Control, Instrumentation and Automation in the Process and Manufacturing Industries November 2017
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Intelligent Connectivity From motion control up to the cloud
Calibration in hazardous areas
SPS/IPC/Drives 2017 exhibition preview
Radar level sensor keeps chemicals safe
TODAY’S
SMART DEVICES DEMAND SMARTER
SEMICONDUCTOR TEST SYSTEMS
NI’s Semiconductor Test System (STS) meets the test needs of today and tomorrow by providing engineers with an open, software-centric platform based on PXI instrumentation, TestStand test management software, and LabVIEW code module development. With lab-grade measurement quality and production-grade performance, the STS accelerates RF and mixed-signal tests from the characterization bench to the production floor, which lowers test time and cost.
Prepare for the future at ni.com/smarter-test. ©2017 National Instruments. All rights reserved. LabVIEW, National Instruments, NI, ni.com, and NI TestStand are trademarks of National Instruments. Other product and company names listed are trademarks or trade names of their respective companies. 28858
CONTENTS
Get ready to see the reality of digital transformation…
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
Welcome to the last issue of Control Engineering Europe for this year. And what a year it has been, with so many technology advances to report on. As the much-hyped move towards digital factories starts to become a reality, and as operating technology (OT) and information technology (IT) move closer together, it looks like this year the SPS/IPC/Drives event will be a busy one. The editorial team will be reporting on our findings in more depth in the February 2018 issue, but we have also previewed the event for you in this issue (pg 26). Our cover story this month also focusses on what visitors to the Festo stand at the exhibition can expect (pg 8).
issues facing machine designers, relating to the control solutions they need to provide to ensure that their equipment is capable of going on the digitisation journeys of their customers. (pg 10) It only remains for me to wish you a good end to your 2017, and we look forward to reporting on more exciting developments in 2018. Suzanne Gill Editor – Control Engineering Europe Suzanne.gill@ imlgroup.co.uk
This issue also includes a report on machine control which highlights the
INDUSTRY REPORT
TEST & MEASUREMENT
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20 Dr Darran Kreit discusses an old technique for measuring torque with angle sensors which is making a comeback due to new developments in inductive angle sensors.
Demonstrating the power of OPC-UA.
EDITOR’S CHOICE 6
Low energy HART modem; Turnkey asset performance solution improves asset reliability and availability.
CYBER SECURITY 22 Finding common ground in IT and OT convergence.
MACHINE CONTROL
EXHIBITION PREVIEW
10 Suzanne Gill collects the thoughts of solution providers relating to current trends and the requirements for successful machine control solutions today.
26 The annual SPS/IPC/DRIVES exhibition takes place from 28-30 November at the Nuremberg Messe in Germany.
FLOW & LEVEL CONTROL
ENERGY MANAGEMENT
12 There is no ‘one size fits all’ level measurement technology for overfill prevention systems, says Christoffer Widahl.
30 The drive towards energy efficiency is not as straightforward as it might appear. It is important to recognise and overcome any barriers to reap the benefits.
14 Find out how radar level sensing is offering a safe solution for chemical storage for a waste-to-energy plant.
CALIBRATION 16 A recent whitepaper discusses the issues surrounding calibration in hazardous areas.
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November 2017
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INDUSTRY REPORTS
DEMONSTRATING THE POWER OF OPC UA
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he OPC Foundation has created the first of a series of demonstration walls which will be displayed at Microsoft Technology Centers across the globe. The walls aim to show the power of the Microsoft commitment to embrace the OPC UA interoperability standard as a secure solution for seamless integration of OT and IT. They employ a variety of vendor devices from different verticals to demonstrate a bidirectional connection to Azure, including device-to-Cloud (D2C) where devices push telemetry data to the Azure IoT platform; and Cloud-to-Device (C2D) which allows for secure browsing of the rich OPC UA information model from the Azure IoT platform and optionally
‘command and control’ machines. Microsoft first demonstrated OPC UA integration into Azure IoT Suite at Hanover fair last year, where over 30 companies participated by providing OPC UA enabled devices for an integrated Connected Factory demonstration. This demonstration led to a decision, by Microsoft and the OPC Foundation, to actively promote the Connected Factory demonstration by developing freestanding OPC UA demonstration walls. Jason Zander, Corp. Vice President Microsoft Azure said: “We see OPC UA as a critical standard for ensuring interoperability between manufacturing processes and equipment. We have been working with the OPC Foundation to
build around 40 OPC UA device walls which are currently being distributed to the Microsoft Executive Briefing Center in Redmond, worldwide Microsoft Technology Centers, the IoT Labs in Redmond, Germany and China and the newly established IoT Innovation Center in Taiwan, to demonstrate the strong ecosystem with connected OPC UA devices and the Connected Factory preconfigured solution running on the Azure IoT platform.”
Wireless is key or enterprise wide IoT adoption Emerson is predicting that the next 10 years will see exponential growth in the adoption of wireless and pervasive sensing applications that help companies maximise safety and reliability, optimise production and enable Industrial Internet of Things (IoT) strategies. Wireless products are a key technology of Emerson’s Plantweb digital ecosystem. As many technologies of the past decade have accelerated and improved information at people’s fingertips, industrial wireless has given manufacturers the digital technology to access essential data to allow for better decision making and to improve operational performance. “Wireless is arguably the most impactful technology for industrial manufacturers since the introduction of digital instrumentation more than three decades ago,” said Bob Karschnia, vice president and general manager, wireless, Emerson Automation Solutions. “Over the past 10 years, industrial wireless, combined with smart sensors, has provided the foundation that will support cloud-based applications, remote monitoring and other Industrial IoT programmes over the next decade.” Collaboration with customers on early installations allowed Emerson to introduce the world’s first industrial
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wireless automation standard in 2007. Since then, Emerson has surpassed 10 billion hours of wireless operations across more than 32,000 networks. While initial adoption focused on harsh, remote and difficult to reach environments, wireless has gone on to expand automation ecosystems from core functions to new applications such as acoustic monitoring, corrosion detection and power consumption monitoring. New plant construction is leveraging wireless technology for other enterprise-wide applications, such as equipment health monitoring and energy management, with upwards of 20% wireless infrastructure. “Companies are increasingly turning to wireless as a cost-effective and highly efficient technology for fleet-wide performance optimisation. In the next 15 years, there could be 100% wireless plants, just as many homes today have cut the cord on wired telephone service,” continued Karschnia. Emerson wireless technologies – based on the WirelessHART standard approved by the International Electrotechnical Commission (IEC) in 2010 – are widely implemented in refineries, oil fields, offshore platforms, chemical plants and other industrial facilities around the world to obtain plant information on-demand.
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Control Engineering Europe
INDUSTRY REPORTS
Trusting autonomous systems The Defense Advanced Research Projects Agency (DARPA) unveiled a research programme called Assured Autonomy that aims to advance the ways computing systems can learn and evolve as well as emphasising the need for trust in autonomous systems as they become more common. Gregory Hale reports.
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uilding on breakthroughs in autonomous cyber systems and formal methods, the Defense Advanced Research Projects Agency (DARPA) unveiled a research programme called Assured Autonomy that aims to advance the ways computing systems can learn and evolve. Goals of the programme are to better manage variations in the environment and enhance the predictability of autonomous systems like driverless vehicles and unmanned aerial vehicles (UAVs).
Advances in sensing, controls, simulation “Tremendous advances have been made in the last decade in constructing autonomy systems, as evidenced by the proliferation of a variety of unmanned vehicles,” said Sandeep Neema, program manager at DARPA. “These advances have been driven by innovations in several areas, including sensing and actuation, computing, control theory, design methods, and modelling and simulation – deployment and broader adoption of such systems in safety-critical Department of Defense applications remains challenging and controversial.” The Defense Science Board Report on Autonomy, released in 2016, emphasises the need for autonomous systems to have a strong degree of trust. Assuring systems operate safely and perform as expected is integral to trust, especially in a military context, the report said. But systems must also be designed so operators can determine whether a system, once it has been deployed, is operating reliably, and, if not, can take Control Engineering Europe
of safety incidents of manned systems – such as the number of accidents per thousands of miles driven – and conducts physical trials to determine the corresponding incident rate for autonomous systems. Studies and analyses indicate that assuring safety of autonomous systems in this manner alone is prohibitive, requiring millions of physical trials, perhaps spanning decades.
Goal-oriented approach appropriate action. Assured Autonomy aims to establish trustworthiness at the design stage and incorporate sufficient capabilities so inevitable variations in operational trustworthiness can be measured and addressed appropriately. “Historically, assurance has been approached through design processes following rigorous safety standards in development, and demonstrated compliance through system testing,” said Neema. “These standards have been developed primarily for human-inthe-loop systems, and don’t extend to learning-enabled systems with advanced levels of autonomy. The assurance approaches today are predicated on the assumption that the systems, once deployed, do not learn and evolve.” One approach to assurance of autonomous systems that recently has garnered attention, particularly in the context of self-driving vehicles, is based on the idea of ‘equivalent levels of safety,’ i.e., the autonomous system must be at least as safe as a comparable human-inthe-loop system that it replaces. The approach compares known rates
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Simulation techniques have been advanced to reduce the needed number of physical trials, but offer very little confidence, particularly with respect to low-probability, highconsequence events. In contrast to prescriptive, processoriented standards for safety and assurance, a goal-oriented approach, such as the one espoused by Neema, arguably is more suitable for systems that learn, evolve, and encounter operational variations. In the Assured Autonomy program, researchers will aim to develop tools that provide foundational evidence that a system can satisfy explicitly stated functional and safety goals, resulting in a measure of assurance that can also evolve with the system. Gregory Hale is the editor and founder of Industrial Safety and Security Source (ISSSource.com), a news and information Website covering safety and security issues in the manufacturing automation sector. This content originally appeared on ISSSource.com, a Control Engineering content partner. www.controleng.com. November 2017
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EDITOR’S CHOICE
Condition monitoring for mobile equipment The modular X90 control and I/O system, from B&R, can now be equipped with
Low energy HART modem ProComSol has released what it believes is the world’s first Bluetooth Low Energy HART Modem. Bluetooth 4.0, which includes Bluetooth Low Energy (BLE), offers many advantages over older Bluetooth standards making it particularly suitable for mobile device communications. The HM-BLE HART Modem Bluetooth Low Energy takes advantage of the low energy features of the Bluetooth 4.0 standard. It contains a rechargeable Li-Ion battery that will last for many days on a single charge. In combination with a Smart Device Communicator App on a mobile device the HM-BLE becomes a full functioned, DD-based HART Communicator that can perform full configurations of valves, multivariable devices, and complex devices such as radar level and Coriolis flowmeters.
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condition monitoring functions to allow operators to continuously monitor the status of mobile equipment. The system help determine exactly which components require maintenance and when. Problems can be detected in their early stages and corrected before they result in unplanned downtime. Typical applications are said to include continuous monitoring of rotating machine components such as hydraulic assemblies, belts, gears and motors.
