Cee 17 10

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

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Drives smarten themselves up for Industry 4.0 Making the most of ALL of your data

Advice on improving your SCADA system defences

Building in IIoT at the design stage

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CONTENTS

All roads lead to Industry 4.0…

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

I can’t write an article these days without the ‘Industry 4.0’ word appearing, and this issue offers many examples of this!

We start the issue with a comment about communication technology developments, which are providing the foundations for Industry 4.0 (pg 4). The drives and motors feature also focusses on the Industry 4.0 effect – and the role that ever-more intelligent drives will play in aiding its adoption (pg 10). We also look at the importance of building communication capabilities into equipment at the design stage, to ensure that devices, equipment and plants are prepared to become part of the smart factory of the future (pg 14)

2017, where I am sure there will be much more information about Industry 4.0 available too! The November issue will include a preview of the event, so watch this space. In the meantime I hope that you enjoy this issue.

Suzanne Gill Editor – Control Engineering Europe Suzanne.gill@imlgroup.co.uk

Our next big event will be SPS/IPC/Drives

INDUSTRY REPORT

INDUSTRIAL CONTROLLERS

4

26 Will there be room for both CNC and PLCs in the factory of the future?

Looking at the impact of Industry 4.0 and the IIoT on industrial communications.

EDITOR’S CHOICE

INDUSTRIAL COMMUNICATION

6

28 Time-sensitive networking (TSN): Benefits for the IIoT and manufacturing.

Universal platform for industrial and process automation tasks; DCS measures operational profitability in real-time.

30 Putting wireless sensor networks to work.

DRIVES & MOTORS

FINAL WORD

10 Examining the role of drive systems in optimising machine configuration and performance and aiding the adoption of Industry 4.0.

33 Charles Corner Corner, managing director at Malton Laser, discusses the emergence of a technology that could revolutionise industrial work spaces and processes.

12 Motor efficiency; aiming high.

34 The rising demand for personalised manufactured goods requires a shop floor agile enough to meet fast-changing production line requirements, says Rob Stoppek, vice president Automation Group EMEA at Parker Automation.

IIoT & BIG DATA 14 Building in IIoT at the design stage is vital to be prepared for the future.

16 Using all your operational data to manage energy consumption more efficiently.

SCADA & HMIs 20 Advice on improving your SCADA system defences.

14 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

Control Engineering Europe

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.

October 2017

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INDUSTRY REPORTS

The impact of IIoT on industrial communications Industry 4.0/IIoT and the new communication technologies coming to market are providing the foundations for the next industrial revolution, says Susanne Cumberland.

T

he networking of devices, machines, and humans on the factory floor has been at the forefront of industrial automation for many years.

Connectivity is not new; and mobile devices, PCs, tablets, and other similar devices have allowed for the collection of large amounts of data for some time.

This idea of large-scale connectivity has now also moved into the world of industrial automation, through the adoption of IIoT/Industry 4.0 concepts.

Intelligent devices and machines create a large amount of data that can provide much new detail about processing and management on the factory floor. With such large quantities of data, there is an increasing need for analytics to create the insights that can improve productivity, efficiency, and ultimately profitability. The use of embedded sensors has begun to influence ‘basic’ components used in

industrial automation.

An example is valves, where sensors detect the status of the valve through the monitoring of selected parameters, such as vibration. By networking smart valves, data can be extracted and analysed to provide valuable information for various aspects of a business; such as predictive maintenance.

Wireless acoustic transmitters have been used with steam traps for monitoring, for example. A failure can result in highpressure steam leaks or an accumulation of water that moves through the pipes and equipment. The latter can rupture steam lines and cause turbine problems, resulting in expensive repairs and significant downtime.

IIoT is helping companies to shift from preventive to predictive maintenance.

Predictive maintenance is the direct monitoring of a machine to relay information on its status, and predict a potential failure. Its application can

help a company reduce unplanned downtime, reduce equipment repair costs, and reduce labour through more efficient use of maintenance teams.

Connectivity IIoT cannot happen without connectivity, and this increasing demand for the networking of devices has boosted the shift from fieldbus to Ethernet networking.

However, the cost and inconvenience of a ‘rip and replace’ of the network has limited Ethernet growth, some factories are having parallel installations deployed so their production lines can evolve. However, some industries, like automotive, are moving more quickly to Ethernet. The growing demand for electric cars is having an impact on Ethernet networking. Electric cars have different production requirements to a combustion-engine car meaning a factory rebuild is a must and this is an opportunity to use Ethernet networking instead of fieldbus.

OPC UA and TSN Within IIoT, awareness of OPC UA is expected to increase and will grow significantly over the next few years. OPC UA provides an open and dependable mechanism, with the additional benefit of improved security in transmitting data outside of the factory. It is often seen as a complementary technology in industrial automation because of its interoperability. It can be an additional layer that allows vendors to provide machine-to-machine communication without having to create their own, as it will work over Ethernet. Some automation vendors are already

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October 2017

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Control Engineering Europe

INDUSTRY REPORTS introducing it into their higher end PLCs and IPCs – with a number of other vendors also indicating planned releases for 2018.

The implementation of OPC UA is predicted to extend to more basic control products as well as other technologies such as servo drives and variable speed drives. The OPC Foundation has had several developments in 2017 that will include OPC UA.Net standard stack, memorandums of understanding in robotics, and publication of an international standard MCS DCS interface in the oil and gas industry; as well as the release of the OPC UA Pub/Sub definition, due out late 2017. These developments expand the product portfolio that OPC UA will serve.

Another important development is TSN. Time-Sensitive Networking (TSN) enables deterministic real-time communication.

TSN reduces deterministic transfer times and time synchronisation between nodes, allowing fast response times.

This ability to transfer and share timesensitive data is an important aspect for some industrial automation sectors, such as robotics, where a delay in data can cause production problems. TSN-enabled products are planned to be introduced for industrial automation in late 2017/ early 2018. This enablement requires the addition of a dedicated chip on the device. This hardware change (as opposed to merely a software update as is possible for OPC UA enablement) means the rate of release of enabled products will be protracted and TSN is not forecast to be a broadly installed technology in automation within the next five years.

Any form of plug-and-play solutions, which is possible for Industrial PCs and some PLCs, will increase the adoption of TSN; without such a solution, a retrofit is required, an expensive alternative that would hinder its adoption.

Conclusion To remain competitive in industrial automation, vendors need to provide more than functionality; Industry 4.0/ IIoT is a concept that makes use of connectivity and data collection to Control Engineering Europe

SCADA technology looks set to see growth A SCADA market report, published by Allied Market Research, has forecast that the global market will reach $40,240 million by 2022 at a CAGR of 5.1% from 2016 to 2022. The factors driving SCADA growth include a rising demand for safety, reducing transmission losses, and integration with corporate IT by deploying SCADA data to cloud. While there are no emerging technologies which will be able to replace SCADA systems in the coming years, factors that are hindering its market growth include increasing concerns about cyberattacks, management issues with the data generated, and a lack of awareness of IT trends.

Numerous industry players are

offer improved efficiency, productivity, and profitability. One example of how data collection can benefit industrial automation is predictive maintenance on valves for steam traps, which can increase efficiency, reduce repair costs, and reduce downtime.

The increasing demand for connectivity and intelligent devices is speeding industry’s move from fieldbus to Ethernet networking and driving high growth rates for OPC UA. The

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launching new SCADA solutions.

Siemens, for example, exhibited digitisation and engineering efficiency at the Husum Wind exhibition in Germany, where the main area of focus for digitisation was on the Simatic WinCC Open Architecture SCADA System.

In August, Simco Wireless Solutions entered into a partnership with RACOM to grow its SCADA and telemetry business. In June, Thuraya Telecommunications Company launched the Thuraya IP M2M Service to support high volume and throughput machine-to-machine (M2M) applications. In April, Schneider Electric introduced ClearSCADA 2017 with location services and integrated mapping functionalities.

growth of OPC UA has been boosted by the fact that it is open, interoperable, and has improved security. Additionally, it is a software change that is easy to implement, unlike TSN which requires a dedicated chip on the device, meaning that unless there is a plug-and-play solution available, retrofitting is required.

Susanne Cumberland is research analyst, Discrete Machine-Safety at IHS Markit Technology.

October 2017

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EDITOR’S CHOICE

Cable glands for hazardous areas Pepperl+Fuchs has introduced a range of cable glands and accessories designed for use in hazardous areas. Made from polyamide they feature full impact resistance of 7 Joules which eliminates the need for additional mechanical protection that would be in the way during installation.

All parts of the glands for armored cables are captive and kept in the right order. Assembly during installation or disassembly during routine inspections can be done in less time. Many typical faults are eliminated, where safety of human and plant hinges on precise workmanship to ensure ingress and explosion protection.

Cable glands can be ordered from stock in single quantities including all seals and accessories. Boxes with large quantities offer added convenience for machine and equipment manufacturers or panel builders.

Universal platform for both industrial and process automation tasks PC-based control from Beckhoff is now able to provide a universal platform that covers both industrial automation and process automation, through the integration of process-specific

A cool way to detect hot objects Balluff has developed a new BTS infrared temperature sensor featuring an IO-Link interface and two switching outputs.

The sensor is able to monitor temperatures of between 250°C and 1250°C even in inaccessible or hazardous areas. It can also detect hot objects in motion and record temperature values – all without contact.

The pyrometer in the rugged M30 stainless steel housing with IP67 protection is the first in this form factor to offer a multi-function display with plain text information and automatic display orientation, while the IO-Link interface enables parameterisation of the sensor remotely by the host controller or from the control panel.

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October 2017

protocols and interfaces, and by offering an extended range of products for hazardous areas.

For example, full implementation of HART communication functionality has been integrated into its I/O system and into the TwinCAT engineering environment.

TwinCAT automation software can now help reduce development efforts in process technology because it facilitates the application of HART functions directly from the engineering interface. In this way, the TwinCAT FDT (Field Device Tool) container enables implementation of any field device drivers (Device Type Manager, DTM). An entire HART configuration can be implemented using a single tool.

The Beckhoff CommDTM integrates the TwinCAT platform into existing process control systems. With its help, the DTMs can be implemented in any FDT container. This applies to all field devices connected to the HART-capable

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DCS enables profitability to be measured in real time Schneider Electric has improved the capabilities of its EcoStruxure Foxboro distributed control system (DCS).

EcoStruxure is an IoT-enabled, open and interoperable system architecture and platform. Delivering edge control; apps, analytics and services, it enables scalable design and operation of connected systems with cybersecurity built in to every layer.

Historically, DCSs have been limited to controlling the efficiency and safety of the process, without being able to measure and control other critical operating variables – especially profitability – in real time.

With customisable real-time accounting (RTA) models built in, the DCS enables engineers to evaluate the real-time financial performance of an industrial operation directly at the equipment asset level. It also empowers them to more easily identify the impact their actions and decisions have on the profitability of the operations they control. The RTA models can be manipulated and adapted to suit a variety of industrial operations across multiple segments, enabling a wide range of customers to reap far more value from their existing systems.

EtherCAT Terminals. These devices can be configured and parameterised remotely without requiring direct PLC access. In addition, the Beckhoff OPC UA Server and Client enable secure global distribution of process data, as well as convenient system control and remote maintenance capabilities.

The new EtherCAT Terminals in the ELX series are also HART-capable. With intrinsically safe inputs/outputs, they enable the direct integration of field devices installed in hazardous areas, Zones 0, 1 or 2, into the automation system.

Control Engineering Europe

More Integrated.

More Synergies.

Less Work.

LEAP™ for Operations Increases Operational Productivity and Throughput.

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Connected Industrial Connected Plant

www.honeywellprocess.com/LEAPforOperations Š 2017 Honeywell International Inc.

2016 MOBILITY, ETHERNET & WIRELESS STUDY

Using and integrating Ethernet technologies Respondents to the Control Engineering 2016 Mobility, Ethernet, & Wireless study identified five key findings about integration, use, and spending for Ethernet technologies and how they help users of automation, controls, and instrumentation increase productivity: 1. Technologies: More than half of respondents use, buy, or specify Ethernet switches (62%), wire or cable (61%), networks (53%), or routers (52%).

2. Usage: The majority of end users interface with industrial Ethernet technologies at work (on the plant floor/operations); 36% have these technologies reaching into enterprise, and 33% use them at customer locations.

3. Integration: Three-quarters of respondents reported their controls, automation, and instrumentation are somewhat/highly integrated with Ethernet technologies. Over the past 12 months, integrating Ethernet devices has been somewhat challenging for 62% of companies, but they worked out the issues on their own, unlike the 11% who needed to call in a third-party.

4. Security: Rules mandated by IT departments are followed at 54% of companies when implementing security for Ethernet devices; 20% use local department rules, and 8% rely on employees to make security decisions on their own.

5. Expenditures: Fifty-three percent of respondents expect spending for Ethernet products and services to increase over the next year; 38% expect it to remain the same as last year. The majority of the budget allocated to Ethernet technologies is spent on products and software rather than services.

View more information at www.controleng. com/2016MobilityEthernetWireless.

