products. MTS is a pure ‘push’ model based on past history and forecasts, while the MTO is a ‘pull’ model which obeys instant demands. The balance of both flows, operating at different speeds – where the former is predictable and fact driven and the other is random and asynchronous – is a challenge. Automating this whole process, with a complex network of conveyors makes the production facility costly, rigid and inflexible,” said Grebici. Today, most personalisation tasks are made manually, close to the final packaging line. The idea is that the line that is highly automated or robotised will pull the mass-produced components as they are needed. The link between the ‘pull’ and ‘push’ is established in an asynchronous manner. According to Omron this is best achieved through the use of autonomous intelligent vehicles (AIVs), which it believes will be a game changer in the factory of the future. Finding the best way to produce large quantities of a product with greater variety at reasonable cost is where Industry 4.0 technology will really come into play and, according to Grebici, mobile robotics will be a vital element as they offer the ability to create more flexible ‘assemble to order’ production scenarios. “They should not be considered as simple replacements for humans in an existing production line set up or as simple transportation solutions,” said Grebici. “They can offer a way to destructure a production process, allowing it to better meet consumer demand for personalised products. They should be considered as a disruptive technology that can be used as enablers to create asynchronous production environments. “AIVs are autonomous, collaborative and importantly do not require any change in production facilities to operate within a flexible and reconfigurable production site. Of course, the success of flexible production to create more personalised goods will require more than just replacing conveyors or manually driven trolleys. It is about horizontal collaborative work being undertaken between the supplier and end consumer and a vertical and open integration of the information layer. This is where consumer, manufacturer, technology providers, machine builders, suppliers and operators are working in a collaborative eco-system and I believe that this is what Industry 4.0 is all about,” concludes Grebici. “The manufacturing sector needs to stop being slaves to the speed of conveyor belts and rigid production lines. Industry 4.0 cannot simply be applied to today’s production setups,” said Grebici. “Industry 4.0 should be considered as an opportunity to change the way things are produced, with its elements being employed where it will offer benefits and improve productivity. However, it is vital that the people working in the plant are involved in any changes. The new way of doing things in the manufacturing sector should always be collaborative… starting with the people on the plant floor.” Control Engineering Europe

May 2017

Together facing a brighter tomorrow At Yokogawa, we believe the sky’s the limit. And to reach beyond today’s horizons, we work step-by-step with you to make the unimagined a reality. That’s how we move forward, through the synergy of co-innovation partnership. Join hands with us, and together we can sustain a brighter future. Yokogawa: Building a better tomorrow with you today.

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FOCUS ON THE SMART FACTORY

SAFETY FIRST: How Industry 4.0 can optimise safety Andrew Minturn discusses the role of the human in Industry 4.0 and how to ensure safety.

ndustry 4.0, a buzzword derived from Germany, is set to redefine the current working environment. This new era of industry can be visualised as a highly adaptable workspace, able to react and respond to changing customer requirements almost instantly. Based on information generated and stored, individual production lines can help to transform operations simply and effectively. It is inevitable that automation is primarily associated with Industry 4.0. However, it is crucial that there is a clear recognition that the role of people in the production will never be redundant. In fact, one of the main beliefs of Industry 4.0 is that people are the key players. Connectivity between humans

May 2017

and machine, with the integration of IT, is fundamental to the success of Industry 4.0. In a traditional production environment, with lines or cells frequently geared to the manufacture of a single product, the safety of those working in the facility is generally straightforward to monitor. A risk assessment of all aspects of the operation – from individual components through to operator ‘touch points’ with equipment – will create a guide which in theory should remain valid until the use of that line changes or alterations are made to the equipment within it. Immediate hazards can be minimised and risks to operator safety averted, as long as correct procedures are followed.