Turnkey asset performance solution improves asset reliability and availability UK-based IoT systems integrator and managed service provider, InVMA, has introduced a turnkey asset performance management solution – AssetMinder – which allows users to securely connect to mobile and fixed assets, regardless of their type. With the resulting data cloud-based analytics can be utilised to improve the reliability and availability of those assets, minimise total cost of ownership, and reduce operational risks. Customers across any industry can use the tool to monitor and manage data from all types of assets and retrofitted sensors for properties such as location, level, temperature, vibration, moisture, humidity or flow and can be alerted when pre-determined thresholds or rules have been met. AssetMinder is offered as a hardware/ software solution which includes connecting to assets using most standard or proprietary protocols. It allows for the support of purely analogue signals too. The customer assets are connected, via serial, USB or Ethernet port or analogue or digital I/O, to the AssetMinder gateway. The gateway monitors the data from the asset (and its own location), stores it and identifies when
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Valve position sensing in the great outdoors Traditionally, limit switch boxes with mechanical, magnetic or inductive contacts are used to detect the position of the valve in valve actuators. However, open solutions are becoming popular due to their compact design and easy installation. The new F31K2 dual inductive sensor with ‘outdoor’ functionality completes the range of Pepperl+Fuchs open solutions. The sensor and control electronics are integrated in a single module enclosed in a tough, translucent housing together with the terminal compartment. The materials used for the housing are resistant to high temperatures, UV and corrosion. Typical areas of use include outdoor applications with Ex-nA approval for zone 2/22. A 4-wire DC version is available as an electronic output stage. The new F31K2 completes the Pepperl+Fuchs product program of open solutions for valve position feedback on valve actuators’ with dual inductive sensors. The products in the range meet all the requirements of modern applications in process automation, from the compact F25 for small standard actuators to F31 sensors with or without a terminal compartment and flexible actuator system to the ultimate F31K2 outdoor sensor.
a data parameter has moved versus a completely configurable set of rules. The data payload (up or down) is secured and sent to AssetMinder via 3G/2G where it is historised. The information is then displayed in a user-configurable dashboard, which is displayed on a web browser. Alerts via SMS, voice or email can be configured. Control Engineering Europe
COVER STORY
DECENTRALISED INDUSTRY 4.0 AUTOMATION PLATFORM SPS/IPC/Drives exhibition visitors will be able to experience the flexibility of Festo’s MultiCarrier-System (MCS) with batch sizes down to one. Also on display will be Festo’s new IP20 and IP65 rated automation platforms with IoT gateways and a direct link to a cloud.
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xplaining what contribution Industry 4.0 is already making to the booming automation technology sector, Eberhard Klotz, head of the Industry 4.0 campaign at Festo, said: “Industry 4.0 is far more than a marketing hype. It is backed up by specific projects and products.” An example of this is Festo’s membership of the Industry 4.0 platform, which advises the German government. Festo also develops basic and further training concepts and measures for new career paths, and carries out visionary research in the Bionic Learning Network with autonomous and self-controlling systems such as BionicANTs or the prototypes of interactive, collaborative, pneumatic seven-axis robots like the BionicCobot.
Industry 4.0 products Festo is already delivering some real automation technology products for Industry 4.0: integrated drive packages, modular valve terminals with OPC-UA, CPX-E System
IOT gateways, decentralised CODESYS controllers and autonomous mechatronic subsystems with IP20 or IP65. In addition, there are apps and cloud concepts. “However, the most exciting innovation in pneumatics must be the Festo Motion Terminal,” enthuses Klotz. It is the first automation platform to be designed as a cyber-physical system which is able to replace up to 50 individual pneumatic functions. “Festo is able to draw on a wealth of user experience from pilot production projects in our Scharnhausen Technology Plant,” said Klotz. “This includes topics such as energy management and optimisation as well as innovative one-piece-flow concepts based on standardised networking, mobile maintenance with tablets or automated, flexible test systems for individual products. This experience is also incorporated into our new products.”
CPX-E automation platform The CPX-E system is a high-performance system for factory automation. It Systemaufbau und Systemintegration
Ethernet ready for Industry 4.0 CPX IoT Gateway Host PLC
Master CPX-E-CEC Motion Control System
CPX-E Control System
Encoder Ethernet IO-Link Valve Terminal HMI
CPX-E Remote I/O Vision
CPX-E Remote I/O System
CPX Terminal
Third Party Products
Figure 1: Variants of the CPX-E system.
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CMMP-AS/CMMP-ST
Safety-PLC
Figure 2: System configuration and integration.
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consists of individual function modules that can create a modular, compact and flexible system. Depending on the module combination, the system can be used as a purely remote I/O system or as a (centralised or decentralised) control system for factory or process automation. From a functional point of view, the CPX-E control units are designed as EtherCAT master controllers and motion controllers. These are high-performance control units which can be used both for extensive PLC functions and, in the Motion Control M1 variant, also for multi-axis applications with interpolation. The basis for this is the programming system CODESYS V3, with additional software libraries for both simple and complex motion control applications: • PLCopen Parts 1 and 2 • Robotics (PLCopen Part 4) • Cam disc editor • CNC editor (DXF file import) A further special feature of the control units is an integrated PROFINET device or EtherNet/IP slave interface. This allows a decentralised control system to be integrated into appropriate host systems. The OPC UA interface is available for Industry 4.0. Bus modules for PROFIBUS, PROFINET, EtherCAT, EtherNet/IP (and Modbus/TCP) are available for the configurations as a remote I/O. In addition to the usual digital and analogue I/O modules, IOLink® master modules and a counter module are available. So, Festo can offer a portfolio for the decentralised automation of sub-systems and small machines with IP20 and IP65, all in line with a flexible Industry 4.0 host environment. Control Engineering Europe
You rely on maximum flexibility. You are looking for intelligent and intuitive solutions. We are making pneumatics go digital.
Pneumatics goes digital: world first Festo Motion Terminal VTEM Including IoT/Cloud services. Different functions, always the same hardware! Whether for standard directional control valve functions or for presetting the travel time, you can now control functions using apps. For maximum flexibility and standardisation, reduced complexity and installation times, and many other benefits. Find out more: awww.festo.com/motionterminal
28. – 30. November 2017 Nßrnberg Messe Hall 9, Stand 361
MACHINE CONTROL
MACHINE CONTROL FOR today and tomorrow Suzanne Gill collects the thoughts of solution providers relating to current trends and the most important requirements for successful machine control solutions today.
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any machine control end users are currently in a transitional state, moving towards the requirements of a more connected, smart, industrial environment. This means that machine builders now need to be delivering solutions that are capable of going on this IIoT journey with their customers. Paul Davies, solutions architect – Architecture & Software at Rockwell Automation, believes that it is still vital for machine builders to take a customercentric approach to machine building and to take the time to truly understand the very specific needs of every customer. According to Davies there are three machine building requirements that should be considered as central tenets in meeting the needs of the market as it is, and as it is becoming. “These requirements can be thought of in terms of design, development and delivery,” said Davies. “From a design perspective, there is a need to produce machines as quickly and cost-effectively as possible. The production process of the machines being built should be under constant scrutiny to ensure they are as efficient and simple as possible.” From a development perspective, machines need to be flexible enough to fit existing customer environments and infrastructures. Davies said: “The use of open architecture for control and engineering requirements, where possible, is vital. The machine must also meet the needs of evolving end users and consumer demands for flexibility. Giving end-users the capability to, for example, change the size, shape, flavour or packaging varieties will make a machine more valuable to them.
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Combining the hardware to achieve flexibility, with open control and software applications, that allow for quick change-overs of product lines, will result in a compelling package which can help the end user meet the demands of modern production.” Finally, from a delivery perspective, Davies says it is important to remember that end users do still have a variety of more traditional requirements, such as machine availability and efficiency, in addition to the more recent considerations based around connectivity, such as visibility of machine data that will allow users to further improve the yield or reduce the costs of running their machine. “To that end, building-in analytics packages that feed data back to the end user (and potentially to the machine builder) is important. With remote monitoring dashboards containing information about the machine’s OEE, machine builders can offer servitisation models, as well as improving the design of the machine according to experience of how equipment performs in real terms.” So, wherever an end user may be on their IIoT journey, they will need to know that the machine they are buying has a degree of future-proofing built in. By nurturing the relationship with their end users, exploiting IIoT connectivity and striving for open flexibility, machine builders could benefit from the shift towards calculating the total cost of ownership rather than purchase price when making purchasing decisions. Michael Thomas, head of production machines at Siemens Digital Factory Division, believes that plants and machines need to be flexible, simple to use and quick to modify or retrofit,
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while, at the same time helping end users to minimise costs. “Every machine or plant is different in terms of system performance needs and complexity,” he said. “Increasingly intelligent motion control solutions are now merging performance and modularity and connecting powerful hardware with efficient engineering and innovative software to help achieve all of these goals,” said Thomas.
Digital twins
Thomas highlighted another important development for the machine control designer – the creation of a digital twin to act as a precursor to the actual machine. “This digital representation helps to facilitate easy and cost-effective testing and optimisation of the machine before it is physically created – resulting in big time savings,” he said. “One possible key to success in this area is virtual commissioning,” suggests Thomas. “A digital twin can facilitate easy and cost-effective testing and optimisation of a machine or plant. In addition, alternative control concepts can be investigated at the planning phase without too much effort. In this way, efficiency checks also become an integral component of the design. This solution also allows for subsequent adaptation of the machine.”
Constants Benny Magrafta, head of software R&D at Unitronics, has been involved in automation for over 25 years. “During this time two machine control requirements have remained constant,” he said. “These are cost and time. More recently, another imperative has joined these needs – a requirement to deliver Control Engineering Europe
MACHINE CONTROL solutions that are smart factory-ready. “Cost is an age-old issue,” said Magrafta. “Customers will always want a Mercedes for the price of Volkswagen. They want solutions that stay in budget but which also meet all of their requirements.” He goes on to say that the cost of the controller should never be the most important factor in a specification decision. “Select a PLC that is rugged enough to meet the needs of the application environment and which also has sufficient memory to support I/O and execute the programme,” he said. Magrafta goes on to highlight the importance of software, particularly when it comes to helping speed up time to market. “Consider whether your choice of controller has the ability to store code and functions; or whether it includes HMI screens that enable you to re-use your work and save time. Look for software that has a short learning curve and maybe even advanced tools for collecting and manipulating production data, recipe management, built-in alarms, and multi-language support. “The right software should allow engineers to create HMI screens worthy of a graphic designer! Setting up and
implementing communications can be a major time-waster, so look for software that enables rapid set up and implementation of a broad range of communication protocols – from fieldbus to advanced communications.” In conclusion, Magrafta said: “Machine builders need to make sure that their choice of controller helps them ensure that their offerings are Industry 4.0 ready. For example, with a built-in PLC webserver for remote production monitoring and management; SNMP to integrate the PLC into IT infrastructure as an IT asset; and SQL to interface with factory ERP/MRP servers to communicate directly with a facilities’ backend systems.” David Randall, business development manager at Lenze also commented on the requirements for today’s machine control systems. He lists what he believes are the top three considerations: • Fast, flexible programming – In the pursuit of competitive advantage, end users want more capable, flexible and highly customised equipment, putting greater pressure on machine builders and system integrators, requiring the rapid, reliable development of complex, bespoke control applications.