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

Industrial Ethernet technology benefits 53%

Data access

35%

Ease of use

32%

Productivity increases

29%

Cost savings Less downtime

20%

More effective maintenance

20%

Better asset management Time savings (speed)

17% 16%

More than half of survey respondents agree that the use of industrial Ethernet technologies provides better data access. Source: Control Engineering

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Average annual salary Less than $50,000

5%

$50,000 to $69,999

$100,000 or more

15% 41% 25% 14% $90,000 to $99,999

$70,000 to $89,999

The average automation professional earned $96,000 in 2016. Source: Control Engineering 2017 Career & Salary Survey

½

of end users report their HMI hardware to contain at least one Ethernet port (10/100/1000 Base-T).

Source: Control Engineering 2017 HMI Software & Hardware Study

36%

of end users prefer to purchase motors and related variable speed drives, and ac/dc controller products as separate units.

Source: Control Engineering 2017 Motor & Drives Study

44%

of end users expect IIoT and/or Industrie 4.0 to increase information flow and innovation at their facilities. Source: Control Engineering 2016 Industrial Internet of Things & Industrie 4.0 Study

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

Control Engineering Europe

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DRIVES & MOTORS

Drives smarten themselves up Mike Lomax examines the role of intelligent drive systems in optimising machine configuration and performance and aiding the adoption of Industry 4.0.

M

achine manufacturers are under pressure to provide shorter development times for highly advanced machines, with less manpower available to them. As the drive towards Industry 4.0 adoption gathers pace the requirement for real time data to inform operational decision-making is growing.

The keyword with Industry 4.0 is connectivity – between all participants in the production process, whether human or mechanical – even in facilities where Industry 4.0 adoption may still be some way off in the future, it is important that any components or systems are at least compatible with the requirements of Industry 4.0 – and have the ability to connect to, and communicate with, internal and external networks.

While this is relatively easy to achieve with new components, replacing all systems to ensure compatibility is an unrealistic option and this has led to the development of a variety of devices which enable standard components

to offer at least basic connectivity to Industry 4.0 systems, without impacting on the automation logic.

Enhanced functionality is a particular requirement with drives. Modern drive systems now have sufficient intelligence to perform position movements and velocity control. These functions are now regarded in the same way as accessing email via a mobile phone – almost a minimum expectation. A further expectation with Industry 4.0 is that drive systems are able to acquire data on machine functionality and performance, to then configure and present this data externally.

Thanks to advances in drives, manufacturers can now allocate functions directly to the drive, via inbuilt technologies that eradicate the need for an external PLC. The latest servo drives, for example, now include the IEC61131-3 PLC operating system which represents a step change from the minimal functionality offered by previous generations of drives.

The implications of this new capability can take time to fully understand, but essentially the drive now has the ability to solve control challenges in real time, whenever and wherever they may occur – a key facet of Industry 4.0. Furthermore, removing the PLC and going direct to the drive eradicates any time lapse, and so optimises cycle time and Modern drives can enable more proactive maintenance regimes as they can be production supplied with integrated software tools capable of performing key predictive maintenance functions, with minimal additional programming effort. consistency.

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Staying in sync However, even if a drive system does contain the appropriate problem-solving tools or function blocks, the challenge of synchronising multiple movements on the machine remains. Where the bus system in use is not deterministic, the solution is for the drives to communicate between themselves, without having to refer back to a central control system.

This is where technologies such as SERCOSIII – one of the first deterministic bus systems, which can now be installed directly into the drive – come into their own. However, a deterministic system is not necessarily a prerequisite for Industry 4.0 adoption as drives can store real time data and send it in a non-deterministic way to upward systems.

With such a range of function tools available within the drive, it is important that selecting the right tool for the job is as straightforward as possible.

The goal should be that a machine builder programmer, with no previous experience of the particular challenge in front of him, is able to easily access and use these functions.

The solution lies in the use of tried and tested PLC function blocks which can be used freely in IEC 61131-3 PLCs and can even be incorporated within conventional ladder logic programming.

A variety of function blocks are now available and can be selected depending on the individual application requirements. Their capabilities range from correcting the positions of products on conveyor belts, and the control of winders, to closed loop register control and even the creation of a complete motion profile for cross-cutters and cross sealers.

Creating a machine HMI Creating an interface between the machine and operator – another Control Engineering Europe

DRIVES & MOTORS vital component of Industry 4.0 – has previously required central PLC involvement along with a bus system, to convey key machine set-up information and variables to the drives. Diagnostics and machine status information is then redirected to the PLC before being displayed on the HMI. Although modern bus systems can achieve this, it can require a great deal of programming effort when all the required information is already contained within the drive system. To address this, many drive systems now also contain all of the tools needed to create a HMI. In some instances, a central PLC may not even be required as the drives are capable of using a full range of inputs and outputs which would normally be connected to the PLC. A key factor which must be kept under control is the time taken to set up and commission the machine. Intelligent drives now offer a number of tools that can reduce start-up time through the

optimisation of the axis movements and process synchronisation.

These rapid start-up tools have been designed to enable the drives to be moved at an early stage of the machine commissioning, even before the machine control software is installed on the system. This results in rapid and easy testing of machine mechanics with only basic IT tools, such as mobile phones or tablets, required to gather information.

Help with maintenance?

Modern drives can now even play a part in a proactive maintenance regime as they can be supplied with a fully integrated series of software tools capable of performing key predictive maintenance functions, with minimal additional programming effort. This software can be set up to continuously monitor, in real time, the condition of the machine mechanics and process conditions – from waveform analysis through to analysing the

rate of temperature change, as well as checking for backlash, increased friction or process overload. If a fault condition arises, a code is generated and passed to the machine HMI. Furthermore, if a critical issue is identified which requires the machine to cease operating immediately, this decision can be made inside the drive, minimising lost production and the risk of machine damage resulting from unsafe operation.

Whether or not Industry 4.0 is the immediate goal, what is undeniable is the enhanced processing power and functionality of intelligent drives which present numerous opportunities to optimise programming, production and maintenance. With the need for central PLC’s now eliminated in many instances, not only is component count reduced but more advanced machines can now be created in much shorter timeframes.

Mike Lomax, electrification manager at Bosch Rexroth

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DRIVES & MOTORS

MOTOR EFFICIENCY:

AIMING HIGH Brian Bannister argues that it is better for OEMs to build in compliance to electric motor energy efficiency requirements now, avoiding the need for future product redesigns, and providing customers with immediate energy saving benefits.

N

ew European statutory efficiency requirements for electric motors, which came into force on 1 January this year, demand that all AC industrial electric motors – from 0.75kW up to 375kW – operate within the EU Directive’s specified parameters.

The most common solutions offered to achieve these levels of efficiency are based upon either an IE2 motor with a variable speed drive (VSD) package or a stand-alone, direct on-line IE3 motor. So, compliance should be your first goal. How you achieve it, however, can be dictated by numerous factors. For applications where equipment is driven by motors with powers lower than 0.75kW or above 375kW, there are currently no guidelines or specific requirements.

IE1 efficiency motors can still be used in the EU if they are currently held in stock by equipment/machine manufacturers.

However, motor manufacturers cannot

continue producing them for customers within the EU, but can still supply regions outside Europe and countries where the same levels of efficiency are not demanded.

IE4 and IE5 motors High performance permanent magnet IE4 and IE5 motors might be considered by some as ‘over the top’ solutions, but they do offer immediate and future benefits for both OEMs and end users.

An obvious benefit is compliance for the foreseeable future. Consequently, design engineers can develop equipment with confidence, knowing which motors they can incorporate in their designs to achieve specific performance characteristics, while not having to dramatically change machines from a weight and size point of view.

Some IE4 and IE5 motors offer up 50% savings in weight and can offer size reductions of up to two frame sizes.

When making decisions about

Some IE4 and IE5 motors can offer up 50% savings in weight and can offer size reductions of up to two frame sizes.

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compliance – in addition to meeting the required efficiency standard – the issue of payback on investment should be considered. It is estimated that an IE3 motor carries around a 20% premium over an IE2 alternative, but energy savings due to the higher efficiency make it possible to achieve payback in less than two years.

In the future, IE4 and then IE5 motors will start to become obligatory. So it is worth adopting the higher efficiency motors today to start to reap the benefits of greater savings on energy now. Certainly, this might be the case if VSDs are already being used because both IE4 and IE5 permanent magnet motors require them.

Policing While compliance is obligatory, essentially it is down to the OEMs and their customers to police this.

According to DEFRA’s Environmental Reporting Guidelines June 2013: ‘The Companies Act 2006 (Strategic Report and Directors’ Reports) Regulations 2013 requires quoted companies to report on greenhouse gas (GHG) emissions for which they are responsible. Quoted companies, as defined by the Companies Act 2006, are responsible to report on environmental matters to the extent it is necessary for an understanding of the company’s business within the Annual Report, including where appropriate the use of key performance indicators (KPIs).

If the Annual report does not contain this information, then it must point out the omissions.’

Control Engineering Europe

DRIVES & MOTORS Some public bodies are required to, or should consider, reporting GHG emissions. To fulfil these reporting requirements, companies need to monitor and control both their own emissions and those of their suppliers.

This will help them measure the impact of the suppliers’ operations upon their own emissions and include them in their calculations. Smaller companies are, therefore, also being encouraged to achieve similar GHG emission reduction goals.

It would appear that purchasers of electric motors must determine whether motors supplied comply with the appropriate standards as part of the monitoring process to achieve and maintain compliance.

It is still permissible to use and supply >0.75kW IE2 motors provided they are used with a variable speed drive, if they were placed on the market prior to 1st January 2017; or if they comply with one of the many other rules currently

New VSDs for high-power applications WEG has expanded its CFW500 series of variable speed drives (VSDs) to enable users in high-power applications to achieve further energy efficiencies. The new E frame size, for the rated power range of between 18.5 kW and 22 kW, is suited to use in applications such as mechanical engineering systems for conveying, turning, hoisting, pumping and ventilation.

The new VSDs feature an integrated micro PLC with pre-programmed macros for positioning, timing and acceleration functions. It can be programmed locally, via an LCD display, or externally with a computer over a variety of interfaces, including CRS232, USB and CRS485. Users also can download the corresponding SuperDrive G2 programming software from the WEG website free of charge.

The VSDs are designed for fast installation and easy operation. Numerous plugand-play modules are suited to distributed automation architectures and can be connected to all common fieldbuses.

in force (there are exclusions applicable to brake motors, integrated motors and motors specified for intermittent duty).

But how this might reflect on you and your products is also worth considering.

It may briefly be cost beneficial to stick with older technology but it will impact on the end users on-going efficiencies

and GHG emissions.

Surely, it would be better to build in compliance with future known requirements today in order to avoid later product redesigns and associated price increases?

Brian Bannister is a motor specialist at Lafert Electric Motors

SCADA I DATA HISTORIAN I COMMUNICATION PLATFORM

CYBERSECURITY & MOBILITY Optimize your performance SCADA / BMS-FM Smart Building Security Data Integrity Industry 4.0 Mobile App

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IIOT & BIG DATA

BUILDING IN IIoT

AT THE DESIGN STAGE The IIoT, networking and big data are already reshaping the manufacturing world although the full benefits are still largely unrealised. Dave Randall says that machine builders and end users need to think about the future now by making sure these technologies are built into machines and components from the design stage, to ensure the best results.

G

iving manufacturers the ability to harness the power of big data to maximise operations was highlighted

by VDC Research as the single biggest Industrial Internet of Things (IIoT) trend to watch out for in 2017. Meanwhile, another recent survey found that more than 80% of executives believe that adopting IoT technologies is critical for success in the future.

However, a staggering two-thirds of automation firms have admitted that their customers are not currently realising the full benefits of data gathering, networking and connectivity.

As a result, many are missing out on the opportunity to drive up efficiencies, cut costs and downtime, and improve

business performance.

Given the shift in culture that operating in today’s data-driven world demands, it is not surprising that further change is still needed. Traditionally, price has been the main driver for most machine builders.

However, with data becoming increasingly important as the manufacturing sector moves forward, it is vital that machine builders start to consider how this fits in with their technologies and the capabilities they offer.

Transferring operations Enabling machine operators to access overall equipment effectiveness (OEE) data at the plant level has the power to positively transform an operation. At its most basic level, drives are connected to a cloud-based system and information is transmitted, allowing users to identify how a device is performing, whether it

The gathering of intelligence from devices such as drives makes it possible for engineers to enjoy a much higher level of control than has been possible in the past.

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stops at any point and why, and how much energy it is using, for example.

Beyond this, the gathering of intelligence makes it possible for data analysts and engineers to enjoy a level of control like never before. In particular, users can determine where significant efficiency gains can be achieved by optimising the way in which machines run to reduce energy consumption. It is also possible to cut operating costs, improve productivity through enhanced machine availability and extend service life by determining exactly when and how a device needs to be used.

Predictive maintenance Data is also being used to implement planned and predictive maintenance programmes for machines within a plant. By monitoring performance it is possible to identify fluctuations and patterns in operating statistics, such as how many amps a motor is pulling, to foresee if a part is wearing and possibly close to failure. This allows engineers to make an informed decision about when to change it before it stops and enables them to carry out the necessary work during scheduled maintenance slots.

This proactive and strategic approach to servicing ensures that productivity is never lost and it has the potential to save vast sums of money by comparison with reactive maintenance.

Essentially, advanced communication and analytics technologies are facilitating diagnostics and smart decision-making based on real-time Control Engineering Europe

IIOT & BIG DATA analysis and this is imperative if end users are to remain successful in an increasingly competitive marketplace.