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Challenges However, a plant operating under Industry 4.0 principles potentially presents a very different and more intricate set of challenges. Reconfiguration of production areas at short notice, involving the rapid changes of tooling and even the physical movement of equipment, can pose a range of safety challenges, while the sheer number of configurations achievable to meet potential requirements may entail a separate risk assessment for each. Yet, with another of the key features of Industry 4.0 being the safety of personnel and data under a secure value-creation network, these considerations cannot be ignored if compliance with local, national and international regulations is to be maintained. Fortunately there are a variety of technologies available to counter these issues – and it is no exaggeration to say

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FOCUS ON THE SMART FACTORY

that Industry 4.0 offers the opportunity to increase safety further due to the ability to gather data in real time and then act upon it before a potential hazard becomes a real one. For example, a range of devices can be fitted onto equipment capable of detecting and reporting operator behaviour which may pose a risk to safety. This equipment can take a number of forms; among the most common are intelligent cameras which gather digital images or footage and pass these to a central control point, automatically highlighting any abnormal behaviours such as entry into a restricted area. Many systems designers also opt to equip their machines with safety sensing devices which can immediately sense if a human operator has moved into an unsafe area or positioned themselves too close to a particular piece of plant. In such instances, the default response is usually to power down the machine or, in the case of a collaborative robot, to slow down to a safe speed, allowing the individual time to move away from the hazard.

Level of risk The decision on which device to use depends primarily on the level of risk involved. This type of feature is also beneficial when equipment has to be moved. Previously, for example, a machine would need to have all its guards in place and be completely switched off before any action could be taken. Given that there will always be a desire to avoid switching off machines completely to avoid additional warm-up Control Engineering Europe

times and quality issues with first-off components, this is a major advantage in the dynamic production environments associated with Industry 4.0. Meanwhile, many Industry 4.0-compatible technologies now have additional safety features built into them, rather than having to be added afterwards. One example is Industry 4.0 compatible drives which can be used to create a machine protocol with a unique number, highlighting immediately a potential safety issue if a different protocol is used. A further technology which has become commonplace in Industry 4.0 environments is the dedicated safety protocol. There are a number of these on the market – openSAFETY, SERCOS and ProfiNet to name but a few – with all common bus systems now having a safety version. All have been designed as an advance on older wire-based systems for powering down and enable a greater flow of information to ensure uptime is maximised and that equipment only powers down as a last resort. An alternative to these is a safety zone module which continuously checks wires and negates the need to invest in a separate safety bus system in certain applications.

Risk assessment While these features are beneficial, it must be remembered that the basic tenets of sound health & safety practice must still be adhered to. A risk assessment of every scenario likely to be encountered (effectively, any machine

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configuration which can be selected) must be undertaken, with operatives receiving the necessary training to work effectively in this more dynamic environment. Applications which have always needed physical guards around them will continue to need the same level of protection – the most unpredictable and vulnerable aspect of any manufacturing environment has always been and remains the individual people working within it and no effort should be spared in protecting them irrespective of the manufacturing processes adopted. While individual system components may be considered to be ‘safe’, it may be a very different story when considering their use in combination. Applying this to an Industry 4.0 environment, one example could be the added requirement to programme alternative routes for autonomous or robotic equipment that experiences an obstacle on its route around the facility. This anticipatory consideration may be seen to go beyond traditional production environments. It highlights the need for health & safety personnel to receive the necessary training to truly understand the ethos and capabilities of Industry 4.0. By working together with component suppliers and safetyqualified engineers, achieving a safe, Industry 4.0 compliant production environment is an easy target. For more information visit http://www. boschrexroth.co.uk/industry4.0 Andrew Minturn is product manager at Bosch Rexroth. May 2017

FOCUS ON THE SMART FACTORY

Integrated industry and the future of smart factories Commonly known as the Industrial Internet of Things (IIOT) or Industry 4.0, Integrated Industry is the concept of a fully connected manufacturing system, where there is communication at each stage of the production process, says Gavin Stoppel of Harting.