In addition to age-old machine control demands, a recent new requirement relates to the need to deliver solutions that are smart factory ready.
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The advent of pre-developed and tested function blocks – such as Lenze’s FAST blocks – eliminates much of the heavy-lifting in control software development, reducing programming time by up 70%. This allows more time to be spent on the machine features that really make a difference for their customers. • Seamless connectivity – In the modern production environment, data is king. Smart data analysis techniques are delivering significant improvements in the areas that matter most to equipment owners – including quality, reliability, productivity and efficiency. For machine control systems this means the ability to record detailed information on equipment performance – and to share that data via fieldbus connections – are now basic requirements. For machine builders, however, the big opportunity comes not simply from the generation of data, but from the ability to transform the data into something that adds value for the customer. This can be achieved in a number of ways – from remote monitoring and troubleshooting to the development of automated intelligent predictive maintenance solutions. • Simulation and augmented reality – Machine builders and end users both want solutions that work first time. Rising complexity and tight development timescales are relentlessly squeezing the time and money available to build prototypes or fix issues that emerge during testing and commissioning. Virtual prototyping, of individual machines or even complete factories, can now offer a way to evaluate new concepts and identify issues or improvement opportunities. The advent of virtual and augmented reality technologies means that operators can participate in the simulation too, allowing the ergonomics and human interface details to be evaluated earlier and more effectively. Motion and control equipment makers need to embrace this trend and support their hardware offerings with digital models and simulation tools. November 2017
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FLOW & LEVEL
LEVEL MEASUREMENT FOR OVERFILL PREVENTION APPLICATIONS There is no ‘one size fits all’ level measurement technology for overfill prevention systems, says Christoffer Widahl.
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he overfilling of tanks and vessels is a leading cause of serious incidents in the process and bulk liquid storage industries, especially as the materials involved are often hazardous, flammable and even explosive. For companies storing hazardous materials, investment in a robust Overfill Prevention System (OPS), complying with current safety standards, is essential. IEC 61511 provides best safety practices for the implementation of a modern OPS within the process industry. Additionally, API 2350 provides minimum requirements to comply with modern best practices in the specific application of non-pressurised aboveground large petroleum storage tanks. Minimising the risk of overfills involves many independent protection layers. The primary layer is the Basic Process Control System (BPCS), which monitors and controls the production processes. A correctly functioning BPCS will prevent the need for the other layers to become active. The second layer of protection is the safety layer (typically denoted as an OPS), which must remain separate
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Prevention
SIS
Basic Process Control System (BPCS)
Mitigation
Overfill Prevention System (OPS)
and independent of the BPCS to provide redundancy. This should prevent an overfill from occurring if there is a failure or problem with the BPCS. The next layer is the passive protection layer, which provides secondary containment such as dikes or concrete walls. Finally, there is the emergency response layer, which involves alerting the emergency services. There are two basic types of OPS – Manual Overfill Prevention Systems (MOPS) and Automatic Overfill Prevention Systems (AOPS). MOPS are seen to be easier to implement and less complex, with lower initial costs. They typically consist of a level sensor or switch that transmits an audio-visual alarm to an operator, notifying them to take appropriate actions such as manually opening or shutting off a valve to prevent an overfill. AOPS include the ability to achieve higher risk reduction factors, shorter response times, and a reduced workload for operators. They typically consist of a level sensor, a logic solver and a final control element in the form of actuated valve technology. Within overfill prevention solutions, there is no ‘one size fits all’ level
Emergency response layer Fire brigade
Passive protection layer
Secondary containment (e.g. dike)
Safety layer Basic process control system
DCS and tank gauging system/inventory software
Minimising the risk of overfills involves many independent protection layers.
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measurement technology and system. Different applications have their own challenges and requirements, so it is important to select the appropriate technologies for each. These include: Electro-mechanical float and displacer switches: Used for point level, interface, and density applications, where the buoyancy of the displacer in the fluids is the primary measurement principle. Displacers have moving parts that require frequent cleaning and replacement. They are affected by mechanical vibration and turbulence, the mechanical parts can give false readings, and maintenance costs can be high. Displacers are increasingly being replaced by modern electronic technologies that offer greater diagnostics and reliability, and lower lifecycle costs. Vibrating fork switches: A point level technology which operates using the concept of a tuning fork. Two prongs are immersed into the process vessel and an internal piezo-electric crystal oscillates them at their natural frequency. This frequency varies as the fork is immersed in the medium. Any changes are detected by the electronics, providing an effective means of detecting the presence or absence of liquids. With no moving parts to wear or stick, vibrating fork technology is less prone to failure than other technologies. Operation is virtually unaffected by flow, turbulence, bubbles, foam, vibration and changing density. Guided wave radar: Low energy microwave pulses are guided down a probe, which is submerged into the process media. When the microwaves are reflected from the product surface to the transmitter, the level can be measured. Because a proportion of the emitted pulse continues down the probe, an interface can also be detected. Guided wave radar transmitters are easy to install, and no compensation
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FLOW & LEVEL is necessary for changes in density, dielectric or conductivity of the medium. Changes in pressure, temperature and most vapour space conditions have no impact on measurement accuracy. The technology is unaffected by high turbulence or vibrations, and buildup has practically no effect, meaning that there is no need for recalibration. With no moving parts, maintenance requirements are low. Non-contacting radar: Non-contacting radar gauges use pulse radar or Frequency Modulated Continuous Wave (FMCW) techniques. Microwaves are emitted towards the surface and reflected to the sensor, with the level being directly proportional to the time taken between transmission and reception of the microwave signal. With FMCW, the radar transmits a continuous signal sweep with a constantly changing frequency. The frequency of the reflected signal is compared with the frequency of the signal transmitted at that moment. The difference between these frequencies is proportional to the distance from the radar to the surface, thus the level is measured. This technology is unaffected by density, viscosity, and conductivity, and little affected by coating and vapours. It is easy to install and commission, and as there is no contact with the medium and the radar has no moving parts, little maintenance is required. 2-in-1 technology: Non-contacting radar level gauges featuring 2-in-1 technology can be used simultaneously in both a BPCS and an OPS. This technology is used in Emerson’s Rosemount 5900S 2-in-1 radar level gauge, which consists of two separate and independent electrical units and a common antenna. This solution allows for cost-efficient safety upgrades of existing tanks by replacing a single BPCS or AOPS sensor with two continuous level measurements, with little or no tank modifications.
Application types There are three general application types in the process and bulk liquid Control Engineering Europe
storage industries where overfill prevention measures are employed. These are process vessels and storage tanks within process applications, and storage tanks deployed within the bulk liquid handling industry. Each presents different challenges, so the most appropriate overfill protection technology differs accordingly. Process vessels: The choice of technology to use as part of the AOPS depends on the vessel’s shape, size and design. For example, on cone-shaped tanks level sensors are top-mounted, which creates several options, including guided wave radar transmitters, non-contacting radar gauges and vibrating fork switches. Many vessels have restrictions including agitators, heat exchangers and other internal structures that require the use of a separate chamber to perform the level measurement. For these applications guided wave radar transmitters are recommended. Should a side-mounted solution be required, vibrating fork switches provide the ideal solution. Within distillation columns, involving high temperatures where vapours rise through the column, different components will condense at different temperatures and accumulate for withdrawal. Here chambers are required, and guided wave radar transmitters are commonly used for the AOPS. Blending tanks have agitators, which place restrictions on sensors that protrude into the tank. Using a top-mounted, non-contacting radar is usually a good solution for an AOPS sensor. Sloshing, rapid level changes, vortices and foaming are common in this application, making it important to select a modern and highly capable radar device. In boiler drum applications, SIL 3 guided wave radar transmitters – which are unaffected by changes in process conditions – are required for AOPS, usually with triple redundancy. Tank monitoring system: Tank monitoring system applications include those consisting of multiple small or medium-sized vessels or a smaller tank
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farm, typically 5-20 tanks, requiring an automated system to provide level monitoring, but not necessarily control. These systems ease the workload by removing manual measurements, and increase personnel safety by reducing the need to climb tanks. Tank monitoring would typically involve gross volume calculations, but not fiscal measurements. For these applications, the recommendations for overfill sensors are like those provided for single vessel applications. Correct sensor choice would therefore be determined by the tank type, the available openings, and the liquids stored within. Bulk liquid storage: In bulk liquid storage applications, an Automatic Tank Gauging system (ATG) is typically used as the BPCS, to measure level and calculate inventory. These systems deploy radar technology offering exceptional levels of accuracy, which is required due to the value of liquid being measured. A small inaccuracy of the level can equate to thousands of gallons of volume uncertainty. The AOPS for bulk liquid storage tanks typically consists of a noncontacting radar gauge, a logic solver and an actuator. Alternatives would be to use a vibrating fork switch or a guided wave radar transmitter. Many bulk storage tanks have floating roofs, which place special demands on the level measurement and overfill prevention solution. Best practice is to measure through a still pipe, which requires high precision, non-contacting radar for accuracy. If the tanks do not have a still pipe, an option is to ‘shoot the roof’, which entails putting a reflective metal target on top of the roof to capture the radar beam.
Conclusion Effective overfill prevention systems can reduce risk and ensure safety compliance, but with no ‘one size fits all’ level measurement technology, understanding the application and its specific challenges is crucial. Christoffer Widahl is a senior strategic product manager with Emerson, based in Gothenburg, Sweden. November 2017
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FLOW & LEVEL
RADAR LEVEL SENSOR
keeps chemicals safe
Control Engineering Europe finds out how a radar level sensor is offering a safe solution for chemical storage at a UK-based waste-to-energy plant.