Equally, as more customers demand this level of sophistication, it is important for machine builders to get on board and offer data sharing capabilities as part of their products, making the most of the business opportunities that come with providing these innovative solutions.

Data gathering and connectivity Currently, manufacturers frequently have to retrofit technology that harnesses the power of the IIoT into their machines, particularly where drives are concerned. While the bolting on of networking capabilities creates a perfectly workable solution, this approach does have its complexities and drawbacks. For example, it is crucial that the tools which create the cloud connectivity are the same shape and size as the previous device being

replaced and they offer a good volume to kW ratio.

Retrofitting can also lead to avoidable yet potentially high costs because it will involve replacing a drive that has already been purchased with one that enables data communication. Not building this in from the outset can make a machine marginally cheaper to produce than one that is connected. However, it eventually ends up being a false economy with more money being spent further down the line. Perhaps more worrying is the fact that the machine will have to be a taken offline to install the new components and this will result in stoppage time that can be detrimental in terms of lost productivity.

It is, therefore, better to incorporate data capture and sharing capabilities at the machine-building stage for maximum effectiveness by selecting the right automation technologies. Sophisticated drives are available that gather data, and link seamlessly and securely to the

cloud to deliver accurate performance information, including power usage and running times.

Intelligent devices, such as those in the i500 inverter series from Lenze, measure the data directly from the motor and communicate this to a remote network through a range of interfaces, including Ethernet/IP, PROFIBUS and PROFINET, for outstanding machine control and diagnostics.

As manufacturers begin to ask more of their machine builders and systems integrators, only those with the foresight to build in capabilities for performance monitoring and data sharing at the design stage will be able to offer the connected solutions that deliver the most effective use throughout their lifetime in the factory of the future.

There is one simple choice – either lead and exploit IIoT technologies, or risk getting left behind.

Dave Randall is business development manager at Lenze.

IIOT & BIG DATA

MAKING THE BEST OF ALL YOUR DATA David Wilkinson explains how manufacturers can use operational data in to manage energy consumption more effectively.

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nergy consumption is a serious issue for all manufacturers today. Current legislation, aimed at reducing energy consumption and carbon dioxide emissions in the UK by 2050, have resulted in pressure being put on industry to be accountable for energy consumption and organisations are obliged to share their energy usage data with third-party companies in order to prove compliance.

Those that fail to do so can face significant penalties.

The majority of organisations recognise that, instead of just storing data, they should be analysing it to reveal hidden insights to allow for improved decision making and enabling the prediction and prevention of disruptive incidents and unexpected process downtimes.

So, what can organisations do to ensure data is being analysed in the most effective manner? It is important to make full use of operational data and an Industrial Information Management (IIM) solution can help achieve this goal.

It is estimated that more than two quintillion bytes of data are currently being generated worldwide every day

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as a result of the levels of connectivity which have been made possible by the Industrial Internet of Things (IIoT). So, there is plenty of information available to unearth previously hidden insights into areas of industrial environments that might otherwise have been overlooked. Doing this also enables operational improvement decisions to be made with greater confidence.

Access to data An IIM solution can assist by providing access to both real-time and historical data from multiple sources, allowing operational data to be contextualised, transformed into actionable insights and delivered to an operators desktop or mobile device instantly – even across multiple sites – and enabling metrics such as energy usage to be monitored at the touch of a button.

By taking steps to help organisations identify key operational trends – allowing more data to be received from more sources – an IIM solution also enables operators to address issues quickly, pinpointing and troubleshooting problems before they escalate and ensuring they don’t recur by using

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historical information to facilitate continuous improvements. As a result, the IIM solution also makes it easier to fully understand how and where energy is being used, as well as what changes need to be made to improve energy efficiency.

An IIM solution also helps to improve an organisation’s ability to track downtime, as the current state of any device or asset can be viewed at any time which, in turn, enables better predictive maintenance and helps businesses to know what their equipment is going to do before it does it – from a major shutdown to a single security camera that is preparing to go offline.

Because IIMs are cloud-based solutions, utilising one will also help to close the IT/OT gap, reducing the burden on the IT department by allowing data to be stored securely and accessed quickly, easily and remotely, regardless of geographical constraints.

Recently, a construction company, with sites across the globe, wanted to implement a solution to streamline its operating processes. It had struggled to achieve this in the past as it had numerous disparate and unconnected sites and not all of the sites had an onsite SCADA provision. Having implemented an IIM solution, data from every site, regardless of location, is now collected and stored on a cloud-based platform, before the information gleaned from the data is sent back to the relevant sites to be actioned, helping to make sure that the right metrics are in the right hands, wherever in the world this might be.

David Wilkinson is the managed platform product manager at SolutionsPT. Control Engineering Europe

IIOT & BIG DATA

Putting data to work for a more intelligent plant Greater operating reliability, optimal production and supply chain efficiency can be achieved through the use of new tools that can show what is constricting yields, how efficiently energy is consumed, and even when equipment might unexpectedly fail – all with a level of precision that has never before existed.

Plants generate reams of data every day. The issue isn’t getting the data, it’s what to do with it. Instead of recording the data for later analysis, operators expect data to be analysed in real-time to explain what is happening and what will happen next to create a more intelligent plant.

These intelligent plants will collect and analyse data using known operating conditions, proprietary knowledge and best practices, to identify patterns and root causes.

Process Optimization Advisor and Process Reliability Advisor, are two

software-enabled Honeywell UOP Connected Plant services that combine multiple sources of process and root cause analysis models and run them through a digital twin and advanced data analytics software. Data is streamed securely into the cloud in real time and processed against proprietary process models which apply UOP’s knowledge of chemical processes and catalysis, which identify meaningful patterns in the data.

Using this knowledge, plant operators can gain a deeper understanding of what is causing anomalies in production processes. Theycan be directed to fix problems before they become critical, reducing operating costs and limiting downtime.

Process Optimization Advisor identifies optimal operating conditions based on matching process models, and customer economics. These digital

twins form the basis of operational recommendations that outline the optimal operating conditions for the plant. This data is supported by expert analysis and follow-ups to ensure performance is improving as expected.

Process Reliability Advisor focuses more on issue detection. The service uses refined data, fundamental process models and embedded cause-and-effect models to detect and mitigate issues before they impact plant performance.

This information is based on operational experience and deep process and catalyst understanding, so all plants can benefit from Honeywell’s industrial knowledge.

Central to these services is using refined data to report how a facility is running, how it can perform better, and how it can adjust. With this insight, problems can be uncovered and plant operators can make better informed decisions quickly.

Easy. Quick. Smart.

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AUGMENTED REALITY

AUGMENTED REALITY FOR PROCESS CONTROL

Manufacturers looking to find answers quickly to complex problems within factories, buildings, and process control applications are using augmented reality, says Melissa Top. A self-contained holographic computing device can provide a 3-D augmented reality (AR) view of process data, which can be used with integrated humanmachine interface/supervisory control and data acquisition (HMI/SCADA) software. To understand the advantages of such new tools, it’s interesting to look at the evolution of technology in manufacturing and process control automation. The PLC debuted almost 50 years ago, the effects of which can be found ingrained in much of today’s automation. A short time later, PC-based software emerged, although early iterations were mainly text-based.

Microsoft’s Windows operating system and use of a graphical user interface (GUI) provided a way for automation software to monitor and control equipment via 2-D graphic symbols that, over the years, grew in ability and complexity. Processors evolved from 32to 64-bit, and introduced a paradigm shift in process control. Mission critical data could be collected at breakneck speed, and the former 2-D images used in HMI/SCADA software could be rendered quickly in 3-D for a lifelike representation of connected objects and environments.

Innovation continued. The PLC gave necessity to PC-based control, which led to GUIs making life easier for operators, which led to advances in graphics processing. The next step is using holographic computing devices with ‘digital twins.’

location-based features in modern HMI/ SCADA software include: • NFC (near field communication) allows users to connect to supported devices without the need for a physical connection, enabling users to monitor or configure data and settings remotely with automatic connection and without more infrastructure.

• GPS (global positioning system) leverages latitude and longitude information to display data associated with that location and associated equipment. Mobile users can view information preconfigured for a user’s physical location.

• OCR (optical character recognition) allows mobile devices to derive information from scanned standard alphanumeric characters.

• Barcode scanning helps prevent operator confusion by utilising physical tags associated with equipment.

• QR codes (quick response codes) allow users to scan pre-established physical QR codes on a device and retrieve current and historical information about that device in real time.

AR application benefits A typical Industry 4.0 AR scenario can involve training, simulation, maintenance, remote assistance, or a number of other use cases. A technician

Location-based features Compatibility with holographic computing devices is one of many AR and data mobility features in manufacturing or process control applications. Additional

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using an integrated device with HMI software can look at the ceiling and see the relevant information about the HVAC system, how the equipment is laid out, and learn about specifications such as pressure and flow. Installations and aggregates obscured behind linings and false ceilings also can be visualised, together with their current status messages. In this way, errors can be detected and corrected more quickly.

If ventilation is not working properly, perhaps it turns out that the error is not in the fan, but in the power supply. This instance can be seen quickly in the AR environment. The operator can then call up corresponding circuit diagrams and signal states. Documentation, such as maintenance instructions, also can be opened in a context-sensitive manner.

AR can produce solutions within factories, buildings, and complex, multiasset environments. Workers equipped with solutions such as an integrated HMI can get in touch with service representatives immediately through the connected device and either provide or receive instructions for repair, along with corresponding interactive holograms.

Beyond AR Developers and users are pushing the boundaries of what’s possible with hardware and software in AR. Just as technology for manufacturing and process control evolved from the earliest days of the PLC, through DOS, through 2-D GUIs and 64-bit computing, it’s inevitable that new ideas will expand upon today’s AR capabilities.

Melissa Topp is the senior director of global marketing at Iconics. This article first appeared on www.controleng.com Control Engineering Europe

UK INDUSTRY REPORT

SEEING THE BENEFITS OF ‘DOING THE RIGHT THING’ Schneider Electric has published a report which reveals that 87% of UK organisations are torn between doing the right thing for the environment and meeting their business objectives.

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he study, ‘The Secret to Sustainable Success,’ found that while businesses understood the need to become more sustainable, nine-in-ten UK organisations were more focused on short-term economic outlook, with only onein-ten being focused on delivering transformational change.

With energy consumption expected to increase by a factor of 1.5 in the next 40 years, and CO2 emissions needing to be halved to meet climate targets, 79% of organisations feel confident that they can overcome the challenges presented by the increased demand for energy and create a sustainable business for the future. However, when it comes down to the practicalities of delivery, only 13% feel well prepared to address the rapid growth in energy demands.

The report revealed that almost half of organisations are targeting change through innovation projects – whether it be to use less energy by finding efficiencies in operations, embracing robotics to address the skills gap or

adding sensors to identify maintenance needs before they occur. The modus operandi is to ‘do more with what you already have’ and ‘keep the existing equipment operational’.

Commenting on the report findings, Mike Hughes, zone president UK & Ireland at Schneider Electric, said: “Organisations are operating in unprecedented times. While the benefits of sustainability are becoming more universally accepted, many still hold the belief that this comes at a cost to the business’ bottom line. Yet there doesn’t need to be a trade-off between sustainability and business success. In fact, quite the reverse.”

Digital adoption Today, gaining visibility and uncovering unnecessary energy usage is achievable by adopting digital processes. This opportunity is certainly resonating with UK businesses, with 70% actively considering digitising operations moving forward. This consideration is triggered by a reduction in energy usage and overhead costs.

Making the investment to The secret to sustainable success digitise is key to turning an organisation from a reactive to a proactive state and the returns are recognised by 69% of decision-makers, as they expect to see a noticeable rate of return within the first 12 months. Moreover, 75% believe that once disparate data sources have been consolidated they will have the capability to intelligently connect people, processes and data through devices and sensors in the first year.

“The reality is that doing the right thing comes with immediate and longterm rewards,” concluded Hughes. “The secret to sustainable success is visibility – as you can’t measure what you can’t see. Today we have access to data that provides insight into how effectively operations are run, how proactive actions can help improve reliability, safety and sustainability to drive efficiency and market advantage in the long term.”

Striving for success in unprecedented times

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To request a catalogue call 01788 568 008, e-mail ukmarketing@wago.com, or visit www.wago.com

FOOD INDUSTRY FOCUS

Starting your Industry 4.0 journey Suzanne Gill finds out why the UK food industry needs to embrace the idea of Industry 4.0 and why the journey needs to start now.

I

t is important to understand that success in industry 4.0 is not about how much money you are able to invest. It is about having the vision and courage to start to make changes. There is agreement that data is key, so start by looking at your sensors, and other plant floor devices where this valuable data is already being created, and find a reliable and secure communication network which can move it to a place where you can start to get some real value from it.

Nicholas Temple, marketing & global accounts manager, UK & Ireland, for B&R Automation, says that engineers in the food processing sector need to start to consider how they are positioned to compete and how their role may change as a result. “Industry 4.0 will not occur overnight, but it is important that engineers become more IT literate and they must be prepared to work across the traditionally separate lines of IT/ OT,” he said. “They also need to start to develop new skills in data management and security.”

Skill and creativity will be vital to success. For example, with data collection and storage, plant managers

need to focus 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 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. Orange Box 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 is able to share this information with higher-level systems.