here are four key elements that lead to Integrated Industry within a manufacturing environment – modularisation, digitalisation, customisation and miniaturisation. A modularly constructed production plant offers a previously unattainable level of flexibility in production. Each section of the factory can be individually accessed and maintained, giving the flexibility to alter the individual production modules without disruption to other processes. Another factor is the modularisation of products; the HanModular® industrial connector family, for example, allows users to combine various connector inserts in a single connector housing. This flexibility means that power, signals and data can be combined flexibly within one connector, saving space whilst performing more efficiently. Innovative products are flooding the market, providing smart solutions to integrate digital concepts into factories. These innovations allow for central machine monitoring and process optimisation. Products such as the HARTING MICA Industry Computer can be retrofitted into existing factory set-ups, removing the need for costly refurbishments whilst implementing the changes needed to bring existing machinery up to date and meeting the requirements of a smart factory.

Customisation Industrial production is becoming more flexible and more intelligent. It

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is, therefore, important that individual production requirements are met, as customised solutions solve problems that standardised products cannot. Customisation is a key part of creating an Integrated Industry environment because the systems can be tailored to specific requirements; to provide an increased level of power, for example. These bespoke components help to create a ‘smart’ factory which manufactures more efficiently.

Miniaturisation A key theme within Integrated Industry is the growing trend of miniaturisation, specifically with regards to connectivity. In particular, saving space is crucial while still providing the same amount of power, signal and data. HARTING strives to provide solutions that deliver maximum

HARTING’s latest connectivity solutions provide maximum power, signal and data whilst maintaining a smaller footprint.

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performance, and the introduction of three major new connectivity developments – the ix Industrial, M8 D-coded and T1 Industrial - represent a big step forward in this direction. The ix Industrial is set to replace RJ45 as the industry standard, combining compactness with robustness for harsh industrial applications. Providing a standardised interface according to IEC/ PAS 61076-3-124, this product is costeffective and gives users investment security as well as providing the correct contact point for future applications in the IoT. Likewise, the M8 D-coded is pushing the boundaries set by the traditional M8 connector, which only transmits signals. The M8 D-coded avoids taking up further space with additional power interfaces by simultaneously supplying data and power to field equipment with its PoE-capability in D-coding. Even more exciting is the T1 Industrial – a single-pair Ethernet solution that increases the ease of implementing Ethernet whilst remaining cost-effective. While normal Ethernet requires either 2-wire pairs or 4-wire pairs, the T1 will create a new standard for the industry which defines a transmission channel over an unshielded twisted-pair cable with a length of up to 15 m for on-board passenger car networks and shielded cabling up to 40 m for use in automation, rail and aviation industries. An IEEE working group are already developing the 10Base-T1 Extended Reach Standard. This standard could replace all conventional field buses with Ethernet through the extension of transmission distances to a planned 15,500m. The development of these Ethernet standards shows that the practical realisation of Integrated Industry concepts is becoming ever closer. www.HARTING.co.uk Control Engineering Europe

Han® Modular Smart Modular Connectors

The market standard for modular connectors Merge power, signal and data into a unique connector Integration of multiple connectors into a single unit Shorter installation times Significant reduction in space requirements Cost savings on components and the entire system For more information phone +44 (0) 1604 827500 or e-mail salesUK@HARTING.com www.HARTING.co.uk/new-han

FOCUS ON THE SMART FACTORY

When and where will Industry 4.0 happen? Chris Evans evaluates the current status regarding Industry 4.0 realisation.

any people are now invested in working towards achieving the goals of Industry 4.0. For a concept that started life as a German government strategy it has captured the imagination of many around the globe. With so much effort being put into talking about the concept, it is interesting to look at the aspects of it that are close to being realised. Looking closer at manufacturing you could argue that four design principles that define Industry 4.0 are being realised right now: Interoperability: Machines, devices, sensors and people connecting with each other via the Internet of Things (IoT) or Industrial Internet of Things (IIoT) Information transparency: The aggregation of raw sensor data to higher-value context information. Technical assistance: Systems aggregating and visualising information for humans to make informed decisions and solve urgent problems. Plus, cyber physical systems undertaking tasks too taxing for human co-workers. Decentralised decisions: The ability of cyber physical systems to make decisions on their own and to perform their tasks as autonomously as possible. Mitsubishi Electric Automation Systems is acting as a development partner for achieving all four of the above Industry 4.0 principles. Whether that be by developing hardware and software products that enable the functions laid down in the principles, or working with partners to create systems and solutions that realise them, we are, to a greater or lesser degree, responsible for making it happen. It will