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ory Riverside Energy is a waste to energy plant, near London in the UK. It utilises waste to provide a safe, secure, affordable and sustainable energy supply. As one of the largest operations of its kind in the UK, the facility generates around 525,000 MWh of electricity each year from processing 750,000 tonnes of waste. The energy from waste combustion process presents many challenges – from bulk handling of the incoming waste streams to the monitoring and control of the outputs to the environment. At various stages chemicals are also used on the purified water systems. These chemicals are stored in tanks at strategic points across the plant. In one such area there are four polypropylene plastic chemical tanks containing Sodium Hydroxide (Caustic Soda) 32% and Hydrochloric acid (32%) – each product
utilising a ground floor bulk storage vessel and a smaller ‘day tank’ on an upper floor, used for process-critical dosing and neutralisation. Accurately monitoring the level in these tanks became a headache for engineers at the plant. All of the tanks had been originally supplied fitted with low-cost ‘back pressure’ level systems that failed due to corrosion and build up. With fumes and vapours escaping through the housings, they were unreliable, inaccurate and unsafe. Sensors used in such applications need to be properly specified. They need to be made of the right materials and of the right construction. During fitting or removal, both the sensor and process also require containment, isolation and decontamination, as well as requiring comprehensive PPE for those undertaking the task. This often results in mandatory closing off an
area of the plant while any equipment installation or removal is taking place on the vessel. These necessary health and safety procedures incur extra safety risks and cost. Stored chemicals – especially those that are highly acid or alkali – can leave residues and can give off vapours and fumes which can result in a hazardous environment for personnel. At Cory, these chemical products needed to be careful monitored and accurately measured to remove any risk of overfill, and ensure the process has ample supply. “We wanted to find a new level system that would avoid any repeat of the issues experienced with the original sensors, ideally eliminating process contact,” explained a Cory instrument engineer. VEGA proposed the use of its contactless radar sensors, mounted above and outside the vessels looking through the vessel top to measure the liquid level inside.
Contactless measurement
VEGAPULS radar mounted off ‘unistrut’ bracket above the bulk storage vessel looking through the top to measure Hydrochloric acid level inside.
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Radars are mounted above each of the smaller acid and caustic day tanks measuring the liquid level from outside the vessel, for ultimate safety.
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For liquid level measurement of chemicals a sensor generally requires a process connection into the vessel to get its ‘sensing part’ to connect into the process – even when using a top mounted ‘non-contact’ device – it could be a rod, cable or diaphragm. To measure any process variable completely, without contact, would provide many benefits; from longevity of operation, protection from chemicals and the process, and increased safety through reduction or elimination of exposure to harmful substances. Radar has the ability to measure the level of a liquid through an opaque plastic vessel top or window on a nozzle, completely from Control Engineering Europe
FLOW & LEVEL the outside. More companies today are specifying plastic vessels and tanks for chemical and bulk liquid storage. They are quicker to make, are generally more cost-effective, and have good chemical resistance. They can also offer a longer lifespan and low maintenance requirements than equivalent steel painted, lined or coated vessels. Many even come with ‘integrated bunds’ for overflow or overspill protection. Plastic IBC’s are now also one of the most common vessels for bulk transport of intermediate quantities of liquid. Radar technology can be used to measure liquid level through the top of all these vessel types.
How does it do it? Radar uses microwave technology so is able to transmit signals through plastic and other non-conductive materials (like glass and ceramic) and reflect back off a liquid level inside. With a good dynamic range (sensitivity) it can also deal with
any condensate or sublimation on the inside of the vessel roof. Using 80 GHz radar offers several benefits. Firstly, the higher focusing means it achieves good penetration through the plastic vessel roof, it also offers more mounting position options and is less likely to pick up any unwanted false signals. It also offers wide measuring range capabilities, from very small to very tall vessels – up to 30m high. It also offers high dynamic sensitivity to handle condensation and build up caused by fumes or sublimation from the products inside the vessel. It can even measure low-reflectivity, oil-based hydrocarbons in some applications.
Installation best practice Installing the radars above the tank on a suitable bracket perpendicular to the liquid surface is essential. A small gap between the sensor and the vessel top is vital. A sloping roof-top is ideal for
a microwave sensor to look through, as any unwanted signal reflected back by the roof is deflected away from the radar. If this is not possible and the roof is flat, such as with an IBC, the sensitivity of the radar should easily be able to overcome any reflection. If a tank is outside, a cover is necessary to stop snow forming directly beneath the sensor and the sensor needs to be positioned so that water does not pool directly beneath it. However, rainfall down a sloping roof tank situated outside should not affect sensor performance. Cory Riverside Energy now has its first radar successfully working through the roof of the bulk chemical tank, mounted on a simple ‘unistrut’ frame and a VEGAsupplied radar bracket that attaches to them. “The sensors are simple to use and the Bluetooth communication for set up, via smart device App or with a PC and PACTware, makes it so much easier,” said the Cory engineer.
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CALIBRATION
Calibration in hazardous areas A recent whitepaper from Beamex discusses the issues surrounding calibration in hazardous areas.
A
hazardous area is an area – indoors or outdoors – that may contain flammable substances. This could be a liquid, gas, vapour or dust. The area may contain a flammable substance all of the time, most of the time, or only in specific situations. This is why there are many different levels of hazardous areas and also many different types of Ex-rated calibration equipment for use in hazardous areas. There are many ways to design electrical equipment to make it suitable for hazardous areas. Calibration equipment, for example, is often designed in such a way that it cannot provide enough energy to cause the source of ignition, spark or heat.
Liquids Based on their flashpoint – the lowest temperature of a liquid at which it produces sufficient vapour to form an ignitable mixture with air – liquids are classified as either flammable or combustible. Flammable liquids may ignite at normal working temperatures, while combustible liquids burn at higher temperatures. Often 37.8°C is considered as the temperature limit. Flammable liquids have a flashpoint below this
Table 1.
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temperature and combustible liquids above it. Flammable and combustible liquids themselves do not burn, it is the mixture of their vapours and air that burns. Some liquids have a low flashpoint. For example, gasoline has a flashpoint as low as -40°C. It produces enough vapours in normal environmental conditions to make a burnable mixture with air. Combustible liquids have a flashpoint way above normal environmental conditions, and therefore have to be heated before they ignite.
Explosion triangle In order to prevent an explosion, one of the three elements of the Explosion Triangle – flammable substance, air and source of ignition – must be eliminated. In practice, eliminating the source of ignition would be the most sensible. There are various techniques employed in electrical equipment that make them safer for hazardous areas. These different techniques fall into two main categories – eliminate the source of ignition (Exe, Exi) or isolate the source of ignition (Exd, Exp, Exq, Exo, Exm). Table 1 describes some of the different techniques. It also shows the letter written on the equipment classification. The Exi ‘Intrinsically Safe’ technique is the most commonly used and is most suitable protective technique for electrical calibration equipment. Intrinsically Safe equipment is designed for any situation; it will not provide enough energy to generate sparks or high surface temperatures, even in the case of a faulty device. Inside an Exi device, the Exm (‘Encapsulated’)
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technique may also be used for certain parts of the equipment (as in a battery pack).
Hot work permit Using non-Ex calibration equipment in a hazardous is still be possible, but requires special approval from the safety personnel in the factory. It usually also requires the use of safety devices, such as personal portable gas detectors, to be carried in the field while working. Using equipment rated Ex correctly is easier, as it does not require any special approvals. The international standard family of IEC 60079 defines the different standards for related regulations. The IECEx scheme involves international cooperation based on the IEC standards. The objective of the IECEx system is to facilitate international trade in equipment and services for use in explosive atmospheres, while maintaining the required level of safety. The ATEX directive was introduced to unify hazardous equipment and work environments within the EU. The zone classification specifies how likely it is for a certain flammable substance to occur in the atmosphere in a certain area. The classification has been developed to specify the different hazardous areas – Zones. (See Table 2) In ATEX-directive Group II, equipment
> p18
Table 2. Control Engineering Europe
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CALIBRATION < p16 is divided into product categories specifying the use of the equipment in different zones. The product categories of the Group II equipment are specified as following: • Product category 1 – Very high safety level. Can be used even in Zone 0 (and Zone 1 & 2). • Product category 2 – High safety level. Can be used in Zone 1 and 2 (but not in Zone 0). • Product category 3 – Normal safety level. Can be used in Zone 2 (but not in Zones 0 & 1). In the IEC standards, the same thing is expressed using EPLs (Equipment Protection Level). EPLs are specified using nearly the same categories: • EPL a – Very high safety level. Can be used even in Zone 0 (and Zone 1 & 2). • EPL b – High safety level. Can be used in Zone 1 and 2 (but not in Zone 0). • EPL c – Enhanced safety level. Can be used in Zone 2 (but not in Zones 0 & 1). A product category 1/EPL a device (can be used in Zones 0, 1 and 2) is safe even in the event of two simultaneous faults in the device. This means that all protective safety circuits are tripled. A category 2/EPL b device has doubled safety circuits and can be used in Zones 1 and 2. Category 3/EPL c devices have single safety circuits and can be used in Zone 2 only. If there is a need to use electrical equipment in a hazardous area classified as Zone 1, the product category 1 and 2 equipment can be used. If the area is Zone 0, only equipment in product category 1 is allowed. If the Zone is 2, any product category (1, 2 or 3) equipment is allowed. A product in category 1 has the
Table 3.
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Group III: Electrical equipment in Group III is intended for use in places with an explosive dust atmosphere other than mines susceptible to firedamp. It is subdivided according to the nature of the explosive dust atmosphere for which it is intended.
Temperature class
number 1 in its ATEX marking , for example ‘II 1 G’. It also has a letter ‘a’ in its marking for EPL, for example ‘Ex ia’. Consequently, it is important to know the zones where the calibration equipment will be used and select the equipment accordingly.
Equipment grouping Electrical equipment for explosive atmospheres, according to the IEC 60079-0 standard, is divided into the following groups: Group I: Electrical equipment in Group I is intended for use in mines susceptible to firedamp. Group II: Electrical equipment in Group II is intended for use in places with an explosive gas atmosphere other than mines susceptible to firedamp. Electrical equipment in Group II is subdivided according to the nature of the explosive gas atmosphere for which it is intended. Group II subdivisions include IIA, a typical gas is propane; IIB, a typical gas is ethylene; IIC, a typical gas is hydrogen. This subdivision is based on the maximum experimental safe gap (MESG) or the minimum ignition current ratio (MIC ratio) of the explosive gas atmosphere in which the equipment may be installed (see IEC 60079-201). Equipment marked IIB is suitable for applications requiring Group IIA equipment. Similarly, equipment marked IIC is suitable for applications requiring Group IIA or Group IIB equipment.
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The temperature class specifies the maximum surface temperature in the equipment. This is important to take into account and assure that it matches with the flammable gas that may be present in the plant’s own hazardous area. The temperature classes and temperatures are shown in Table 3. Some equipment may also have a maximum surface temperature specified as a certain temperature being in between the classes. Depending on the type of flammable substance in a certain area, the flashpoint and auto-ignition temperatures will be different.