Ralf Hagen, E&A/MES engineering manager at Nestlé Germany, already understands the benefits of bringing legacy equipment into the digital age. He said: “In a smart factory, components need to communicate and interact in a much better way than we are currently used to. A machine should know when it needs to speed up or slow down – when it should request additional materials or refuse them. Currently, these decisions still require the experience of human operators, but in the future machines should be able to handle this autonomously.”

Nestlé turned to B&R’s Orange Box to allow its machine operators to collect and analyse data from previously isolated machines and lines. “We are aiming

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CLIMATE CONTROL

FOOD INDUSTRY FOCUS

Demonstrating how Industry 4.0 solutions might work What will the manufacturing processes of the future look like, and what will their defining features be? Control Engineering UK found out at SAP’s new Experience Business Center in Paris.

Working together, Festo Didactic and SAP have created the Open Integrated Factory demonstrator to show how shop floor and a Manufacturing Execution Systems (MES) will be linked in the era of Industry 4.0. The work pieces in Festo Didactic’s CP Factory are able to tell the machine how they should be processed.

The line can produce completely different products: The parts know what they are and can communicate with the facility through RFID technology. After approaching the correct station, they tell it which part and variant they are, and request to be processed appropriately. Through the use of defined standards, product variations can be manufactured in any given order and quantity on the same production line.

The basis of the Open Integrated Factory is Festo’s CP Factory. This cyber-physical learning and research platform is used to train a broad range of technologies – from plant networking to PLC programming, drive technologies, sensor systems, safety technology, robotics, assembly as well as value chain analysis and optimisation.

The CP Factory consists of a variety of individual work stations that can be configured for different production situations and can be linked to IT systems. The individual cells can be reconfigured in minutes to create new plant layouts. The work piece holder routing system allows each cell to operate individually and to quickly set up an operational production line.

Find out more at https://www.youtube.com/watch?v=Zq88px3hcNY&t=11s

Addressing trends According to Mark Maas, industrial digital factory & innovation lead for TE Connectivity there is a need to address a number of industry trends including greater customisation/differentiation of products – even in high volume production runs; improved energy efficiency; and increasingly more interactivity. “As a consequence I believe we will see a move from make-to-stock to make-to-order.” So, the food industry needs to work out how it can 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 Industrial Internet of Things (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 will be the result of ongoing studies and developments,” said Maas.

Conclusion for intelligent analysis that identifies the root causes of a problem before it occurs. Over the next four years, we want to get to a place where the machines warn us of an impending

IT INFRASTRUCTURE

stoppage in advance, rather than having to troubleshoot after the fact the way we do now. Eventually, there should be no more unplanned downtime,” concluded Hagen.

Data is key. It is important to collect and store it securely and to find a way to translate it into actionable information.

The journey has to start today otherwise there is a risk of being left behind.

SOFTWARE & SERVICES www.rittal.co.uk

FOOD INDUSTRY FOCUS

Personal CO2 detectors for brewery workers Because CO2 occurs naturally in the atmosphere, albeit at very low concentrations, many do not fully appreciate that it is a toxic gas. This is now changing in many sectors, including the brewing industry.

C

O2 is produced during the brewing production process so great care is needed when working in environments where it may be present at elevated levels.

“Products are specifically designed to detect hazardous gases widely used within the oil and gas, marine and steel industries, and a similar picture is developing in the brewery industry.

Workers who enter drinks storage areas without adequate gas monitoring equipment are potentially entering a life-threatening environment,” said Melina Ho, regional marketing manager at Crowcon Detection Insruments. “So, when New Zealandbased DB Breweries approached us to help them find a gas detection solution,

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we were delighted to support the company.”

Crowcon was initially asked for support from the company’s health and safety advisors, a trend which is increasing within the food & beverage industry as gas detection policies become more rigourous.

If workers are equipped with personal monitors before they enter a risk zone, gas levels can be monitored.

In DB Breweries case, Crowcon’s singlegas Gasman CO2 IR was selected, largely because of its infrared sensors.

Infrared sensors tend to have a faster response time and longer active life than other CO2 sensor technologies, as well as performing better at the lower temperatures that can be encountered in cellars. As part of the gas detection

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solution, service and calibration of instruments is provided.

A hazard CO2 is a hazard throughout the manufacturing process, right through to packaging and bottling, and even to the bars and eating establishments where the drinks are served. Because CO2 is heavier than air if it escapes, it will sink to the floor, where it can form deadly, invisible pockets. It collects in cellars and at the bottom of containers and confined spaces, such as tanks and silos.

Hamish Clentworth, a DB Brewery spokesperson, explains: “One of the key factors in selecting Crowcon was the flexibility of its device. The ability to select the alarm function to best suit the working conditions ensuring safety is paramount as it ensured minimal disruption. Furthermore, the response time when increased CO2 levels are present was impressive, which means our employees are alerted of the possibility high levels of CO2 in good time.

Ultimately, our company has a duty to protect its employees from exposure to hazardous CO2 gases. Early detection can be the difference between life and death.”

Even when gas detectors are deployed; maintaining protection for every employee can be a challenge as CO2 can be present in many different areas so gas detection devices must be seen as an integral part of an employee’s daily routine.

To this end DB Breweries has made it company policy that employees use personal CO2 detectors at all times.

Control Engineering UK

Complete control wherever you happen to be ... ... with PASvisu visualisation software Web-based HMI software PASvisu enables simple configuration and optimum visualisation of your automation projects. So you can achieve a convenient, comprehensive overview of your plant locally and via remote access.

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MACHINE FOOD INDUSTRY VISION FOCUS

Your flexible friend in the food factory Suzanne Gill finds out where thermal imaging technology can help around the factory.

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aximising plant uptime requires the ability to predict when components or electrical connections are verging on failure.

Thermal imaging has an important role to play in any predictive maintenance programme. Essentially, it can make the invisible, visible to provide clear evidence of a fault via an abnormal heat signature. It can be applied to many applications – from high voltage equipment, low voltage cabinets, motors, pumps and heating elements to monitoring systems for energy loss or missing insulation.

But why choose a thermal imager as a temperature monitoring solution over other options? Anders Andreasson, director global business development Automation & Industrial Safety at FLIR said: “Thermal images can measure temperature without contact so the technology offers a quick and easy to use solution.”

Andreasson explains that, while this is also true for other solutions, such as spot pyrometers, thermal images can offer more. “We also offer an image so you know where you are measuring.

This makes it easier to align the sensor and to evaluate exactly where the measurement is being taken. Another benefit is that we can measure on

an area, not only on a spot. Thanks to built-in analysis we can then find the warmest, coldest or average temperature of an area. The sensor can then transfer only the measurement or alarm signal over standard industrial protocols like ModbusTCP or Ethernet/ IP. This saves bandwidth and simplifies installation.”

Thermal imaging is widely used within the food industry. For example, to monitor conveyor ovens, where it can even form part of a feedback loop to help control temperature. It can monitor temperature uniformity across the width of the cooking belt and can raise the alarm if the heating element inside an electric oven fails, or there is uneven heating across an air impingement oven.

Packaging Thermal imagers can also help ensure packaging integrity. For example, a thermal imaging camera employed to inspect heat-sealed cellophane covers over microwaveable meals would be able to see heat radiating from the lip of the container where the heat seal is formed. The temperature along the perimeter of the pack can be checked by the thermal imaging camera partnered with machine vision software.

This type of programme matches the geometric pattern of the image and its

Thermal imaging can be used as a quality control tool in the food industry.

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temperatures against a comparative, computer stored template. An added function could be laser marking of a poorly sealed package so it can be removed at the inspection station.

An issue that indirectly affects product safety is the integrity of cartons that overwrap and protect food containers.

One of the most popular ways of sealing the pack is to use heated glue spots on the carton flaps. Checking the efficiency of this process is another task to which thermal imaging technology can turn its hand.

Cold and hot While higher-than-normal temperatures are common indicators of impending problems in electrical connections and components such as bearings, lowerthan-normal temperatures can also demonstrate a problem.

Infrared cameras can be used to visualise sub-zero temperature patterns so are equally suited to ensuring industrial freezers are working optimally.

In a single pass, the camera can provide a thermal image showing any failure in insulation that might compromise performance or lead to downtime.

Averting fire A small electro-mechanical fault can have far-reaching consequences and the effects of a fire are often underestimated. Indeed, around 35% of all industrial fires are caused by electrical faults. With thermal imaging included in the preventative maintenance regime, the majority of problems that could cause an outbreak of fire can be detected before they have an opportunity to damage the efficient running of an operation.

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MACHINE VISION

The journey to becoming an enabling technology

As the UKIVA celebrates its 25th anniversary, Paul Wilson takes us through the machine vision journey the association has presided over and he takes a look into the next 25 years of machine vision too.

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here has been many developments in the past 25 years as vision technology evolved from using a disparate collection of components from other disciplines to the high performance dedicated systems available today. Vision is now very much considered to be an enabling technology.

Vision integrated into a manufacturing process can have a significant effect in terms of reducing the amount of waste (defective product) produced, energy consumption required to produce the defective product and time wasted in producing defective product. End-of-line inspection, based on ‘pass/fail’ decisions, can prevent defective product reaching the customer, but there could be a lot of waste. In principle, the earlier in the process that a vision system can be used, the earlier it would be possible to detect if the product is starting to go out of specification. This allows preventative action to be taken by adjusting the process with the aim of eliminating defective product altogether.

Making vision accessible Machine vision technology exists in a fast-moving environment, where developments in processing power, camera sensors (especially CMOS sensors), illumination, optics, software capabilities and image data handling standards constantly push back the boundaries of what is achievable. Cameras with higher resolution, faster operation and smaller physical size are linked with ever more powerful processing systems to enable more complex inspections to be carried

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out or give better performance for existing applications.

Along with all of these developments has been the emergence of the ‘plug and play’ concept for vision which facilitates system design for vision systems integrators and opens up possibilities for non-specialist users to reap the benefits that vision inspection can offer. This has opened up vision capabilities to machine builders who wish to integrate vision into their products and to end-users. While this has broadened the accessibility of vision, in terms of setting up a vision system, it should be remembered that a key requirement of getting good results is getting a good image to start with. Clearly, choosing a suitable camera is important, but getting the right illumination is critical, so some knowledge and understanding of vision is usually needed even for self-build systems. Vision systems integrators will be needed to supply complete turnkey solutions including product reconciliation, rejection and handling.

There have been a number of key developments during the past 25 years that have contributed to plug and play capabilities. These include: • Simple to use measurement tools • Smart cameras • Camera connectivity • Embedded vision Most of these developments are a consequence of the continuing evolution of semiconductor technology during this period which has allowed the development of smaller and faster processors, massive data storage and an extraordinary range of image sensors.

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Measurement tools An early stage in the development of vision technology was the use of PCs instead of minicomputers for image measurements. However, before the introduction of the PCI bus in 1993, no PC bus was fast enough to be used for image data transfer within a PC. The solution was typically to install processing power on the frame-grabber board or to use a secondary bus dedicated to image transfer.

Although IBM-compatible PCs had begun to be used before 1995 as the basis for vision systems, the advent of Windows 95 made ‘point and click’ programming easier to implement.

Improvements in PC programming power and memory paved the way for the development of PC-based image processing toolkits and libraries, which were used by vision experts to set up the inspection and measurement. From these came the self-contained machine vision applications with a simple interface framework that offer a plug and play approach for PC-based systems. These feature tools for a host of vision tasks such as detecting the presence/absence of features, part alignment, part measuring, surface inspection (looking for scratches, stains or irregular features), 1D and 2D code verification, character reading, label inspection etc. These then provide nonvision experts with easy-to-use tools to set up measurement routines.

Smart cameras The development of smart cameras represents a literal plug and play capability by moving all of the image processing capability into the camera

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MACHINE VISION < pUK8 itself. All of the measurements are made in the camera and a result output signal produced which can be sent directly to a PLC. In addition to built-in processors, the on-board software will feature the sort of measurement tools described above. Set-up can usually be made through a standard web browser. This can be reset for different product types and even moved to different locations to carry out different inspections. Another form of smart camera, which has gained real traction in recent years, is the 3D smart camera. These have truly been made possible by the developments of processors capable of handling the 3D calculations but that offer the possibility of individual or networked 3D imaging.

Camera connectivity For PC-based vision systems, the images need to be transferred from the camera to the PC for analysis and measurement, so camera connectivity is very important.

Smart cameras overcome this issue since the on-board measurement removes the need to transfer the actual images.

Image data transfer possibilities were transformed by the introduction of the GeniCam standard which is the umbrella standard required by all modern machine vision interface standards. It allows access to devices such as cameras or strobe controllers no matter which technology is used.

The first dedicated data transmission

standard for machine vision was CameraLink. Further standards, such as GigE Vision, CoaXPress, CameraLink HS and USB3 Vision have followed, offering different data transfer rates over a variety of distances to suit the particular application. These offer real plug-andplay capabilities since cameras from any manufacturer that meet a particular standard are interchangeable.

Of these, GigE Vision has probably had the most impact in the factory environment since it allows data transfer over distances up to 100m using industry-standard Ethernet cables and switches. Consumer interfaces, such as USB 2.0 and USB 3.0 and USB 3.1, also provide plug and play capabilities since cameras with these interfaces can be readily connected to a PC. However, these devices require the installation and use of the camera manufacturerâ&#x20AC;&#x2122;s own software, rather than the generic software packages that are available for the machine vision standards.