May 2017

not be universal, but for those engineers, designers and companies searching for new industrial solutions and taking an active role in automation, it will happen. Whether it is a system integrator working with a standard industrial articulated arm robot to make it work interactively with the process, or connecting machines spread around the world for an improved maintenance strategy, the driving force is greater efficiency, increased competitiveness, extended functionality and improved reliability. These drivers are universal and current, it simply depends on how much a business or organisation is able to invest in terms of time and resource to achieve those ends. For Mitsubishi, all activities relating to the increasing digital transformation of companies – creating the ‘smart factory’ if you like – fall under the ‘e-F@ctory’ umbrella, which is a fundamental part of the Mitsubishi Electric automated factory approach. This encompasses the e-F@ctory Alliance – a global network of partners with over 300 members worldwide – which includes manufacturers of industrial components as well as specialist system integrators and software providers. All partners offer complimentary technologies that provide the customer with ‘best in class’ solutions.

Collaboration These partner companies collaborate at an individual level to offer flexible and optimised solutions and play a large role in delivering new technology that comprises the steps on the road to digitalisation, Smart Manufacturing and Industry 4.0. Delivering real-world projects that clearly illustrate the points we have raised

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is, of course, the only way to validate the company’s beliefs, so here are two great examples that help define how and where Industry 4.0 will actually happen. A project undertaken with Intel on an IloT gateway to process big data for savings worth millions of dollars defines each of the principles mentioned very well. Intel has developed more than a dozen big data projects that have bolstered both operational efficiency and the bottom line – reducing product test times is one of them. Every Intel chip produced undergoes a quality check involving a complex series of tests. Intel found that by using historical information gathered during manufacturing, the number of tests required could be reduced, resulting in decreased test times. Implemented as a proof of concept, this solution avoided significant test costs for one series of Intel Core processors. For Intel, this pilot is forecast to save millions of dollars annually and will provide other valuable business benefits. The big data project was realised, in-part, by using a Mitsubishi Electric MELSEC-Q series C Language Controller, to aggregate and securely input data into a big data analytics server. The data input process involves validating, filtering, and reformatting the data to make it easier for the big data analytics software to work on it. The controller is an embedded solution equipped with numerous features characteristic of intelligent systems, including robust network connectivity and the high computational performance needed to process large amounts of data collected from sensors or via the network when supporting sophisticated system control and operations. It was built to satisfy the Control Engineering Europe

FOCUS ON THE SMART FACTORY diverse requirements of an automated factory solution – including reliability, a tolerance of harsh environments, and long-term availability. These features make it a robust and reliable product that requires little maintenance for realising IloT manufacturing applications.

A holistic approach In another project a holistic approach to predictive maintenance was realised by working with e-F@ctory Alliance member FAG Schaeffler. This solution is also indicative of all the principles in Industry 4.0. It builds on the capabilities of the latest FAG SmartCheck condition monitoring sensors by integrating them with an intelligent PLC based sensor controller for a more holistic approach to condition monitoring. The Smart Condition Monitoring (SCM) solution adds to the usual ‘traffic light’ alerts with detailed diagnostics, in-depth analysis and recommended actions to minimise unscheduled downtime and maximise

The MELSEC iQ-R Series controller is said to offer a bridge to the next generation of automation.