Environmental conditions It is important to ensure that the equipment is suitable for the environmental conditions where it will be used. For example, the safe operating temperature of the device must match the temperature in which the equipment is used in a plant. In wet and dusty conditions, the protection rating of the equipment casing needs to be considered. This can be classified IP (Ingress Protection) or NEMA. Different protective techniques may require different classification on the casing. It is also important to remember that the casing of some Ex equipment is made out of non-static material to avoid accumulation of any static electricity. Depending on the classification, there are limits on the size (static) of labels that can be put onto the device. For example, Group I equipment, for Zone 0, with gas Group IIC, may have a label sizing an area of maximum 4cm2. It is important to keep that in mind before attaching any identification labels onto Ex equipment. Control Engineering Europe
UK INDUSTRY REPORT
TIME TO TORQUE ABOUT ISO 6789-2:2017
Neill Brodey outlines key changes to the newly revised BS EN ISO 6789-2:2017 standard and what this means for manufacturers and tool users.
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he BS EN ISO 6789:2003 divided requirements into three sections – design conformance testing; quality conformance testing and recalibration. The intention was to allow different groups of users to identify the relevant clauses for their needs. The 2017 edition takes this logic further and divides the standard into two distinct parts. As a result, the type of documentation supplied with tools has changed. With new requirements for design and quality control, Part 1 relates to the manufacturer and conformance, whereas Part 2 focuses more closely on the calibration of torque tools. In essence, the key changes have been made to protect the word ‘calibration’, which is often used too casually. Calibration is defined by ISO as: ‘a set of operations that establish, under specified conditions, the relationship between values of quantities indicated by a measuring instrument or measuring system… and the corresponding values realised by the standards.’ While most of the requirements from the 2003 edition are carried into Part 1, there are new design requirements which manufacturers need to be aware of. These include the introduction of new maximum torque values for hexagonal output drives. Additionally, changes have been made to certain quality conformance requirements. For example, the time to attain the last 20% of the torque application during testing has now been more tightly defined according to the size of the torque tool.
Control Engineering UK
Manufacturers will also now need to state that the tools adhere to the new requirements of Part 1 by supplying a ‘Declaration of Conformance’ with the tool, as opposed to a ‘Calibration Certificate’.
Part 2 inclusions Part 2 of the standard now covers the traceable calibration of the tool, and the requirements of the calibration equipment. This includes highlighting the steps that need to be taken to distinguish uncertainty factors that may cause the calibration values to vary from calibration to calibration for that particular torque tool. Therefore, should a manufacturer also wish to produce a certificate of calibration, they must issue it in accordance with Part 2 of the new ISO 6789 standard. For a new torque tool model that has not yet been seen by the laboratory, calibration to this standard takes around 60 minutes. What does this mean for the tool user? Those who were previously content with buying a new torque tool and putting it into service on the basis of the ‘Calibration Certificate’ supplied by the manufacturer, can still do so. However, in its place, there will be a ‘Declaration of Conformance’. This
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comes with a date of issue, but retesting should take place within 12 months, or 5,000 use cycles of the tool being put into use, rather than the date of the Declaration of Conformance. However, for those working in environments with stricter quality control processes that require a traceable ‘Calibration Certificate’ issued by an accredited laboratory, it will be necessary to request that the tool be tested to Part 2 of the standard as well. This will provide the tool user with both a ‘Declaration of Conformance’ and a ‘Calibration Certificate’. The update to ISO 6789 should, in the long run, help to provide more clarity, with two distinct parts and separate documentation to match. The 2017 edition is now published and should be used in place of the old 2003 edition. However, in Europe the Euro Norm or EN version has a 12-month period of overlap (February 2017 – February 2018) where either edition can be used. Neill Brodey is managing director at Norbar Torque Tools, home to the first laboratory in the world to be accredited to perform calibrations on hand torque tools to the newly revised BS EN ISO 6789-2:2017 standard. November 2017
UK1
UK INDUSTRY REPORT
Handbook simplifies temperature measurement Industrial temperature measurement
New Process Safety Management qualification
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ABB has released a handbook that explains how to maximise temperature measurement accuracy in industrial applications. The Industrial temperature measurement: Basics and practice handbook, offers explanations of the key areas that users need to consider when implementing and operating temperature measurement technology. It covers a variety of topics including the principles of temperature measurement; sensor and transmitter options and how to select them; ensuring accuracy through calibration and verification; and the options available for explosive and SIL applications. “As one of the most widely measured parameters in any industrial application, temperature provides an invaluable indication of what’s happening in a process,” said Steve Gorvett, DP Flow and Temperature Product Manager for the UK at ABB. Download the handbook as a PDF from: http://bit.ly/2xzDiU1 A B B M E A S U R E M E N T & A N A LY T I C S
Industrial temperature measurement Basics and practice
— The most important methods for measuring temperature and their basic principles are described.
Teresa Budworth, chief executive at NEBOSH, said: “Collaborating with the HSE allowed us to combine our ability to deliver strong, credible vocational occupational safety and health qualifications with HSE’s industry-leading knowledge and expertise. We piloted the qualification, which attracted delegates from global organisations operating in oil and gas, chemicals, utilities and manufacturing industries. We are delighted that 94% of those who took part would recommend the qualification to a colleague and their employer.” www.nebosh.org.uk
Partnering to accelerate commercialisation of digital industrial innovation A new partnership between Siemens and the University of Sheffield aims to accelerate digitalisation, boost digital skills, and promote technology and knowledge exchange to meet the needs of increasingly-digitalised industry.
(l-r) Juergen Maier, CEO, Siemens UK outside the MindSphere Lounge with Professor Sir Keith Burnett, President and Vice-Chancellor at the University of Sheffield.
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The partnership is based on the use of Siemens MindSphere Innovation Network (MINe) to connect a university’s estate and research assets into its MindSphere IoT platform. This data will then be made available to improve teaching and research collaborations between academics and industry partners, to uncover new business models and create commercial opportunities through digitalisation. In addition to linking its estate and research assets into MindSphere and acting as a living lab for graduates, the University of Sheffield and Siemens have also invested in a bespoke space for collaboration and learning between students, local businesses and other partners. Students, academics, industry partners and Siemens experts will use the area to access MindSphere to harness the value of the data produced from the University and the various projects connected to the cloud-based platform.
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03/TEMP-EN Rev. E 05.2017
The National Examination Board in Occupational Safety and Health (NEBOSH) and the Health and Safety Executive (HSE) have joined forces to develop a new qualification for the process industries – the NEBOSH HSE Certificate in Process Safety Management. Designed for high hazard industries, where process safety management is critically important, the new qualification applies principles and best practice to manage process risks, helping to protect people and valuable assets. Commenting on the development,
Numerous practical details provide the user with valuable information about temperature measurement in industrial applications.
Commenting on the launch, Juergen Maier, CEO, Siemens UK, who has led the Government’s Industrial Digitalisation Review, said: “Using digital technologies to transform business operations is key for the UK to drive competitiveness, improve national productivity and take advantage of the commercial opportunities offered by an increasingly digitalised industry.” The aim is to help develop the skills needed for the future, build the UK’s world class capabilities in data science across universities, enable the development of new business models and create opportunities to grow new start-up businesses locally. Control Engineering UK
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MACHINE DESIGN
Making commercial production of battery modules feasible
Control Engineering UK finds out how Horizon Instruments overcame the challenges of developing a high-speed cell picker system, as part of the AMPLiFII (Automated Module-to-pack Pilot Line for Industrial Innovation) project.
T
he trend for electric vehicles has resulted in a rise in interest in the adoption of electric and hybrid drive technologies for future car propulsion. Volvo has announced that it is switching from 100% reliance upon the internal combustion engine to electric based propulsion. The recently completed London Taxi Company factory will be producing electric taxis, supported by a Government-funded network of charging points. In Europe, France has announced it wants all cars sold after 2040 to be electric. A Government-funded project is now underway to demonstrate that commercial production of batteries for electric vehicles is both feasible and cost competitive.
The AMPLiFII (Automated Module-topack Pilot Line for Industrial Innovation) project aims to create a proof of concept for a new automotive battery pack assembly line. Within the pilot battery assembly line, special purpose machine builder and system integrator, Horizon Instruments, has developed a high-speed cell picker system using Festoâ&#x20AC;&#x2122;s H-handler technology. The cell picker presented several challenges. Daniel Bolton, technical director at Horizon Instruments, explains: â&#x20AC;&#x153;We faced a number of technical and practical constraints when designing the battery module production line. There was a confined space in which to fit the equipment and strict budget parameters, as well as a lead-in time of just seven months. We also needed
High speed battery cell pick and place with the Festo H-handler.
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November 2017
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to find a way of electrically testing each cell, rotating cells on demand and placing the cells into each module with high degrees of accuracy and at speed.â&#x20AC;?
Put to the test The pilot line required groups of 30 cells to be tested simultaneously for current and voltage before each cell was picked and placed in the battery modules. Warwick Manufacturing Group (WMG), part of Warwick University and project lead had identified a standard battery testing unit as being fit for purpose, but unit costs and space constraints meant that it was not possible to accommodate 30 individual battery testers. To solve this problem, Horizon and WMG developed a bespoke multiplexer interface which allowed a single battery tester to be used. This not only delivered savings on space and capital cost, but enabled data collation regarding test status. The area available for battery assembly system is rectangular and measures approximately 1.2m by 2.0m. Following testing, the battery cells were found to need aligning accurately and sometimes inverting before being inserted into the module located on the conveyor. The number of battery cells required for a module varies and is configurable via a recipe. 100 individual cells per module is typical, with a total weight of approximately 9kg once assembled. Again, space was at a premium. There Control Engineering UK
MACHINE DESIGN was not sufficient room to employ a standard robotics solution, which would require a circular movement around the module in order to place all the components. Another solution was required. Horizon considered a number of options to arrive at a bespoke design before a solution was found by Festo. Bolton explains further: “We were confident in the quality of the technology, having worked with Festo on previous occasions. More importantly for this project, Festo was capable of delivering a total Cartesian robot solution; so we didn’t need to co-ordinate multiple suppliers or worry about product compatibility. It delivered a custom, cost-competitive system within eight weeks of the order being placed and also provided technical support throughout the design, installation and commissioning process.”
The automated solution At the heart of the AMPLiFII battery pick and place system is the Festo EXCH 60 H-Handler, a highly dynamic 2D planar surface gantry, controlled by a Festo CPX valve terminal. The EXCH is aimed at high-speed assembly operations where small, light mass-produced items need to be positioned quickly and flexibly. The gantry has a rectangular working area, which makes it more economical than SCARA or Delta kinematic robots: both in terms of mass – around 150kg – and space requirements. The EXCH has a standard XY axis, but its single belt enables precise positioning at high speeds within a compact envelope. It also features a connector so that Z axis equipment such as a gripper can be integrated into the handling system with ease. Powered by two fixed motors, the EXCH H-Handler delivers an optimum dynamic response when compared with other Cartesian gantry systems. By eliminating the need to use separate gantries for each axis, the EXCH delivers precise alignment. It operates at speeds of up to 5m/sec and acceleration rates of up to 50m/sec2, and is capable of Control Engineering UK
Automation solutions provider, Horizon Instruments, designed and integrated the Festo handler and conveyor system.