Embedded vision The rapid evolution of computing power in embedded, single board computer systems is providing new, exciting possibilities for vision. Embedded vision systems, based on platforms such as NVIDIA Jetson, Raspberry Pi, CompuLab and ODROID, are finding increasing use in applications where space is constrained, cost is an issue and a self-

Smart camera measurements using point and click machine vision software (Courtesy Stemmer Imaging).

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contained vision solution is required.

An even newer approach is the system on chip camera which is optimised for advanced digital imaging, combined with a comprehensive image processing library (IPL). These systems, including smart cameras, provide a scalable choice of embedded vision solutions.

Factories of the future Looking forward to the next 25 years, machine vision is set to make a significant contribution to the smart factories of the future. Just as with current vision systems, connectivity between systems and the interchange of data will be crucial, especially as cameras generate large quantities of image data. To that end, in 2016, the German VDMA and the OPC Foundation set up the VDMA OPC Vision Initiative working group to develop an OPC UA companion specification for machine vision. For straightforward integration of machine vision systems into production control and IT systems. At the lower level in smart factories, data will be produced by a host of smart sensors which will certainly include industrial cameras. Other applications could include bespoke manufacturing where vision systems are used to determine required dimensions which are immediately transferred into a manufacturing process.

The move towards Industry 4.0 is already underway, with the emergence of products which can monitor an entire production process in real time, to identify which machines or processes have the greatest impact on overall productivity. Work is in progress involving some UKIVA members to integrate vision systems into this type of system. Code reading and verification, a well-established application for vision, will be a key factor in this process in order to eliminate operator data input error.

Paul Wilson is chairperson at the UK Industrial Vision Association. Thanks are due to UKIVA members Alrad Imaging, Allied Vision, Bytronic Automation, Cognex, Multipix Imaging, Scorpion Vision, Sick (UK) and Stemmer Imaging for their contributions to this article.

Control Engineering UK

Making the right industrial ethernet connection

19th October 2017

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NEW PRODUCTS

Smart camera performs in harsh industrial environments While there are a plethora of vision systems available today that offer complex inspection capabilities at incredible speed but their performance can be reduced in harsh industrial environments.

Turck Banner believes it can now offer a solution with the Banner VE series of smart camera which is able to offer good performance even in the toughest applications.

The smart camera features robust metal housings and, with the addition of a range of optional lens covers, achieves an IP67 rating for use in environments where heat, vibration or moisture are a concern.

Banner’s free Vision Manager Software provides a number of tools and capabilities that enable its smart cameras to solve a wide range of vision applications, such as item detection, part positioning, feature measurement and flaw analysis. Included in the tool set is the Circle Detect tool which can be used to inspect parts, products, packaging, or other objects that are in the shape of a circle or arc, or contain a circle or arc.

This makes it easy to find imperfections as well as measure or determine circumference, diameter or the bend radius of a target.

The software includes runtime editing capability that reduces downtime and the software emulator allows for offline building and troubleshooting of applications. An inspection analysis feature allows users to review past inspection results, view system logs and quickly configure inputs and outputs.

FTP image export capability enables

Expanded range of IO-Link enabled devices RS Components (RS) has expanded its range of IO-Link compatible hardware and ancillaries.

IO-Link, the first standardised IO technology (to IEC 61131-9) for communication with sensors and actuators, will play an important part in the growing creation and adoption of fully connected solutions based around Industry 4.0 and the Industrial Internet of Things (IIoT) concepts.

The majority of IO-Link devices are equipped with M12 connectors, which can be used without any restrictions for IO-Link’s switching mode and communication mode.

Created by sensor manufacturers – including SICK, OMRON, ifm technology, BALLUFF, Baumer, Rockwell Automation and Pepperl + Fuchs – IO-Link’s pointto-point communication (which is Fieldbus independent) is based on three-wire sensor and

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October 2017

actuator connections, without additional requirements regarding the cable material.

Each port of an IO-Link master is capable of processing binary switching signals and analogue values, with serial IO-Link communication taking place via the same port. Easy wiring, automated parameter-setting and extended diagnosis add further functionality to its mix of capabilities.

The combined features offer benefits including reduced design and installation efforts and costs, reduced complexity, enhanced design flexibility, and standardisation of cabling and interfaces.

Of particular importance to the IIoTbased smart factory approach, IO-Link sensors can provide an easy and affordable continuous source of information, thanks to the new datacapable connection paths down to the lowest automation level.

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the automatic export of inspection images as well as the creation of custom file names for each exported image.

This facilitates the recording, tracking, and analysis of inspections and builds on Vision Manager’s capability to export images over TCP/IP. The VE Series seamlessly interfaces with the factory floor using EtherNet/ IP, Modbus/TCP, PROFINET, and Serial RS232 communication protocols.

Photoelectric sensor offers easy alignment and reliable detection Carlo Gavazzi has introduced a vandal proof photoelectric sensor in a robust aluminum housing capable of detecting at distances of up to 60m, allowing for detection of both vehicles and persons especially within harsh weather conditions.

The PD140FNT60 through beam sensor is designed for automatic and industrial door and gate applications.

The company’s through beam technology helps it achieve longdistance detection. The lenses are adjustable in both 200° horizontal and 30° vertical directions which allows for flexible mounting, even when the emitter and receiver are mounted at different heights.

Supply voltage is 12- 24 VAC/aDC, 1A SPDT relay output, connection is made using a self-lifting terminal block, 1.5 mm2 (AWG 16) and a test input built in to the emitter, Yellow LED for output indication and Green LED indication for power ON.

Control Engineering UK

MAINTENANCE

Improving maintenance outcomes

WITH MACHINE LEARNING

Mike Brooks proposes the use of machine learning software to improve plant reliability and to reduce unplanned downtime.

T

here is a significant need to carry out failure prevention using data-driven truths instead of guesstimates, evidenced by the fact that a combination of mechanical and process induced breakdowns account for up to 10% of the worldwide $1.4 trillion manufacturing market, according to a 2012 report from The McKinsey Global Institute.

While companies have spent millions trying to address this issue and ultimately avoid unplanned downtime, only recently have they been able to address wear and age-based failures.

Current techniques are not able to detect problems early enough and lack insight into the reasons behind the seemingly random failures that cause over 80% of unplanned downtime.

This is where using machine learning software to cast a ‘wider net’ around machines can capture process induced failures.

To avoid unplanned downtime, companies must identify and respond effectively to early indicators of impending failures. Traditional maintenance practices do not predict failures caused by process excursions.

That would require a unique technology approach combining machines and processes; particularly for asset-intensive industries such as manufacturing and transportation. With the right technology in place, organisations can sense the patterns of looming degradation, with sufficient warning to prevent failures and change outcomes.

Predicting downtime Advanced machine learning software has already demonstrated its capabilities Control Engineering Europe

in the early identification of equipment failure. Such software is nearautonomous and learns behavioural patterns from the streams of digital data produced by sensors on and around machines and processes. Automatically, and requiring minimal resources, this advanced technology constantly learns and adapts to new signal patterns when operating conditions change.

Failure signatures learned on one machine ‘inoculate’ that machine so that the same condition will not recur.

Additionally, the learned signatures are transferred to similar machines to prevent them being affected by the same degrading conditions.

For example, a North American energy company was losing up to $1 million dollars in repairs and lost revenue from repeat breakdowns of electric submersible pumps. The advanced machine learning application

learned the behaviour of 18 pumps.

The software detected an early casing leak on one pump that caused an environmental incident. Applying the failure signature to the rest of the pumps provided an early warning, allowing early action to be taken to avoid a repeat incident, preventing a major problem.

In another case, a railway freight firm operating across 23 states in the US used machine learning to address perennial locomotive engine failures costing millions in repairs, fines and lost revenue. The machine learning application operates in-line, in real-time and was deployed on a large fleet of locomotives examining lube oil data to provide an early indicator of engine failure. The application even detected a degradation signature while the engine passed a low-pressure test. Diverting the locomotive for immediate service resulted in the company saving millions of dollars in costly downtime and fines.

Conclusion

Mechanical and process induced breakdowns account for up to 10% of the worldwide manufacturing market.

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Companies can no longer rely solely on traditional maintenance practices but must also incorporate operational behaviours in deploying data-driven solutions. Extracting additional value from existing assets and implementing an advanced machine learning programme can deliver fast improvements. With the right software solutions, predictive technologies will detect the conditions that limit asset effectiveness, while providing prescriptive guidance to ensure continuing profitability and improving margins.

Mike Brooks is senior business consultant at AspenTech.

October 2017

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SCADA & HMIs

CYBER SECURITY FOR

SCADA SYSTEMS Technologies keep evolving to address cyber security. However, users do need to stay current to keep attackers out. Kevin Finnan and Jeff Melrose offer advice on improving your defences.

S

upervisory control and data acquisition (SCADA) systems have been part of the process industries for many decades in oil & gas pipeline and other remote control and monitoring applications.

While the technology continues to evolve, the underlying use case remains. Gathering and transmitting data from distributed sensor networks, and sending control commands.

The term SCADA itself has come to mean many things and is often used interchangeably with distributed control system (DCS) and other automation system configurations. To keep things clear, we should begin by defining what a SCADA system is in the context of this article.

A SCADA system supports bidirectional communication between

distributed field devices and a central control area. For example, an oil & gas company might use a DCS to control a refinery, but a SCADA system will be used to control the pipelines coming into and leaving the refinery. As a result, the SCADA system can cover longer, more linear distances than a DCS, such as when used to support a pipeline. In many respects, SCADA systems are a proto-Industrial IoT (IIoT) application with respect to the basic functionality.

Traditional deployments Using a hypothetical remote pipeline pumping station as an example (Figure 1). All the field instruments and actuators connect to a remote terminal unit (RTU), which serves as a data consolidation and translation point. The RTU also works with whatever backhaul

Figure 1: Traditional SCADA systems use an RTU as a gateway to gather information from sensors and send orders to actuators. It is the critical point for the installation and often becomes the primary attack target for hackers.

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transmission medium is in use, such as 900 MHz radio, satellite or any other media necessary to handle the required bandwidth and distance.

The various field devices may use assorted communication methods to connect to the RTU, but the RTU serves as a gateway, converting it all to one protocol so it can transmit everything in one data stream. Some local control functions may be useful or necessary at the site. The RTU can, additionally, perform these, or a PLC or other small controller may be used, but it too will report its activity through the RTU. Older radio communication methods for many of these systems often proved unreliable, with 900 MHz systems susceptible to interference. Newer approaches offer improvements, but many pipeline operators retain the older platforms, and their problems due to cost constraints.

The RTU frequently serves as the focus for cyber attack methods. Hackers often find older RTUs poorly defended with unsecured communication, so they become the path of least resistance into the network.

One of the most famous hacks along these lines was in western Ukraine.

In December 2015, attackers started shutting down the electrical grid by gaining access to devices similar to RTUs spread among substations. In this particular case, the units themselves were not the only weak links, but they were targeted because of their poor defences and strategic positions. Once reached, tripping one caused a high level of disruption.

Control Engineering Europe

> p22

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SCADA & HMIs < p20

SCADA 2.0 = IIoT As old as the SCADA concept is, it has not lost any of its importance. In fact, the role of SCADA systems is growing, which is broadening its definition.

With a higher degree of protocol standardisation and greater connectivity to corporate IT networks, the potential attack surface and attack worthiness for cyber criminals is also growing.

The trends toward business systems using and processing SCADA data creates new avenues and reasons for system exploitation. Sharing data is often lifeblood for many companies, but new threats can emerge in the process.

On the other hand, new technologies are changing the picture further as the IIoT merges with SCADA to become SCADA 2.0. This has some way to go, but the possibilities are intriguing. Let’s think what it might look like, and how it could affect security considerations (Figure 2).

For starters, the RTU, at least as a gateway, will disappear as there will be no need for it. The individual field instruments and actuators at the hypothetical pipeline pump station will all communicate directly with the ubiquitous network, just as a technician visiting the site might call back to the office on a smartphone. The data from the devices goes to the cloud and can be captured and used by whichever

part of the company needs it, from anywhere. At this point it is difficult to say exactly what the network might look like – certainly 4G or 5G capable – but the communication will be direct. New networking technologies, like LoRa WAN, may enter the arena.

Setting up these installations will be simpler than with current systems. Install the field device, turn it on, and click to connect it to the cloud. This will remove all the manual operations still being undertaken at many sites. Add a level instrument to the storage tank, and the need to send a human to the top to look inside every month disappears.

There may still be a need for control functions at the site. A natural gas compressor or other equipment may need fast loop control, which will call for a local PLC. Control via the cloud is still a long way off. These installations may use the PLC as something of a data consolidator, but the decision can be made on a case-by-case basis.

If the cloud architectures are what they need to be, this type of a system should be very secure. By eliminating the RTU/gateway and less-reliable backhaul communication methods, a hacker will have to gain access to multiple field devices one at a time, rather than gaining access through the RTU. A single IIoT device is not connected to the

Figure 2: Tomorrow’s system will get rid of the RTU/gateway because its function will no longer be necessary. Sensors and actuators will communicate individually via ubiquitous wireless networks. A hacker may be able to disrupt single devices, but they can no longer serve as a means to gain access to the owner’s network.