asset availability for an entire plant. Increases in operating temperature, excessive current draw, changes in vibration characteristics and significant shifts in other operating parameters that are indicative of impending problems in rotating machines are reported over Ethernet. The technology has been developed to allow the sensors to monitor the full range of parameters 24/7, allowing this information to be interpreted to give an overview on the asset health. Linking multiple sensors into the control

system enables the controller to analyse patterns of operation that are outside the norm, with a series of alarm conditions that can provide alerts when attention is needed. The SCM analysis provides detailed diagnostics, offers suggestions for where additional measurements should be taken and provides maintenance staff with more precise error identification. It even provides recommendations as to the remedial actions that should be taken, with clear text messages presented to personnel. This information can also be networked to higher-level systems for ongoing trend and predictive maintenance analysis across all the assets around the plant. Early recognition of deterioration, for example in bearings or other motor driven system components, can prevent costly breakdowns and allow preventative action to be carried out, maximising production time and efficiency. Chris Evans is marketing & operations group manager at Mitsubishi Electric Automation Systems Division – UK.

Do you want your products to be seen by Senior Engineers responsible for designing, managing & maintaining plants & factories in the UK & across Europe?

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Control, Instrumentation and Automation in the Process and Manufacturing Industries

Suzanne Gill – Editor +44 (0)1732 359990 or email suzanne.gill@imlgroup.co.uk

2016 IIOT & INDUSTRY 4.0 STUDY

Integration trends in instrumentation, controls One-third of respondents to the 2016 Industrial Internet of Things & Industy 4.0 study are involved in the instrumentation, measurement, and controls systems or devices industry – 82% of whom reported to be investing more in advanced technologies to support IIoT, Industrie 4.0, or digital manufacturing initiatives. Below are four additional findings from this report segment: 1. Perspective: Thirty-seven percent of instrumentation/controls engineers do believe that IIoT and Industry 4.0 are helpful to their existing initiatives, and 45% would describe them as “different words for what we’ve been trying to do all along.” 2. Useful attributes: Respondents involved with instrumentation, measurement, and controls systems or devices have found the interoperability (53%), security (42%), and analytics attributes (38%) of the IIoT framework to be the most useful. Regarding the Industry 4.0 platform, respondents most value the real-time capabilities (44%) and interoperability functions (40%). 3. Technologies, services: The most useful groups of technologies and

services in supporting IIoT/Industrie 4.0/digital manufacturing in the instrumentation/controls industry are wired or wireless networking, device bus, Fieldbus networks, I/O modules and systems (53%) and HMIs, SCADA, historian, alarm management or data acquisition systems (48%). 4. Annual budget: Companies involved in the instrumentation, measurement, and controls systems or devices industry estimate a $1.2 million annual investment in IIoT, Industrie 4.0, and/or digital manufacturing areas; 39% estimate $100,000 or less. View more information at www.controleng.com/2016IIoTStudy. Amanda Pelliccione is the research director at CFE Media, apelliccione@ cfemedia.com.

Top 5 expected benefits of IIoT, Industrie 4.0 implementation Connect people, data, machines Increase innovation Increase information flow

64% 49% 46%

May 2017

Spend more on products/ software

Don't know

25% 36% 20% 19% About the same

Spend more on services

36%

of end users report spending more on Ethernet products and software than on services. Source: Control Engineering 2016 Mobility, Ethernet & Wireless Study

30%

of end users are seriously concerned about the cybersecurity of wireless communications devices and protocols within their facilities. Source: Control Engineering 2016 Cybersecurity Study

4/5

of engineering firms has integrated – or has plans to integrate – process sensors and transmitters. Source: Control Engineering 2016 System Integration Study

59%

of end users are currently using or planning to use elements of both IIoT and Industry 4.0 in their facilities. Source: Control Engineering 2016 IIoT & Industry 4.0 Study

Improve data analysis

44%

MORE RESEARCH

Ease system integration

44%

Control Engineering covers several research topics each year. All reports are available at www.controleng.com/ce-research.

More than half of instrumentation/controls engineers expect their company’s implementation of IIoT and/or Industry 4.0 to better connect people, data, and their machines. Source: Control Engineering.