100 picks per minute with a repetition accuracy of +/- 0.1mm. The CPX terminal allows electronics and pneumatics to sit on a single, standalone base. With modules available for PLC control, multiple fieldbus standards, motion control, inputs and outputs, it is said to reduce the number of components on the machine while giving the controls engineer greater flexibility. This combination of control, speed and precision was critical to the success of the battery pack assembly line to demonstrate commercial viability. It allows each cell to be picked, rotated, aligned and placed in the modules within 1.2 seconds. Commenting on the project, Steve Sands, head of marketing at Festo, said: “This project is very significant for us because it is the first time our EXCH H-Handler has been applied in the UK. However, the automation technology now incorporated in this pilot line for electric vehicle batteries was originally developed for the construction of solar panels; so it has already proven its ability to handle delicate components and place them with great precision at speeds compatible with commercial production. This technology also has the potential to bring the benefits of automation to other industrial processes, such as high speed assembly, materials handling and palletising.”
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Charging ahead In addition to the pick and place system, the pilot line includes a Bosch Rexroth conveyor system and a Siemens control system. Festo servo motors are also used to provide vertical movement, and the transportation system for the battery input trays relies on Festo actuators. Commenting on the successful commissioning of the new automotive battery pack pilot line, Professor Robert Harrison of WMG said: “The Government recognises that it is critical for the UK to embrace the opportunity created by the shift to electric vehicles. This is a proof-of-process pilot-line that, via the high-speed cell picker and other stations, will allow us to demonstrate our ability to automate the cell-to-module packaging process and help pave the way to upscale to a full production plant in the Midlands region. AMPLiFII will develop new knowledge, skills, technology and facilities to support UK industry as it seeks to use new technologies and processes in vehicle battery systems. The project will help develop the next generation of traction batteries for electric and hybrid vehicles. It will combine the best human and automated assembly methods to manufacture battery packs and lay the foundations of a new UK automotive supply chain based around automated technology.” November 2017
UK5
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CHALLENGE GEMS WITH YOUR MOST DEMANDING APPLICATIONS Gems understands that standard products are not always the best solution. The company provides design and development services including custom components and feasibility studies. A Gems program manager structures each project to meet individual needs, timing and budget, making the company the ideal partner for your next development cycle.
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ems is a leading global design and manufacturer of electro-optic, liquid level, flow, magnetically actuated reed switches and pressure sensors, solid-state relays and barriers, liquid and pneumatic miniature solenoid valves, and pre-assembled fluidic systems, with facilities in North America and UK. It is a division of Fortive Corporation, a Fortune 500 company with global presence. Gems experience spans a wide range of markets and applications in fields such as medical, oil and gas, marine, HVAC/R and general industry. The company is proud of the latest addition to its Liquid level indicators range. The LED SureSite® provides a clearly visible indication from more than 100ft. It requires power and is unaffected by extreme thermal changes.
CVD sensors are produced on wafers in large batches, using polysilicon deposited on a stainless steel substrate, with the strain gauge patterns being chemically milled. This process enables sensor assemblies to be produced in volume and at low unit cost.
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It can also be easily mounted to the exterior of tanks and is widely used in marine applications, where quick visual communication of tank contents is critical. The LED suresite is built to withstand constant vibration and shock while operating. Gems have been level sensing experts for over 60 years, using the widest range of material compatibility in the industry with durable and reliable performance. It has a large portfolio in flow switches and meters designed specifically for versatility performance, and quality, using corrosion-resistant materials. At its Basingstoke facility in the UK the company manufactures and assembles its pressure product range. Gems has been manufacturing on this site for around 52 years. Today the facility employs 70 people working in various areas of the business. The site has a dedicated ‘Innovations’ and engineering team, production and operations including customer service and finance, all of whom share a passion to drive the business forward. The 22/2600 series from the CVD range and the high-performance 4000 series from the thin film range are manufactured at the site, for use in a wide range of test and measurement applications. Electronic switches are also manufactured on site along with assembly of the 5000 series, 9600 series
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and the slimline borehole 3700 series for all water applications. Gems is the only European sensor manufacturer to offer such a broad range of products and to provide comprehensive technical, application and product support. Continuous product development, supported by consultation with customer in a range of industry sectors, ensures that the company’s technology continues to be cutting-edge, with innovative solutions, developed to support customers changing requirements, being introduced on a regular basis.
Pressure solutions Pressure transducers are widely used in process and industrial applications, where they often have to withstand aggressive operating conditions, ranging from high pressure hydraulic spikes to extremes of temperature, mechanical shock and vibration. However, within each ruggedly designed transducer there is, typically, an extremely sensitive pressure sensing mechanism, combined with a sophisticated electronics package. Together these can provide accuracies of better than 0.25% of full scale output, with almost zero drift over time, yet with a response to changes in pressure of 1msec or less, and an operating life in excess of 100 million cycles. These outstanding levels of performance are only possible thanks Control Engineering UK
ADVERTISING FEATURE to a number of highly innovative and carefully controlled methods of construction. Three of these make use of advanced strain gauge technology: sputtered thin film, chemical vapour deposition (CVD) and micro-machined silicon (MMS); while a fourth uses capacitance as a method of detecting changes in pressure.
Gems slimline pressure transducers have been specifically designed to meet the rigors of long term immersion.
Atomically bonded Sputtered thin-film technology evolved from the manufacturing processes used by the electronics sector for the production of integrated circuits. The production technique, although relatively straightforward, requires advanced engineering systems and carefully controlled conditions to create an atomically bonded strain gauge sensor on a stainless steel diaphragm. This construction is extremely robust, with the diaphragm being suitable for direct contact with almost all liquids, oils and gasses. In addition, the materials of construction for both the sensor mechanism and the transducer as a whole are thermally compatible to minimise non-repeatable errors for hysteresis and thermal stability, and to ensure that coefficients for thermal zero and shifts in sensitivity remain constant across a wide temperature band.
Volume production Although thin-film pressure transducers provide exceptional levels of performance and long term stability, the mechanical complexities of the â&#x20AC;&#x2DC;first generationâ&#x20AC;&#x2122; sensors, mean they could be relatively expensive to manufacture in large volumes. It was to address this need that the chemical vapour deposition process was originally pioneered, using semiconductor manufacturing processes to produce multiple sensors at lower cost, while retaining many of the benefits and performance characteristics of thin film devices. CVD sensors are produced on wafers in large batches, using polysilicon deposited on a stainless steel substrate, with the strain gauge patterns being chemically milled. The wafer is then divided to produce individual sensor Control Engineering Europe
beams, which are laser-welded to a stainless steel summing diaphragm and pressure port, before being connected to internal electronics for signal conditioning and amplification. This process enables sensor assemblies to be produced in volume and at low unit cost. Each sensor generates a high electrical output from a small mechanical deflection, thereby simplifying signal processing, and is inherently stable with an accuracy to within 0.5%. It also offers a long operating life with excellent resistance to pressure shocks and mechanical vibration. Additionally, the use of high temperature vacuum brazing of the stainless steel during sensor production creates a structure with low hysteresis and creep, together with high strength and corrosion resistance.
Smaller solutions By comparison, micro-machined silicon (MMS) sensors are produced with similar technology to that used in the manufacture of integrated circuits on silicon wafers, with ion implantation allowing a strain gauge structure to be diffused into the internal lattice of the silicon. This optimises the unique mechanical and electronic properties of silicon, enabling sensor and diaphragm size to be reduced proportionately, and without adversely affecting factors such as hysteresis, linearity or performance under tough operating conditions. In common with CVD technology, the production methods used for MMS transducers allow larger volumes to
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be manufactured at lower unit cost, although unlike CVD devices where the diaphragm is in direct contact with the media MMS sensors are generally protected with oil-filled isolation diaphragms. This need can also be met by the use of capacitance sensors, where a flexible ceramic diaphragm and a fixed plate form the two capacitance surfaces. Pressure or vacuum applied to the diaphragm will therefore cause a proportional change in capacitance, with the output signal again being fed directly to integrated electronics for subsequent conditioning and amplification.
Electronics holds the key In recent years there have been developments in manufacturing processes for all of Gems sensing solutions, which combined with detail changes in design and materials of construction, has led to a steady improvement in areas such as performance, stability and reliability. The most important developments have been in the electronic packages that are increasingly being supplied with pressure transducers. In particular, many of the latest devices such as Gemsâ&#x20AC;&#x2122; CVD and thin film transducers incorporate advanced application specific integrated circuits (ASIC) technology, which enables the performance and functionality of each transducer to be tuned to meet the specific requirements of a market, application or customer. Gems MMS transducers, where they are used for hydrostatic level monitoring with liquids with changing densities, the use of micro processor technology allows both temperature and pressure to be monitored and the results to be processed with a known specific gravity, to produce an extremely accurate level reading. Find out more: www.gemssensors.co.uk
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MOTORS
WHY YOUR DC MOTOR MIGHT FAIL Factors that can lead to failure:
Control Engineering UK finds out more about the factors that play a role in DC motor failure.
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he most important element of ensuring a long-service life for your DC motors is to handle them with care. If a motor is dropped it could dislodge small components within it or even fracture them. Another important factor to consider is electro-static discharge (ESD), which is critical for brushless motors. ESD could damage the hall sensors or encoder, rendering them useless and unable to get any feedback from the control system. Brushless motors commutate electrically through block or sinusoidal commutation. Studies show that it is possible to generate up to 15,000 volts in the human body. By releasing that energy you could short-circuit a motor which is why wearing the correct gear and thinking about how you are going to handle the motor is crucial. Environmental conditions also need to be considered before specifying a motor. Each motor will have its own operating temperature range and this is dictated by the heat reliability of
the materials and the viscosity of the lubricant in the bearings. If the ambient temperature falls outside this range, then the motor may fail sooner than you expect. At low temperatures the lubricant will freeze and increase friction within the bearing, causing increasing wear and excessive axial play due to shrinkage of components. You will have the same consequences operating at high temperatures. However, in this case, the lubricant will become a liquid and will run away from the areas where lubricant is needed. Another element that might need to be considered is the humidity of the environment in which it operates. High levels of humidity can cause corrosion within the bearing. This increases friction which has a growing effect on wear. This may damage the shaft and the bearings, restricting the smooth rotating operation of the motor which can affect speed and torque. It also will lead to contamination within the drive due to the abrasive nature that is corrosion. DC motors commutate using brushes, whether graphite or precious metal. It is the brushes that limit the life of these motors and it is the ball bearings that limits brushless motors. The life of the brushes can be influenced by a number of factors in addition to humidity and The effect of load torque on the thermal time constant of the winding. vibration. The use of high current loads
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• Human interaction • Environment conditions • Brushes • Ball bearings • Exceeding operating range will cause electrical wear; high speeds will considerably impact the mechanical wear on the brushes; and the type of operation can significantly deteriorate the brushes if the motor is used for extreme start/stop and left/right operations and temperature. All these factors contribute to the demise of a brushed DC motor. Brushless motors will fail once the bearing has worn out, but in addition, residual unbalancing and bearing load have an impact on bearing life. Data for each motor will specify its limits and operating ranges. This data is not always taken into account. A key parameter is the thermal time constant of the winding. DC motors can be overrun, but not for long periods of time. The thermal time constant of the winding (tw) is what dictates the maximum operating time for an overload. The maxon motor DCX 6 M, for example, said to have a tw of 1.71 seconds, so that motor should only operate for that period while overloaded by around 2.5 times the nominal torque. (In maxon motors, torque is directly proportional to the current, so when torque increases, it has a higher electrical current load demand). By operating for longer periods, the winding will melt due to the excessive current which is producing large amounts of heat leading to the motor seizing.