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network in the traditional sense as its wired predecessors are, so while it might be possible for a hacker to disrupt the individual device, this will not provide a means to access the larger network.

The reality of this concept is still sometime away. Coverage and speed is improving all the time, but 5G or even 4G in all the areas where pipeline pumping stations are located is not yet reality.

Multiple systems One aspect of monitoring technology is the idea of multiple SCADA systems at a single location, and the user might not even realise it. How does this happen?

A turbine-compressor set might have its own system to remotely monitor performance and condition (Figure 3), and there is probably an existing SCADA system. These OEM systems are often included to verify performance requirements written into purchase agreements. This kind of monitoring keeps everyone honest and helps the party responsible for maintenance stay informed as to what is happening.

Having this kind of communication is necessary and is, ultimately, a good thing. But, there can be downsides.

Picture this: at some point the sixmonth-old turbine running a pipeline compressor inexplicably slows down by 20%, and product flow declines as a result. Nobody at the pipeline company called for the change and some investigation shows that it was initiated by the turbine OEM. A message from the OEM reports that a problem seen elsewhere in other units may be present here as well, and to avoid an outage, it is necessary to reduce capacity until it can be investigated. It sounds like a prudent idea, but now the OEM is controlling the process, using its connection to the unit.

Situations like this call for negotiation as to who is allowed to do what.

Invariably, the OEM and the pipeline operator’s SCADA systems will be interconnected, but there must be control as to how they are connected and to what extent. The OEM’s network becomes an extension of the owner’s network and vice-versa.

Control Engineering Europe

SCADA & HMIs But who else is connected to the OEM’s network? What if the OEM outsources some of the system monitoring? Since hackers typically attack a strong network via a weak one, someone wanting to attack the OEM might use the pipeline operator’s SCADA system as the conduit.

The bottom line for the equipment owner is that these situations are already part of the real world, and users must tolerate them for operational reasons.

The defensive strategy is to be very careful as to how the two systems are interconnected. There are methods to control traffic between the two, avoiding open pathways creating opportunities for hackers.

Figure 3: Remote condition and performance monitoring for large pieces of critical equipment by the OEM is already happening. The result is often multiple SCADA systems working in parallel at the same site. The way these systems interact must be carefully controlled.

Threats to come Cyber criminals looking to make money from their exploits have been stealing financial data, personal information and credit card numbers for a long time.

Fortunately, industrial companies don’t

have much in the way of such marketable data capable of being stolen. The scary alternative is ransomware, which has targeted hospitals and now spread to many other users in the recent ‘Wanna

Cry’ attacks.

So imagine this scenario: Returning to our hypothetical pipeline station, the operators at the central control room receive an alarm via the SCADA system

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SCADA & HMIs < p21 because transportation has been shut off. Calling up the HMI, they see a toplevel screen saying that access to the RTU has been locked out and encrypted. The only way to regain control is by paying to get the access code.

The option for the company is to pay, or send somebody out to the site to take it offline and turn operations back on manually. This is only temporary because it is not practical to leave an operator at the site on a continuous basis. The only real solution is to take out the compromised RTU and replace it, at a cost significantly higher than the ransom.

Is this a farfetched idea? Perhaps, but a year ago predicting something on

the scale of Wanna Cry sounded very farfetched too.

Defensive strategies SCADA systems need to be defended using the same strategies as other industrial networks. There are no approaches unique to this situation, but keep in mind the size and complexity of SCADA systems provides many opportunities for determined hackers.

They will scan for weaknesses, and a large, spread-out pipeline or similar SCADA system provides many hidden attack vectors. Here are a few basic defensive suggestions: Maintain physical security at

A changing landscape Trends associated with Industrial Internet of Things (IIoT) and the continued improvement of existing technologies, such as mobile, wireless, cloud and cyber security, has brought about a significant change in the SCADA landscape.

“Unquestionably, cloud-based SCADA software provides an ideal gateway to deliver practical and actionable IIoT information to those who need it” said Pete Rullman, senior product marketing manager at Honeywell Process Solutions.

The traditional approach to SCADA has been a wholly-owned, on-premises solution requiring dedicated support staff with heavy capital and operational expenditures. These costs cover IT equipment and software, as well as physical and IT infrastructure, and cyber security. “This on-site approach offers limited flexibility and ties up valuable resources that might be better used elsewhere,” said Rullman. “To help customers meet their operational and business challenges, automation suppliers are developing SCADA solutions for a hosted cloud environment. New cloud-based SCADA systems represent the natural progression of software in the era of IIoT. Locating functionality in the cloud means end users can move from a capital model to a predictable OPEX model. They can have a functioning SCADA system, literally within hours.”

Honeywell Process Solutions, for example, has introduced Experion Elevate, which makes all SCADA functionality available as a scalable cloud-based service.

This reduces on-premises physical footprint, hardware, software and maintenance.

It also lowers the cost of entry, enabling smaller companies to get operations started even with limited capital. Operators are also free to focus on optimising plant processes while Honeywell handles hardware and software updates, system upgrades, technology migrations, and ongoing maintenance of IT/OT solutions.

“Where cloud-based SCADA makes the most sense is for organisations that are already doing remote SCADA with distributed assets,” continued Rullman.

Experion Elevate is fully interoperable with on-premises Experion SCADA, making it easy to employ flexible hybrid architectures.

“Cyber security is designed into the cloud from the beginning with Honeywell’s solution,” concludes Rullman. “Its hosted data centers are very secure and use best-in-class industry standards for both physical security and cyber security at the data center site.”

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remote sites: RTUs and other networkconnected hardware should be in locked enclosures. Unused ports should be plugged with epoxy.

Update old systems: Any company still running equipment using Windows 95, or even more recent but still obsolete versions, is asking for trouble. Platforms running un-updated software can be just as bad. Wanna Cry only worked on outdated and un-updated Windows platforms.

Use network IDS: Intrusion detection systems are very useful tools, but many companies fear they can disrupt networks. They can be designed for low impact and with passive response to make them easier to use on operating networks.

Train your people: Human beings are still the weakest link in cyber defences. Social engineering, phishing and spear phishing remain effective hacking tools. Don’t open unknown attachments, don’t plug in unknown thumb drives, etc.

Maintain network traffic logs: It’s hard to know if something strange is happening if you don’t know what normal looks like. Logs help establish baselines, so they can help determine where intruders have been and what damage may have been made or attempted.

Use the security resources available: ISA/IEC 62443 offers many helpful resources and best practices for network administrators and defenders, as do NIST 800-14 and 800-16.

Newer technologies will be easier to defend, but many companies find themselves still working with yesterday’s equipment and software. These installations will become increasingly vulnerable if the cyber defences are not kept up-to-date. The job is challenging, but it can be done. Defences don’t have to be air-tight to be effective. Hackers need to be resisted only to the extent necessary to make them look for an easier target.

Kevin Finnan is system consultant, SCADA, and Jeff Melrose CISSP-ISSEP, CEH, GICSP, is principal cyber security manager at Yokogawa Corporation.

Control Engineering Europe

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INDUSTRIAL CONTROLS

Will there be room for CNC and PLCs in the FACTORY

OF THE FUTURE?

As automation in manufacturing increases, control systems are having to become increasingly complex and efficient. We investigate what role different industrial controllers might have to play in the future.

W

hile it is not new, the concept of automation is changing as Industry 4.0 and the IIoT become more prevalent. Alongside the picking, packing, palletising and conveying of former years, automation now also encompasses concepts such as zero-downtime, increased precision, high speeds, efficiency and proactive maintenance. All of this is powered by digital, programmable systems that have been developed and perfected over many decades.

Computer Numerical Control (CNC), for example, is a technology that facilitates the automation of machine tools by means of computers that execute pre-programmed sequences.

“CNC was developed during the 50s and 60s as a logical progression from Computer Aided Manufacturing (CAM) and tracer-based automation,” explains Ian Baird, CNC applications manager for FANUC’s Factory Automation Division.

“Established alongside computer and servo system developments, it helped manufacturers to meet their increasing requirements for repeatable, high-precision production. Today, it’s formed of five main parts – a sequencer, interpolator, servo controllers, logic controller and operator control interface – and is synonymous with precision and control.”

Twenty years after CNC was

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introduced, a cheaper and simpler form of computer-aided control was developed – Programmable Logic Control (PLC).

Programmable Logic Control “PLC was developed in the 1980s to supersede relay logic control systems, which were often less cost-effective, flexible and easy to use because they relied on hardware to perform their key functions. PLC has input and output functionality and can be programmed to perform sequential operations, data processing, or simple axes control.”

PLC was never intended to replace CNC. “Both serve very different purposes and marketplaces, with their own advantages and disadvantages.

Therefore, it would be limiting for anyone in industry to say: ‘I’ve invested in CNC – there’s no room for PLC here’, because they are two entirely different controls,” continued Baird.

CNC is more frequently associated with the concept of automation because the scope of its use extends beyond a simple input-output algorithm. Modern CNC is a flexible, digitally-controlled system that can be tailored to suit a manufacturer’s needs without needing to re-programme the entire system.

“Most modern CNCs also include user interfaces with built-in operation, maintenance and diagnostic screens.

For this reason, CNC is popular with people who want full control over their

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machines, because its functionality does allow you to fly solo after a bit of training,” said Baird. The flexibility of CNC lends it to complex, multi-axis machining in almost any industry. “A CNC’s applications are limited only by imagination. Any application that requires precision motion control needs CNC, whether that be the manufacture of watch parts and medical devices, or reactive atomic plasma etching.”

Simple control tasks PLC, on the other hand, is a good solution for simple control tasks. “If you’ve got an application that doesn’t need a high level of accuracy or flexible motion control, such as an AC motor conveyor, then PLC is often the best choice. It is cheaper than CNC, which would arguably be better invested in more complex applications,” continued Baird.

However, there are some disadvantages to the simplicity of PLC, as Baird explains. “PLC does not have the flexibility of CNC. If you need to change the programme even slightly, you have to re-programme it entirely.

It also doesn’t offer the precision of CNC and is therefore best used as a low-cost solution for basic tasks.” Baird goes on to say that, despite PLC’s low cost, many manufacturers are choosing CNC, due in part to its lower total cost of ownership. “It is interesting to see many designers turning to CNC after Control Engineering Europe

INDUSTRIAL CONTROLS investing in PLC, largely for reasons of flexibility, reliability and cost. The initial cost of CNC is higher than that of PLC, but the return on investment can be higher in the long term because of the CNC’s higher reliability and control. It also gives system designers the flexibility to dictate how much control they want users to have over their machines.”

The long-term cost-effectiveness of CNC can be attributed to its advanced user-programmable features, which can minimise downtime and control the energy usage or output of the machine.

Many CNCs now also come equipped with AI contour control. This means you can control the machine to be within a certain workload, or adaptively control the machine for working overnight.

For example, you can programme it so that it only works at 80% load, allowing you to be more economical with your energy usage. CNCs also come equipped with energy efficiency functions, such as energy charge modules.

The added safety functions of CNCs also lend themselves well to collaborative working with humans.

Baird said: “CNCs come equipped with a digital algorithm that looks after the motion control. This digital system is formed of two parts – a real digital data system and an observer digital system. The observer acts like the ‘ideal’, providing the machine with the parameters in which it should be working. The real and the observer are both driven by the same command, so they should be working in exactly the same way.

“If the real system encounters a disruption, such as an unexpected load, then this causes the real data to deviate from the observer data. The machine will translate this as a collision and respond in one of two ways. If it’s moving slowly, it will stop, and if it’s moving quickly, it will perform a ‘vectored back-off’, where it will retract any moving machinery to avoid damage.

“For high-end machines, you can also incorporate 3D technology, which stops five-axis machinery from moving outside of its pre-determined work envelope.”

Control Engineering Europe

Alongside safety, zero-downtime is an important consideration for manufacturers looking to automate their processes. Unplanned downtime is expensive: it can halt production for days, weeks, or even months. An undetected fault could cause irreversible damage to machinery, and even be hazardous to human operatives.

Minimising downtime “Although it’s unrealistic to expect factories to work seamlessly 24/7, we can aim to minimise downtime caused by minor faults or errors,” said Baird.

This is where the concept of predictive maintenance comes in, which, as Baird explains, is facilitated by CNC control technology. “Predictive maintenance allows us to spot potential problems before they occur, and act accordingly before they become serious. We do this by employing the automation technology that controls the machine as a kind of watchman.

So, is CNC destined to become the sole tool of the factory of the future?

“It’s tempting to dismiss PLC as cheap and cheerful, but it still has a vital part to play in automation,” said Baird. “The best example of this is a production

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line. CNC may be controlling the robot arms, the tooling, milling, and grinding, but PLC is powering the belt that takes a product or material from one part of the line to the next. The complexity of CNC does not lend itself well to such tasks and would be wasted. As part of a factory floor, where simple and complex tasks are done simultaneously, CNC and PLC work perfectly together.”

With CNC and PLC both maintaining a place in manufacturing’s tool-kit, it is now important to look at how they can be developed. “Industrial control systems will continue to evolve, and this will largely come in the form of specialisations suited to specific industries,” concludes Baird. “Thirdparties will also exploit the concept of an open interface in order to integrate the factory with the Internet of Things. With this will come intelligent machines and data collection and analysis on a vast scale, which will help us to identify further process improvements.”