Ethernet products, software, services spending

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Control Engineering Europe

MOTION CONTROL

Motion controllers ADAPT THEMSELVES Adaptive motion controllers can be modified to a controlled process behaviour, among other controlled process benefits, says Vance VanDoren.

very feedback controller is adaptive because it can change its control effort in response to a change in the error between the measured process variable and the desired setpoint. A true adaptive controller, however, also can adjust its individual control efforts, and its underlying control strategy. It can tune its own parameters or otherwise modify its own control algorithm to accommodate changes in the behaviour of the controlled process. An adaptive proportional controller, for example, might adjust its gain when it observes that the process started to respond to its control efforts too quickly or too slowly. This could help maintain tighter control over a process that experiences variable sensitivity like a robot with variable load weights. For example, if a particularly heavy load were to slow the robot’s movements, an adaptive, proportionalonly controller could compensate by increasing its gain. Conversely, it could decrease its gain if its control efforts

became too aggressive after the load was lightened. Either way, the controller has to be able to measure its performance to determine which course to take, if any. It could weigh the load directly, time how long it takes to move the load from point A to point B, or measure how far the arm overshoots along the way. Unfortunately, adaptive controllers are generally slow about detecting changes in the behaviour of the controlled process since long-term changes easily can be masked by, or confused, with short-term disturbances. A long history of control efforts and process variable measurements is generally required to distinguish between short-term and long-term effects. Even when a bonafide change in the behavior of a process is finally detected, it is not always obvious how the control algorithm should be altered to compensate.

Other objectives Despite these challenges, adaptive motion controllers also can optimise the trajectory that the controlled process

follows to reach its destination. This is especially useful in applications where overshoot is undesirable, as explained in the previous robot control example. Once the controller has learned how the robot responds to control efforts, it can compute the final command required to move the arm to the desired position, as well as the sequence of commands required to get it there without having to reverse course. The mathematics required to accomplish this artificial learning can be extremely complicated, and no single algorithm has emerged as the superior choice. However, some variation of online modeling usually is employed where the controller calculates a mathematical equation that relates recent changes in the process variable to the control efforts that caused them. Once the process model is in hand, the controller then can adjust its control algorithm to produce the desired closedloop behavior under the assumption that the recent behaviour embodied in the mathematical model will adequately predict future process behaviour as well. Vance VanDoren, PhD, PE is a Control Engineering contributing content specialist. This article originally appeared in www.controleng.com

‘An adaptive motion controller can maintain tighter control over a process that experiences variable sensitivity like a robot with variable load weights’. Control Engineering Europe

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May 2017

MAINTENANCE

Achieve proper motor alignment by detecting and correcting soft foot A soft foot exists when not all of a machine’s feet sit flat on the supporting base, so that tightening the foot bolts distorts the machine case. This can make a machine difficult to align and result in poor overall machine performance. Eugene Vogel explains.

roper alignment of directcoupled machinery is an essential element for the reliability of a new or repaired machine (motor, pump, gear case, etc). One common impediment to achieving proper alignment and smooth operation is a ‘soft foot’ condition. A soft foot exists when not all of a machine’s feet sit flat on the supporting base, so that tightening the foot bolts distorts the machine case. A common occurrence with four-footed electric motors, this condition may result if machine feet aren’t coplanar,

individual feet are bent, angled or corroded (see Figure 1), or the baseplate is not flat. A soft foot can a make a machine difficult to align, and a distorted case can increase bearing load and create internal misalignment of the machine’s rotating and stationary elements, resulting in poor performance and increased vibration. Proper shimming can usually correct non-coplanar feet, and to some extent feet that are bent or angled. Feet with significant corrosion damage must be re-machined to avoid the consequences of a soft foot condition.