Conclusion There are many factors to consider when selecting a suitable motor for your application. Selecting the right motor can lead to a much greater life-span. Control Engineering UK
Control, Instrumentation and Automation in the Process and Manufacturing Industries Control, Instrumentation and Automation in the Process and Manufacturing Industries
Serving Europeâ&#x20AC;&#x2122;s senior engineers - keeping them Serving Europeâ&#x20AC;&#x2122;s senior engineers - keeping them informed on the latest developments to run their plant informed on the latest developments to run their plant and production facilities as efficiently as possible. and production facilities as efficiently as possible.
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TEST & MEASUREMENT
Selecting an inline thickness measurement system A number of important factors need to be considered when selecting an in-process system for measuring the thickness of film, plate, or sheet materials, says Chris Jones.
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key quality control parameter in metals, plastics and rubber production is thickness (and width) measurement of strip, plate, film and sheet. This measurement needs to be carried out accurately, as the material is being processed. A number of different measurement systems can be used to measure the thickness of a material. Some of these are used offline – random samples of the material are removed from production and measured to verify that they meet the specification. A more effective approach is to install an in-process or fixed inline non-contact measurement solution that is able to continuously measure the thickness of a material as it is processed. If measurements from these systems move towards the outer limits of the specification, machine and process control parameters can be altered to bring the thickness back into acceptable limits.
Finding your solution The first factor to consider is whether to design and build the measurement system in-house or purchase a turnkey system from a supplier.
While there are many sensors that can be mounted inline with simple framework and signals output to a local display or HMI for thickness calculation, verifying the actual measurement accuracy of this type of solution can be difficult. It is considered best practice to use a measurement system that is 10-times more accurate than the production tolerance. With many production tolerances reducing to below, for example <100 microns, it is therefore necessary to produce a measurement system with a capability of <10 microns, which is difficult to achieve, particularly if you have never done it before. Therefore, going to a supplier of a turnkey system is often a more efficient solution. What is important when selecting a suitable system is to understand the combined real-world errors that can occur when using a non-contact thickness measurement system and how these errors can be eliminated or compensated for. While many suppliers state on their datasheet that the measurement system meets a certain resolution and linearity, in the real-world, this performance can be affected by a number of environmental influences. Errors associated with real-world thickness measurement are not always so obvious, but can combine to create significantly large errors. It is, therefore, critical to select a system based on system accuracy, not just sensor accuracy.
Verification of system capability Figure 1: No misalignment, tilting or inclination of the sensors relative to the target object is permissible.
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Look for a measurement system that provides fully automatic process capability (CPc, CPk, etc.) features with
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in-built statistical functions that are available to the operator at the touch of a button. This should also include a store and print out feature that allows the operator to verify the material thickness at any time, with no supplier involvement required. It is important to design a mechanically and thermally stable sensor mounting frame. The mounting mechanism should be isolated from process or machine vibration as best as possible. Mounting with an O-frame is more stable than using a C-frame. Thermal expansion of mounting materials is often overlooked as a source of large errors in precise thickness measurement. Therefore, selecting materials with as low a thermal expansion coefficient as possible is very important. For example, mounting sensors on a typical aluminium or stainless steel extruded profile, with a thermal expansion coefficient of ~16ppm/K, experimental testing has shown that just a 5°C change in ambient temperature can move the sensors by >80µm! In contrast, using a standard grade Invar mounting frame with a thermal expansion coefficient of typically 1.2ppm/K reduces this to 6µm. Specialist Invar grades can reduce this error by half again. Of course, some suppliers of inline thickness measurement systems provide automatic calibration features built into their system as standard, which can continuously compensate for thermal expansion errors. This feature also means the operator does not have to spend time calibrating and checking the system. Control Engineering UK
NEW PRODUCTS
Facial recognition and gesture for machine control At the PPMA exhibition Omron demonstrated the benefits of its OKAO facial recognition and gesture control technology for machine access and control, operating as a facial recognition
system for access control and presenting a contextualised menu dependant on the authorised access level. The OKAO image sensing technology was originally developed for mobile platforms to offer accurate detection and recognition performance at high speed. OKAO’s gesture recognition system allows operators to view the performance of a machine, and control its movement from a distance, providing control and an extra layer of safety by taking the operative out of the machinery’s operating field. The system will allow control over machinery in places where an HMI cannot be installed or operated effectively. The OKAO facial recognition system is said to be more secure than ID cards
Dual robot gripper increases productivity on machine tending applications RARUK Automation now has available a Robotiq Dual Gripper solution which has been added to its existing portfolio of Universal Robots and Robotiq grippers and sensors which can be used to create
Liquid level monitoring up to 500mWG The Aplisens SGE range of hydrostatic level sensors, available from OEM Automatic, are designed for use in a wide range of industrial liquid level monitoring tasks in tanks, boreholes or open water. The standard range is designed for general liquids, with versions also available for liquids containing contaminants and suspensions. A variety of wetted materials and accessories can also be specified.
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a range of off-the-shelf, customised automation solutions. The Dual Gripper has been designed for machine tending applications where the robot is required to remove a completed part from the machine and replace it with a new one for processing. Having two grippers on the same robot arm shortens cycle times, creates a more efficient production line and increases output. It is even possible to have two, Dual Grippers on the same robot to further boost productivity. One early user of the Dual Gripper has reduced changeover times by 50% – from 40 minutes to 20 minutes – when compared with manually loading its PCB products. The company has also recently launched its MiR200 mobile industrial robot which is able to autonomously transport a payload of up to 200kg and can be customised with modules such as bins, racks, lifts, conveyors or even a robot. It also has the option of a hook
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or codes. It guarantees that the system is only accessible to the person present at the reader, and that people only have access to the parts of the system for which they are authorised. The technology can also provide ongoing checks on the operator to ensure that the same person is in control.
Electrical testers for use in tight spaces RS Components has added to its portfolio of test and measurement equipment with the latest electrical testers and a new electrical proving unit from Fluke. The devices are designed for use by electrical safety and installation engineers. The Fluke T6-600 and T6-1000 noncontact electrical testers come with the company’s FieldSense technology, which allows the measurement of voltage to be performed in the same way that current is measured, but without test leads contacting live voltage. The unit’s open jaw is simply slid over a conductor to read the voltage level. The T6 electrical testers are suited to testing in difficult situations by measuring voltage and current without making metallic contact with a live conductor. This enables voltage and current to be measured simultaneously, with true RMS, in tight spaces such as in crowded junction boxes or along conductors with inaccessible end points, all without using test leads.
mechanism that provides a towing capacity of 500kg. The MiR200 robot safely manoeuvres around people and obstacles, through doorways and in and out of lifts. It also complies with EN1525 safety regulations. The robot’s route and task can then be changed using a smartphone, tablet or computer connected to the network and has a battery runtime of 10 hours or 20km. Control Engineering UK
TEST & MEASUREMENT Errors due to non-alignment of the sensors Special attention must be paid to the alignment of the sensors, which are typically installed opposite one another (See Figure 1). No misalignment, tilting or inclination of the sensors, relative to the target object, is permissible in order to ensure the sensor spots are measuring at the same point all the way through the measurement range. For example, for a misalignment of 1mm and an inclination of 2°, there will be a thickness measurement error of 35µm. In the case of a 10mm target thickness, this error increases to 41µm. Combined linearity errors of up to 8µm, for example, can be seen with a vertical target movement of just 200µm of the target in the measurement field, even if the target has the same thickness. The combined error of non-linearity from both sensors must therefore be compensated for. MicroEpsilon has developed its own methods of precise sensor alignment and has patented algorithms for this process. To avoid thickness calculation error, due to movement of the target, both sensors need to be perfectly synchronised so that they perform the measurement at the same time, at the exact opposite point of the target. If synchronisation does not occur, inaccurate measurement data is produced. If measurements are taken at different time intervals, micro-vibrations of the target or of the sensor mechanics will result in a thickness measurement error. For example, for
a time-delayed measurement of 1ms, a deviation of 125µm is produced (assuming 1mm vibration at 20Hz).
Positioning of the measuring range Position, measuring range, thickness deviation and vibrations need to be taken into account when the sensors are installed. For correct thickness measurements, the target needs to be located within the ‘measuring range’ of the sensors. If the target moves outside the measuring range at any time, this can lead to inaccurate measurements. In particular, any special operating conditions, such as start, stop or speed changes, must be carefully considered
when positioning the sensors. Most thickness measurement applications are either in a process/ quality control environment where the object to be measured is fast moving, or in a ‘part inspection’ machine where the object is static and the laser sensors are scanning the part in as short a cycle time as possible. In both cases, it is important to match the laser measurement speed to the spatial resolution or cycle time required. Faster measuring rates are not always best as the laser sensor accuracy can suffer on difficult-to-measure surfaces when using high speed measurement rates. Chris Jones is managing director at Micro Epsilon.
I/O FOR THE MOST EXTREME CONDITIONS WAGO’s I/O system, 750 XTR, is extremely weather resistant and can operate from -40 °C up to +70 °C, making additional heating or cooling equipment unnecessary. It is highly resistant to electromagnetic interference as well as insensitive to vibrations and impulse voltages up to 5 kV, ensuring secure communications in demanding applications. With up to 16 channels in a 12 mm wide housing it requires less space, and has lower energy and maintenance costs; taking automation into extreme environments. To request a catalogue call 01788 568 008, e-mail ukmarketing@wago.com, or visit www.wago.com
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COGNITIVE ENGINEERING
COGNITIVE ENGINEERING Already part of some industrial systems, self-driving cars, autonomous drones, healthcare planning, and virtual assistants, cognitive engineering is permeating every walk of life. Optimised systems combine knowledge, contextual awareness, and situational intelligence, says Bhupendra Bhate.