Only time will be able to tell how CNC and PLC adapt to the factory of the future, but it is clear that they will both form a part of it, if not always working in collaboration.

October 2017

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INDUSTRIAL COMMUNICATIONS

TSN benefits for the IIoT and manufacturing Time-sensitive networking (TSN) is moving from the idea stage to deterministic networking and the result of widespread adoption will lead to the Industrial Internet of Things (IIoT), says Albert Mitchell.

T

ime-sensitive networking (TSN) is finally moving from the idea stage to the main stage of deterministic networking.

The IEEE TSN working group has completed the core set of standards required to implement TSN, the industry has developed the first products to support the technology, and simulations and demos are taking place. Widespread adoption of these technologies is the fullblown Industrial Internet of Things (IIoT) revolution that has been talked about.

Full TSN implementation will take place over several phases, so companies won’t be able to just retrofit the technology into legacy systems. While companies won’t be able to immediately replace the existing machines, they must change infrastructures in a way that allows machines to communicate with each other more effectively. Many manufacturers have seen the benefits of

standardised Ethernet within operations, and with TSN disparate networks aren’t needed to support time-critical and besteffort Ethernet traffic.

The promise of TSN is twofold. First, it’s based on standard Ethernet. The traffic found on standard Ethernet, such as video and HTML, can share the physical network with high-priority deterministic Ethernet, such as motion control. This is important because those industrial products that need deterministic services are now part of the network, requiring attention to latency and jitter. With TSN, all devices that are connected to the network can be part of a validated architecture, rather than being siloed.

TSN isn’t bogged down by going at set speeds at all times. Precise scheduling can speed up or slow down and prioritize delivery of whatever packet of information needs to be delivered. It has

While companies won’t immediately be able to replace existing machines, they must change infrastructures in a way that allows machines to communicate with each other more effectively to take advantaging of time-sensitive networking (TSN) and the Industrial Internet of Things (IIoT). Courtesy: Cisco

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October 2017

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no jitter, even where it can accommodate more devices. Instead of treating every packet the same, it can receive and interpret all data at once, calculate the maximum amount of time that can be expended before transmission, and disseminate all information where it needs to go, seamlessly.

This technology is essential because as more devices come onto a network, the need for that central ‘hub’ to direct all the trains – and ensure they come in on time – becomes more important.

From concept to reality One of the most important concepts of Industry 4.0 is the need for standard technologies that all vendors can operate. Instead of more than a dozen fieldbus protocols, which locks companies into doing business with one vendor (or requires translation devices), the principles of Industry 4.0 requires uniform standards to allow everyone to enter the digital age. That is what made TSN so valuable as a concept, and that is why it received so much attention as the standard was being developed.

What will make the technology into reality more quickly is strong collaboration. Providers of network infrastructure will have to work closely with customers and automation vendors.

If this collaboration takes place the way it should, widespread adoption could occur within two years, and TSN should reach its full potential within five years.

The first step in this line of disruption will be the continued adoption of OPC Unified Architecture (OPC-UA). Once Control Engineering Europe

INDUSTRIAL COMMUNICATIONS

Understanding the requirements of industrial Ethernet cables Ethernet plays a major role in today’s automation systems to pass data through the system at high rates.

The digital performance of a network is subject to the active devices within it, such as the switches and controllers.

However, it is the passive devices such as the cable and connectors which can ultimately determine a networks performance so these devices need to given equal consideration.

The frequency performance of a component will dictate its performance. Cat 5 cables, for example, will be specified for operating frequencies up to 100MHz. However, the cable is suitable for 100MBIT applications using two pairs and gigabit applications (1,000MBIT) using a four-pair cable in association with the correct connector.

It is easy to confuse MHz performance with the MEGABIT. Class

Frequency Data Rate Capability Range 100Mbit 1GBIT

Cat 5/5e 100MHz Cat 6 350MHz Cat 6A 500MHz

2 Pair ✔ ✔

4 Pair ✔ ✔

Clearly, cables of a higher category (Class) meet all the transmission characteristics of the lower classes, and therefore provide additional performance margin in a given application.

OPC-UA integrates functionality into one framework, it should carry TSN with it.

Why IEEE Standards are important In many ways, the success of TSN comes down to efficiency. This is what will help guide in the IIoT to its fullest form. Plus, because the technology is based on IEEE standards, all companies can participate.

Control Engineering Europe

using 22AWG cables as many are not compatible with the increased wire size and the larger outside diameter of Profinet cables.

Power Over Ethernet Spare conductors in an Ethernet cable can be used to provide power to Ethernet devices. Clearly, wire size is important in the calculation of voltage drop in Power Over Ethernet (POE) applications, and is important to bear in mind in cable selection.

Cable selection Stranded Ethernet cable does not have the same performance characteristics as solid conductor and this is important when distance is a factor. Ethernet conductors are typically 26AWG and 24AWG, and it is always best to use the largest size when requiring high data rates over long distance.

The Profinet standard saw 22AWG cables being introduced, with this wire size there is significant transmission performance advantage over 26AWG and 24AWG, full 100m segment length can be achieved with stranded or solid cable types. Three types have been defined within the Profinet standard – stationary, flexible and special application. Care should be taken to select the correct RJ45 connector when

The industrial environment requires suitable cables which need to be of far more robust construction than those used in office environments.

Materials such as PUR are often used to provide mineral oil resistance, high abrasion resistance and are halogen free.

Ethernet cables are available with solid conductors which are only suitable for static applications. Stranded conductors – typically seven strand – are suited to flexible use applications, while highly stranded – typically 19 strands – are sited to use in continuous movement applications.

Download the latest Ethernet Connectivity guide from Lutze: www.lutze.co.uk/fileadmin/luetze. com/assets/en/pdf/brochures/Ethernet_ Connectivity_en_LR.pdf

This means a breadth of products will be available to support TSN from vendors.

If no such ecosystem existed, there would be no critical mass of companies implementing the technologies. Having interoperability – essentially standards that all vendors must adhere to – will drive the industry to develop products that support the TSN standard.

When the IEEE TSN working group

completed the core set of standards required to implement TSN, it became clear that IIoT capabilities soon would be available. As the first TSN products are deployed, we are getting closer to that reality.

Albert Mitchell is senior technical marketing engineer, Cisco.

This article originally appeared on www.controleng.com

Conductor size

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October 2017

29

INDUSTRIAL COMMUNICATIONS

PUTTING WIRELESS SENSOR NETWORKS

TO WORK

As wireless sensor networks become more reliable, their applications continue to grow, as Daniel E. Capano explains.

S

ensor networks are built from an infrastructure of local sensors, a communications medium, and a central, common data processing facility. A wireless sensor network builds on this concept by allowing the untethering of the sensors from the bounded medium. This allows a lot of freedom and flexibility in the placement of sensors and the ability to fine tune the monitoring capability of the network. A wireless sensor network (WSN) is the natural outgrowth of the advances made in wireless technology, miniaturisation, and batteries.

This technology also is driving the proliferation of consumer grade sensors and devices that are the basis of what is popularly called the Internet of Things (IoT) that is capturing the public’s imagination. This article will focus on the basics of WSNs and how to use them.

Readers will already know how wireless local area networks (WLANs) can be used to great advantage by increasing efficiency and reducing lost time; WSNs will expand this concept even further by leveraging existing wireless (and wired) infrastructures to build extensive networks of sensors that will reach into almost every area of life.

either with a central portal or as part of a mesh using other devices to extend range. Wireless sensors rely heavily on power saving algorithms to remain operational over the long term. Battery technology is improving; increased battery capacity, coupled with the capability of going dormant for extended periods of time, allow for expected battery life into several years of operation.

Most mobile devices already have this capability – Bluetooth and Zigbee, for example – as power saving algorithms are a required feature in all Wi-Fi certified devices, as well as in devices conforming to the IEEE 802.15.4-2015: IEEE Standard for Low-Rate Wireless Personal Area Networks (WPANs) wireless standard.

The concept is simply that if there is no activity or event to report, the

Saving power Wireless sensors typically are small, self-contained, low power units with a modest amount of processing power.

The key concept to this technology is the capability of wireless communication,

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sensor ‘goes to sleep’. Upon an event or a predetermined time period, the sensor wakes up, assesses the situation, reports status, and then goes back to sleep. This cycle also can be triggered by a polling algorithm that addresses each sensor in turn. Duty cycle also can be adjusted to switch the sensor on and off, effectively cutting power consumption in half. The point is that these sensors are designed from the ground up to operate as low power nodes.

A matter of size: many small sensors The most significant feature of the new generation of wireless sensors is their size. Sensors are called by names that conjure up distinct images: ‘smart dust’, ‘commercial off-the-shelf motes’, or simply ‘motes’. Their sizes range from nanoscale to macroscopic. The former describes biological or small passive sensors, which may or may not be embedded; the latter refers to larger sensors, such as toll collection tags, access cards, and the like. The idea is to deploy an infrastructure of small, low power, low bit rate distributed sensors with varying degrees of computing power that will form larger, high resolution, almost organic networks.

Data processing will be done by conventional means by fixed central data processing facilities being fed data from the network and performing the bulk of processing. Data processing within the network itself also is being contemplated, creating, in a sense, a ‘distributed processor’. The eventual realisation is a large distributed network communicating with and between a wide variety of sensors that will operate autonomously. This will require a common, open communication and Control Engineering Europe

INDUSTRIAL COMMUNICATIONS data standard to ensure seamless interoperability.

Applying wireless sensor technologies The list of applications for which wireless sensors can be used is quite long. A common application is security systems. Wireless access control and area monitoring are already done extensively by wireless technology. Another is the national power grid, or more familiarly, the nationwide network of weather stations. The common aspect in these already realised sensor networks is the capability to communicate over existing communication infrastructure. However, many systems are highly specialised and employ proprietary communication schemes, adding greatly to cost and complexity, hence the need for a standardised approach.

It is envisioned that future sensor networks will communicate over a large mesh architecture, with each

node having the ability to forward data from other nodes, eventually landing at an aggregator where the disparate data will be processed. Sensors will be deployed in high density networks and in large quantities. They will be internetworked using short-haul, low-power wireless links between nodes, while the existing communications infrastructure, particularly WLANs and Internet connectivity, will be used for long-haul communication.

WSNs will facilitate the instrumenting and control of homes, factories, treatment plants, ships, airplanes – the list is endless. With ubiquitous sensor networks, every facet of operation can be monitored, allowing a building, for example, to report on a structural weakness, or a treatment process to spot anomalies that would be missed by fixed traditional sensors. In an industrial process, wireless sensors could be injected into the process stream and continuously monitor thousands

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of points. Smart sensors that monitor several different parameters also could perform as miniature laboratories, sending data back to a SCADA system for required action. Even the human body can be instrumented using this technology, and will be extensively used to monitor such things as blood chemistry, or the body’s complex electrical activity, communicating this data to the patient’s doctor and warning of potentially harmful events. The list of applications for WSNs is endless.

Finally, a word of caution: as we have seen with the explosion of mobile devices, it is easy to become dependent on them and lose our ability to think for ourselves.

WSNs are not a replacement for critical and analytical thought and action.

Daniel E. Capano is a senior instrumentation project manager at Gannett Fleming Engineers and Architects in New York.

This article originally appeared on www.controlengeurope.com.

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l ss steel channe le ance stainle availab its high performThe innovative range, ge adds to . and Harmer Draina ar 120 system flexibility, and is easier its new Modul gives more drains with s’ merchants, through builder a choice lengths, with quicker to install. or one metre nt or sloping comes in 500mm s, and a range of consta tions, 120 ar Modul of applica t grating system wide range Kitchens, of three differen 120 is suitable for a of fat, sugar Professional ar Leisure. hts that intakes ts. As a result depths. Modul Production & Processing, al and School and ’ report highlig d amoun aceutic for the Future exceed recommende ingly including Food cal & Pharm and reduce The ‘Food tly , yet surpris Retail, Chemi Wales curren d to address these issuescations among and strong ed Breweries, and salt in l is durable compli rate for improv er. action is require ar 120 channe lated health nt high flow immediate Sales Manag “Our new Modulcomes with an excelle ated with food-re r Drainage 316 and the risks associ Willmott, Harme steel as standard and lightweight tions, the report ss says Wayne nce and consumers. consumer percep ing, furthering t performance,” d from 304 grade stainle nt corrosion resista curren excelle ion of market a le insight into “It’s manufactureon request, ensuring Giving valuab as diverse as the regulat eness of implementing le choices grade availab nance. ar system looks at issues ion and the likely effectiv impact positively on new modul may le cumulative range, our minimal mainte nutritional educatexplored how these there was a Stainless Steel es Wayne. “And it’s availab for and des that as rest of our “sugar tax”, er. It conclu and drink sector, “Just like the finish,” continu ant - so no waiting weeks end consum n the consumer, food ive surface ely be a need made by the has an attract builders’ merch shared betwee society, there may ultimat Wales in at your local n Strategy responsibility ns off the shelf ment and wider and Nutritio ement Solutio vely.