Detecting soft foot There are several methods for detecting a soft foot condition and suitable tests should be performed during every machine installation. Some of these tests employ shaft alignment tools, making it convenient to incorporate them into the shaft alignment procedure. Probably the best test for soft foot, though, is to insert feeler gauges between each foot and the base foot pad before tightening the feet. This can be done without setting up shaft alignment instruments or indicators and is recommended whenever a machine case is set in place. When using shaft alignment

Figure 1: Common soft foot results of dial indicator test. (all images courtesy EASA)

May 2017

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Control Engineering Europe

MAINTENANCE instrument or dial indicator setups to detect soft foot, the usual approach is to first tighten all feet bolts and then loosen only one of them while observing the movement on the shaft alignment indicators. The bolt is then re-tightened and each remaining foot is tested in the same way. Dial indicators and some laser systems are indicated in a single plane (vertical or horizontal), so the vertical plane is the preferred plane to monitor for soft foot. Laser systems that indicate in both planes simultaneously are slightly better at detecting movement when the foot bolt is loosened. Some alignment technicians prefer not to re-tighten the bolt, but instead successively loosen each bolt and observe the total indicated movement. They may then reverse the procedure, successively tightening each bolt while observing the indicated movement until all are secured. This extended procedure gives a good indication of how a soft foot condition might affect the alignment process.

Correcting soft foot While the procedure of using shaftmounted alignment indicators may detect the presence of a soft foot with reasonable accuracy, it should not be used when attempting to correct the condition. Rather, manual testing with a dial test indicator mounted at each foot provides a much more effective and efficient means of correcting soft foot. (see Figure 2) With all four bolts tightened, the dial test indicator is mounted to the foundation and set to indicate upward movement of the foot as one foot bolt is loosened. An upward movement of more than 0.05mm indicates a soft foot condition that should be corrected. The foot bolt is then retightened, and the test is repeated for each remaining foot bolt. The most common soft foot conditions are two diagonal soft feet or a single soft foot. These usually indicate two different types of soft foot. Diagonal soft feet tend to indicate a short foot, Control Engineering Europe

Figure 2: A dial indicator setup for a soft foot test.

Manual testing with a dial test indicator mounted at each foot provides a much more effective and efficient means of correcting soft foot. that is, feet are flat but not coplanar. A single soft foot often results from a bent or angled foot. Correcting a short foot is straightforward; correcting a bent or angled foot is more complex. To correct a short foot (diagonal feet are soft), tighten only the two diagonal feet that were not soft, leaving the soft feet bolts loose. Remove all shims from those two feet. Use feeler gauges between the soft feet and the base foot pad to determine the number of shims required for each of the two soft feet. Place the required shims and retest for soft foot. When testing indicates a single soft foot, the foot is likely bent or angled. Loosen only that foot bolt and remove all shims. Use feeler gauges to determine the amount of shims required to correct the soft foot, carefully profiling the gap by measuring in from each side as well as from the front and back of the foot to the bolt hole. When correcting a soft foot that results from a non-coplanar foot or feet, each shim should cover at least 80% of the foot’s area. Best practice is to place no more than five shims between a machine case foot and the base plate or foundation (excluding those used to

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correct angled foot conditions). In addition, no more than one shim should be less than 0.0762. thick, and the sum of the three thinnest shims should be 0.254mm or greater. It’s also important to accurately measure the thickness of any shims that are more than 0.508mm thick, and to verify the thickness of the entire shim stack. For a bent or angled foot, step or stagger a maximum of five shims in a single direction to match the angle of the gap variation. For best results, do not use shims to correct a total gap variation greater than 0.381mm. Bent or angled feet with a larger gap variation should be straightened or re-machined to correct the condition. Proper attention to detecting and correcting soft foot conditions on new or repaired machine installations will save time in achieving proper shaft alignment, prevent frame or casing distortion that reduces machine reliability and efficiency, and avoid increased vibration levels. Eugene Vogel is a pump and vibration specialist at the Electrical Apparatus Service Association (EASA). This article originally appeared in www.controleng.com May 2017

MACHINE VISION

Proof of concept and testing for

INTEGRATED VISION APPLICATIONS A control system integrator and automation vendor have jointly developed a vision lab to offer machine vision testing, advice, proof-of-concept work and validation services.