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Baker Perkin s has introd X-RAY INNO technology uced VATION AND to SOFTWAR 3-Dimension deposit USER-FRIE E BOOSTS al jellies. This NDLY is a high-v DETECTIO A recent develo alue, high-m N SENSITIVI pment in x-ray argin segment of technology TY detector the fast-growing has jelly marke Safeline X-ray allowed Mettler-Toled t and o to significantly the only metho depositing is the power reduce d of their x-ray capab le of manufacturin especially generators, g these compl for shapes at ex density packa the inspection of lowhigh outpu ging such ts and with and pouch as plastic low produ New mould es. trays ction costs. technology the innova that allows This new 0.4mm tion that has rapid and high sensit low-cost shape brought the the 3D jelly allows the ivity detect market benefits of change is integration or starchless of a lower (100W) x-ray depositing 3D jellies can powered generator to be made in and or, in many with solid cases, improv offers equal or soft centre one or two colours; reduction with stripes -fills; and with pieces. The of up to 20% ed detection levels, and layers process uses inclusions whilst offerin under typica ; pectin- or such as real quick-setting Additionally, g a power l operating carrageenan fruit jelly formu Safeline X-ray conditions.

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Research calls for world developed leading health in Wales. A y products Harmer Draina major new food indust capability ge adds to report aimed ry develop to drains with its high perfor and sell health at supporting be its ier products the through builde new Modular 120 system mance stainless steel has been launchWelsh rs’ merchants, channel . The innova quicker to ed. tive gives more install. flexibility, and range, available is easier and Modular 120 comes in 500mm of three differe or one metre nt grating lengths, with depths. Modu systems, and a choice a range of including Foodlar 120 is suitable for constant or a wide slopin Produ range g ction Breweries, Retail, Chem & Processing, Profes of applications, ical & Pharm sional Kitche “Our new aceuti ns, cal and Schoo Modular 120 l and Leisur channel is lightweight durable and e. and comes strong, yet with performance surpris ,” says Wayne an excellent high flow “It’s manuf rate for improvingly Willmott, Harme actured from ed r Draina The ‘Food grade availab 304 grade for the Future stainless steel ge Sales Manager. le and salt in ’ minimal mainte on request, ensuri as standard Wales curren report highlights that ng excellent and 316 nance. intakes of immediate tly exceed corrosion fat, sugar action recommende resistance “Just like the and the risks assoc is required to addre d amounts. rest of our As has an attrac ss Stainless Steel iated with consumers. food-related these issues and reducea result tive surfac e finish,” contin range, our new modu off the shelf health compl at your local lar system ications among ues Giving valuab delivery.” builders’ merch Wayne. “And it’s le availab ant - so no looks at issues insight into curren waiting weeks le t consu Harmer Draina as diverse for nutritional as the regula mer perceptions, the ge is part educa (AWMS) of report tion Alumasc Water tion and the the “sugar tax”, likely effecti of marketing, furthe Management and explor of the UK’s new name for integra ring veness of Solutions ed how these made by the ted water leading manuf management end consu may impac implementing a acturers of responsibility mer. It conclu t positively – and is building draina on choices des that as ge products. one Welsh Gover shared between the there was consumer, a cumulative HARM nment and food For more inform ER DRAINAGE to consider wider societ the y, there may and drink sector, ation on Harme SOLUTIONS order to addre development of a ultimately r’s new Modu Food be visit www.h ss some of a need and Nutriti lar 120 system armerdraina these issues on ge.co.uk more compr Strategy Wales in ehensively.

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PRODUCT FORUM • OMEGA FMG3000 SERIES MAGMETER The FMG3000 Series magmeters are insertion-style magnetic flow sensors with no moving parts. All models are constructed of corrosion-resistant materials to provide longterm reliability with minimal maintenance costs. When these magmeters are used with OMEGA’s comprehensive line of installation fittings, sensor alignment and insertion depth are automatic. Fittings are required for installation. Please refer to accessories below.

• For 0.5 to 8 in. Pipes • No Moving Parts • 0.05 to 5 m/s (0.15 to 16.4 ft/s) Flow Rate Range • Accurate Measurement Even in Dirty Liquids • Blind 4 to 20 mA or Frequency Output • No Pressure Drop • Corrosion Resistant Polypropylene These versatile, simple-to-install flowmeters deliver accurate flow measurement over a

wide dynamic range in pipe sizes ranging from 0.5 to 8”, satisfying the requirements of many diverse applications. FMG3000 Series magmeters offer a variety of output options for use with OMEGA flow instrumentation that has a frequency or 4 to 20 mA output.

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REPORTS SUPPLY OF 600,000 FLOWMETERS TO BEER INDUSTRY Titan Enterprises reports on its long-standing working relationship with Vianet (formerly Brulines) for the development and supply of beer flowmeters. Over the last 20 years - Titan Enterprises has delivered over 600,000 of these flow measurement devices in various guises.

This close working relationship started when Brulines were developing a telemetry product to provide pub chain owners with data on their bar activity via an electronic point of sale (EPOS) system. After trialling several flowmeters, Brulines sought a solution to resolve flowmeter bearing lifespan problems and the unreliability of the optical detection method. Titan Enterprises proposed an adapted version of its 800-series turbine flowmeter as the design included durable sapphire bearings proven reliable for many thousand hours operation, and a Hall effect detector which was not subject to problems with discolouration inside the pipe. To ensure the flowmeter was ‘fit for

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October 2017

purpose’, Titan additionally adapted the cable type as well as the body and increased the cable length to 10 metres. These adaptions enabled Brulines installations to be maintained in beer cellars with differing wire runs to the control panel without any junction boxes.

Following the widespread reliability and success of the original product, Vianet subsequently turned again to Titan Enterprises to develop an “intelligent” flowmeter (IFM) for their For further information on the 800-series turbine flowmeter please visit www.flowmeters.co.uk/turbineflow-meters-titan-800-series-turbineflow-measurement-ideal-oem-flow-meters/ or contact Titan Enterprises on +44-1935812790 / sales@flowmeters.co.uk to discuss a potential OEM development project.

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OMEGA FMC-5000 CORIOLIS MASS FLOW METER The FMC-5000 Coriolis Mass Flow Meter is designed according to the Coriolis Force Principle. It is widely used for flow measurements and custody transfer in many industries such as petroleum, petrochemical, chemical, pharmaceutical, pulp and paper, food and dairy, and more. As an advanced flow and density measurement instrument, it is widely used in the measurement of liquids, gases and slurries, and garners a high reputation among customers around the globe. Coriolis meters are typically used in applications like batch control, blending, filling, dosing, custody transfer, process gas measurements, and more.

The FMC-5000 Series Coriolis Meter is designed according to the principle of Coriolis force. Under the alternating current effect, the electromagnetic coils mounted on the measuring tube will make two parallel measuring tubes vibrating at a certain fixed frequency. Whenever mass (either liquid or gas)

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contact Trevor Southerden trevor.southerden@imlgroup.co.uk or contact Trevor Southerden 359990 E: or Antsy Park, Coventry T: 01732 T: 01732 359990 T: 01732 359990E: trevor.southerden@imlgroup.co.uk T: 01732 359990 E: trevor.southerden@imlgroup.co.uk E: trevor.southerden@imlgroup.co.uk E: trevor.southerden@imlgroup.co.uk Control Engineering Europe October 2017 www.controlengeurope.com

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FINAL WORD

Aiming for a more FLEXIBLE FUTURE The rising demand for personalised manufactured goods means that companies now need a shop floor that is agile enough to meet fast-changing production line requirements, says Rob Stoppek, vice president automation Group EMEA, Parker Automation.

C

ustomers are transitioning from being passive buyers into active participants in the product development process.

Businesses that fail to adapt to this risk losing revenue and customer loyalty. For many manufacturers this means a huge shift away from providing high-volume products through mass distribution. Advanced technology tailored for industrial automation has made it easier to design and implement flexible automation, allowing manufacturers to handle product changeovers with the minimum amount of downtime.

The automation evolution on Manufacturing has shifted focus from the requirement for high volumes of undistinguished products at affordable prices to more customised, continuously changing products.

Fixed automation was initially developed to produce a single type of

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October 2017

product at high volumes at the lowest possible cost. On the manufacturing floor a few decades ago, fixed automation produced a limited assortment of products manufactured in very large batches. The advantage of this is that the initial cost of fixed automation is lower than its more flexible counterparts, and efficiency is optimised when machines are running only one programme. However, with modularity not part of the original factory design brief, any reconfigurations to the production line can be timeconsuming and costly to implement.

Programmable automation â&#x20AC;&#x201C; which is the next link in automationâ&#x20AC;&#x2122;s evolutionary chain â&#x20AC;&#x201C; can accommodate limited configuration changes after the initial setup. The changeover process often requires significant amounts of labour and machine downtime.

The most modern approach, flexible automation, is one in which the operator can combine a mixture of recipe control and mechanical automation. By utilising this combination, processes can be switched seamlessly at the touch of a button, meaning that manufacturers can produce a wider range of products on a single production line. It also enables machines to adapt to the next generation of product specifications, as fully flexible automation equipment usually uses electromechanical

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positioning technology for changeovers that are fast and highly repeatable.

Each type of automated manufacturing has its drawbacks and advantages. The setup cost of fixed automation technology is low, compared to programmable or flexible automation, but the cost-effectiveness decreases sharply as soon as variations in production become necessary. Flexible automation on the other hand is the most cost-effective option over the total equipment lifetime, despite a higher initial setup cost.

Factories are now making the transition to Industry 4.0, and these smart factories, with an endless stream of data, can access the data in real time, and make autonomous decisions to adapt processes and improve efficiency.

Scalable stepping stones How will manufacturers transform their operations from fixed or programmable to flexible automation? Ideally they will want to look for ways to use existing technology that is already available to identify a clear path towards manoeuvering in this direction.

The trick will be to select automation products and solutions that will be reliable, scalable and configurable to a wide range of applications. The emergence of technologies such as programmable automation controllers and electromechanical actuators already provide the building blocks of flexible automation. The former by combining motion and machine control in a single platform and the latter by seamlessly accommodating different product sizes and process changes.

As flexible automation takes over, robotic arms will cease to be fixed in one position on the factory floor, but will be able to be moved around using linear mechanical stages in either single- or multi-axis configurations.

This will increase the usefulness of the collaborative robot, an articulated arm with increased safety controls that will be able to work alongside humans.

Improved HMIs will also enable easier recipe changes and on-the-fly adjustment.

Control Engineering Europe

FINAL WORD

Are we ready for a paperless manufacturing environment?

Charles Corner, managing director at full service sheet metalwork manufacturer, Malton Laser, discusses the emergence of a technology that could revolutionise industrial work spaces and processes.

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aperless technology is slowly emerging across all areas of our lives. But, is there a place for paperless technology in the manufacturing environment?

Industrial work places are often dynamic – with a number of engineers having to collaborate and share information in order for the department to run successfully – and increasing numbers of manufacturers are starting to acknowledge the value that removing paper-led processes and moving to digital systems can deliver.

The changing demands of an industrial work space – from customer requirements and material shortages to production challenges – means engineers need to be able to access upto-date, accurate project details to take decisive action quickly.

Utilising electronic tablets, rather than relying on paper and pen, means that real-time data is available immediately via digital displays, speeding up the flow of information from engineer to engineer as well as eliminating the need to produce and share paper reports.

In a strict, process-reliant environment the speed at which valuable information can be accessed directly translates to cost savings, or the lack thereof. For example, should a product recall situation arise, having the ability to access product traceability information via a digital system could quickly isolate the bad batch, as opposed to having to search through a paper filing system to find the required information.

Another important consideration when it comes to paperless technology Control Engineering Europe

is how easy these systems make sharing and collaboration.

Having a platform for employees across a number of departments to share documentation, access real-time data and have the ability to edit and share ideas ensures the smooth flow of information and departmental processes.

Additional advantages It is clear that these benefits are closely related. However, there are a number of additional advantages to implementing paperless systems in a manufacturing environment that should also be considered. By utilising a paperless process, managers are able to plan for the next shift, generate status reports immediately via an automated system and identify documents by a searchable database, rather than by sifting through stacks of paper. Information associated with a particular production process can be captured digitally, so no additional time or errors occur by having to update log books.

By eliminating all of the various maintenance, planning and production steps that require manual actions within paper-based systems, engineers are freed-up to focus on more important value-adding tasks.

Paperless systems are also beneficial when confidential information needs to be stored securely. Rather than having to house bulky filing cabinets, paperless technology allows for virtual storage of information, freeing-up valuable floor space.

Malton Laser is always on the lookout for ways in which we can

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Charles Corner is managing director at Malton Laser.

streamline our in-house processes, enabling us to pass on valuable cost savings to our customers. We recently trialled the Panasonic Tough Pad FX-G1 system in our pressing department.

Having previously relied on paper-led processes, not only has this paperless system significantly reduced our paper consumption, but it has also enabled our engineers to save time.

The system allows the team to pull up the specification of any job at the touch of a button. Another major benefit is the amount of free space that has been gained by doing away with printing equipment, enabling more pressing and rolling equipment to be housed in the pressing department.

It is not just engineers, managers and company owners that recognise the importance of paper reduction.

Customers are now also far more conscious of a company’s environmental credentials.

When you consider the amount of paper that can accumulate between orders, reports, rotas and instructions, paperless systems seem an obvious choice for helping to reduce waste.

By removing all but necessary paper, a company can improve its organisation, but also significantly cut the cost of paper purchasing and disposal, ultimately resulting in reduced energy consumption.

October 2017

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