fter integrating a large volume of complex, machine vision projects, control system integrator MartinCSI partnered with Omron to create a lab offering machine vision proof-of-concept, testing, and validation services. Visionguided capabilities extend far beyond identifying defective parts. Complex applications can easily be solved with the right mix of cameras, lighting and optics, lenses and filters, and userfriendly application development environments. Identify and fix inconsistencies By collecting data from vision inspection, companies are able to identify and fix inconsistencies early in the production process. Vision inspection is used in virtually all manufacturing industries to boost product integrity, increase production efficiency, meet regulatory compliance, and protect a brand’s reputation. MartinCSI provides industrial and control data collection systems in North America, engineered for customers’ application needs. Other capabilities include motion, robotics, safety, and designing and building vision systems for challenging applications and environments. Company industrial control system design and system integration projects include those in the automotive, utilities, food and beverage, pharmaceuticals, glass and plastic, chemicals, and more.

client with a proof of concept (PoC) in the quoting process to determine the proper lighting, cameras, lenses, and controller, which provides a more defined quote because vision equipment can vary significantly in cost. 2. When installing a vision system for quality control, gather a complete collection of samples that range in sizes and different defects. With those samples, the integrator’s vision system can more accurately detect the defects. 3. Install the vision system in an enclosure to help control lighting and part presentation, which will make the system more reliable. The enclosure helps eliminate changes in ambient light.

Machine vision applications The complexity and volume of projects that required integrated vision led to the addition of Omron vision equipment

to complement lab-based technologies. The engineering lab helps customers see and understand application capabilities of machine vision, identification, and sensing technologies. The vision lab has allowed customers to view pass/fail tests, barcode matching, data collection, part presence, and absence as well as inspection and measurements. A step-bystep process is used to resolve complex machine vision applications. The vision lab, which opened in May 2015, includes smart cameras, highspeed vision systems, lenses, lighting, mounting options, and vision algorithms to help fit the technologies to various applications. Companies making use of the lab include manufacturers and distributors who conduct PoCs as needed. MartinCSI engineers also can help with quoting projects and providing PoCs, including with other vendors’ vision systems. MartinCSI is a US-based system integrator. Jim Sellitto, is principal and vice president of business development, and Laura Mann is marketing coordinator at MartinCSI, a US-based system integrator. Laura Studwell is Omron’s industry marketing manager.

Fixturing and lighting help with machine vision setup and software configuration. Courtesy: MartinCSI

Help with machine vision From a system integrator’s perspective: 1. There is a benefit to providing a

May 2017

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PRODUCT FORUM •

INTELLIGENT AUTOMATION SYSTEMS INAUGURATES NEW OPERATIONS IN THE UNITED KINGDOM Intelligent Automation Systems is a corporation of complementary business services that provide application engineering and design, supply, implement, test and repair industrial automation systems. This includes HMIs, motion controllers, brushless and brushed servo systems, linear systems, 2/3/5 phase stepping systems, AC induction systems, and spur and planetary gearboxes. “Intelligent Automation Systems has maintained operations within the UK since 2007. To offer seamless, comprehensive, customised solutions to our customers in diverse industries across the UK, we recently merged our activities. Our Hyde Park facility offers cutting-edge industrial automation from global manufacturers like Trio Motion, Sanyo Denki, Fastech, Kinco Automation, RTA and SPG,” says Ajay Karavadra, Technical Director. “What gives Intelligent Automation Systems a distinct advantage is our team of engineers who draw on more than three

decades of cross-product technical know-how to provide exceptional solutions that are truly out-ofthe-box, delivered within on-time schedules, and do not exceed customer budgets.” The new operations will continue to design, source, build and implement advanced solutions ranging from one-off requirements to highperformance industrial automation systems for custom-built machines of OEMs. “Using cutting-edge technologies and high-performance products, Intelligent Automation Systems is the single-source go-to partner,” Ajay Karavadra adds. “Every solution is backed by local training and aftersales technical support. What’s more, Intelligent Automation Systems can quickly ramp up material deliveries or even ensure just-in-time lean inventory from its extensive warehouse.” Tel: +44 20 8432 2749 E-Mail: sales@intelligent-automate.com www.intelligent-automate.com