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ptimised systems using cognitive engineering are helping humans by combining knowledge, contextual awareness, and situational intelligence. The human versus machine debate has been going on for entire careers, especially for those who have spent a lifetime building machines, programming them, feeding them with data, and then directing them to provide the needed results. Machines have the potential to move more quickly with greater strength and analyse faster than humans and without fatigue or becoming distracted. Human differentiation derives from a keen sense of perception, the ability to look at things from numerous angles and make objective, informed decisions. The human mind perceives and reacts to situations by combining knowledge (acquired through past experiences and learning) with a contextual understanding and situational awareness of things.
opening an app to other methods such as gesturing, sign language, facial expressions, voice commands, or interpretation of emotional state. These require advanced voice and image processing tools. Reinforcement learning algorithms under development will enable cognitive systems to identify and respond to various gestures and emotions. The challenge is to accurately engineer models of the broader environment of inputs and interactions. Robots equipped with advanced machine vision can nearly eliminate errors on the production line. 2. Decision making: Decisions need to be quick, bias-free, based on evidence, and backed by strong reasoning algorithms. In an industrial manufacturing plant, sensors collect huge amounts of data at every stage of the production line. The focus must shift from building analytical capabilities on the cloud to edge-empowered businesses with access to real time insights. Fault-model
libraries under development can speedup learning and fast-track reinforcement in cognitive systems. These libraries analyse and study patterns of various plant processes and machinery over an extended period of time. The consolidated learning is then fed to cognitive systems to give them a massive head-start. Cognitive systems trained this way autonomously can optimise processes to lower costs or speed up production. Artificial intelligence (AI) may be used for monitoring to ensure that production matches wider goals in manufacturing plants. 3. Open standards: With so many companies developing AI and machine learning tools, the creation of industry standards will enable businesses to invest in a standard set of tools to build machine intelligence. Bhupendra Bhate is chief digital officer for US-based L&T Technology Services. This article origianlly appeared in www.controleng.com
Combined cognition Cognitive engineering is the rise of technologies that help machines sense, analyse, and learn better, as well as contextualise. At its core, cognitive engineering is about humanising machines. Many products using cognitive engineering or machine intelligence focus on one aspect of cognition: knowledge or contextual awareness or situational intelligence. Intelligent systems combine all three aspects in one machine. Three areas can advance cognitive systems. 1. Interactions: Interactions must evolve from pushing a button or Control Engineering Europe
Flow diagram shows cognitive engineering in action, adapting the elements of the control loop: sense, decide, and actuate. After an action, the system used input to learn, considered past learning, and incorporated contextual understanding and situational awareness to guide the next action. Courtesy: L&T Technology Services Ltd.
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TEST & MEASUREMENT
MEASURING TORQUE
with angle sensors
Dr Darran Kreit discusses a technique for measuring torque with angle sensors which was first used in the 1950s. Although it offers many advantages, the technique had fallen out of fashion but is now making a comeback due to new developments in inductive angle sensors.
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easuring the torque applied to a stationary metal shaft is usually straightforward. Provided the elastic limit of the shaft is not exceeded, the amount of twist in the shaft is proportional to torque: Measure the degree of twist; look up the shaft material’s Young Modulus; apply a mathematical formula from the Engineer’s Handbook and you should have a good measurement of torque. Measuring torque in a continuously rotating shaft is more difficult. There are several ways to do it but the most common solution is to infer torque from the amount of power required to rotate the shaft. This usually means measuring the current supplied to the motor driving the motion. It’s simple, elegant but inaccurate because current consumption depends on other factors such as speed, voltage supply, bearing condition and temperature.
Figure 1: Torque measurement using multi-speed resolvers.
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Torque measurement with strain gauges A more accurate solution is to measure the twist in the shaft using strain gauges or surface acoustic wave (SAW) devices. While this is accurate, it does have the complication of requiring either a slip ring or some wireless method of signal transfer between the strain gauges on the shaft and the outside world. It is important to understand that there is a big difference between strain gauge theory and strain gauge practice. Strain gauges tend to have big temperature coefficients and a nasty habit of coming unstuck in tough conditions. Measuring torque using strain gauges or SAW devices in the lab is often OK, but is not a realistic proposition for many industrial applications. There is another solution – which many have forgotten and which was first used in the 1950s to measure torque in engines. The technique measures the twist, and therefore the torque, in
Figure 2: Measuring torque and absolute angle with inductive encoders.
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a shaft by measuring the phase shift between two ‘multi-speed’ resolvers mounted and aligned on the shaft. As the shaft rotates, each resolver produces two signals, one of which varies as a sinusoid and one which varies as a cosinusoid. (Figure 1 shows just the demodulated sinusoidal signal). When zero torque is applied the signals from the two resolvers show zero phase shift. As torque is applied, the phase of one output appears to shift relative to the other. Accordingly, the phase shift is directly proportional to the applied torque. Using a multispeed resolver with a high number of cycles only a small amount of twist is required to produce a significant phase shift. This makes it a highly sensitive technique that is suitable for measuring twists of <1° or even <0.1°. It is not necessary for the shaft to be long – the length of shaft needed for this approach can be <25mm. This can be achieved using a deliberately flexible shaft or by arranging the resolvers concentrically – one inside the other – and connecting the inner and outer parts of the shaft using a stiff torsion spring. Unlike strain gauges, resolvers are robust, reliable and accurate. They are non-contact devices so there is no need for slip-rings or radio frequency signal transportation. One reason that this technique fell out of fashion is probably because resolvers also fell out of fashion. Pancake or slab resolvers (flat with a big hole in the middle) are the ideal shape for measuring torque but they are costly. Furthermore, specifying a resolver’s Control Engineering Europe
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Accurately everywhere
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TEST & MEASUREMENT
Increased measuring accuracy for industrial scales The Combics range of industrial scales from Minebea Intec have a new level of precision, with a measuring accuracy of 60,000 increments. The move is a response to the increasing quality standards demanded of customers in the food, pharmaceuticals, chemical and logistics industries. Users of these products can expect to benefit from less production waste and more reliable processes. With a resolution of up to 60,000 increments, the
drive and processing electronics can be tricky. Since today’s engineers are mostly familiar with digital electronics, they are also, perhaps, reluctant to get to grips with analogue electronics and measuring phase shift of AC signals.
The new generation Today resolvers are increasingly being replaced by more modern solutions – inductive encoders or ‘incoders’. Incoders operate using the same inductive principles as a resolver but use printed circuits rather than wire wound transformer constructions. This is important to minimise the incoder’s bulk, weight and cost while maximising its measurement performance. Incoders also offer the simple and easy to use electrical interface – DC power in and serial data out. Because incoders are based on the same fundamental physics as a resolver they offer the same kind of operational advantages, including high precision and reliable measurement in harsh environments. What’s more, they are the perfect form factor for angle measurement – flat with a big hole in the middle. This allows the shaft to pass through the middle of the incoder’s stator with the rotor attaching directly to the rotating shaft. This eliminates the need for slip rings in the same way as resolvers. (Figure 2 demonstrates torque Control Engineering Europe
industrial scale can now comply with even the smallest of tolerances, for example when measuring out very precise doses of liquids or powders. For all applications such as filling, counting, manual formulation, individual weighing and checkweighing, aspects such as production waste and cost can be minimised through the use of a single scale, as the new precision level extends the range of application and thereby optimises the entire process.
and absolute angle measurement with inductive encoders.) Because all of the incoder’s electronics are already within its stator there is no need to specify and source separate electronics. Incoders are also available with up to four million counts per revolution, so just a tiny angular twist is enough to give high resolution torque measurement. The thermal coefficient of an incoder is small when compared to what can be achieved with strain gauge arrangements and any dynamic distortion effects from shafts with high angular speed can be eliminated by using the same clock signal to trigger readings in both encoders. Unlike the strain gauge technique, there is no danger of damaging the equipment with excessive or shock applied torque. This technique also provides two measurements – angle and torque – for less than the cost of measuring torque with a strain gauge. Measuring torque with angle sensors may be an old technique but the addition of the modern inductive encoder is now rejuvenating the use of inductive physics for angle measurement and with it, rejuvenating this useful, robust and effective method for torque and angle sensing. Dr Darran Kreit is technical manager at Zettlex UK.
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LXS, LXSR, LES, LESR, LKSR, LPSR series New closed-loop current transducers, based on a custom Hall Effect LEM ASIC, perform at the level of fluxgate transducers, achieving the highest levels of quality and traceability using advanced manufacturing techniques. Offset drift is over four times lower than the previous generation of closed-loop transducers based on Hall cells and very similar to those using fluxgate. There are 6 families and 22 models available with various options, such as an integrated reference (VREF ), footprint (3 or 4 primary pins with different layouts), with an aperture and/or with integrated primary conductors and overcurrent detection. • • • •
1.5 to 50 A nominal current PCB mounting Low offset drift (4 – 14 ppm/°C) Overcurrent detection output (LPSR models) • -40 to +105°C operation • 100 % compatible with previous LEM generation • Multi-range configuration
www.lem.com At the heart of power electronics.
CYBER SECURITY
Finding common ground in IT and OT convergence The interconnection of information technology (IT) and operational technology (OT) is a source of new opportunities and challenges. With increasingly automated and robotic supply chains, manufacturing and engineering companies are becoming more connected, but this exposure to external data flows inevitably leads to new risks, says Robert Wakim.
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ne of the biggest challenges for the industrial sector is to understand the level of risk and the impact that cyber security attacks can have, particularly as the transition to Industry 4.0 gathers speed. Over the last two years, Stormshield has worked closely with Schneider Electric in a joint effort to respond to these industrial security issues. We understand network, workstation and server protection, while Schneider Electric understands OT. What has been interesting is the realisation that there is a significant gulf between the priorities of manufacturing engineers and the priorities of security and IT teams. For the engineers, the focus is on availability. Production must continue because any interruption could result in a serious set-back and it must be safe because engines, motors
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and processors carry a physical risk to operators. IT, on the other hand is not unduly worried about availability, but a computer network security breach could wipe out essential data and has the potential to let hackers gain access to control systems. The joint project revealed that, particularly in Europe and the US, many manufacturing enterprises believed that their production processes were unconnected to the Internet, or hadnâ&#x20AC;&#x2122;t considered that there was even an Internet connection in the factory. This was well illustrated recently by a post from a chemical engineer detailing how a problem arose in his control room which monitors multiple petrochemical factories. The local control system went down, the computers showed an error which resembled a ransomware attack, and it was only when a colleague went to make a coffee, that they realised the same error message was showing on the Internetconnected coffee machine. Instead of being solely connected to an isolated wi-fi connection, the machine had mistakenly been connected to the internal control room network. The likelihood, given the timing of this attack, is that the network was infected by WannaCry ransomware, which was also responsible for infecting millions of devices worldwide running on Windows XP.
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The fact is that the gap between the factory and the Internet has become small, even non-existent, and with the growth of IoT connected devices, cyber security risks are escalating. For most engineering firms, however, the focus remains firmly on designing sophisticated systems that are robust and safe, and this is having a detrimental effect on securing networks.
How high is the risk? In many ways, the lack of real concern in the industrial sector to date is understandable. Working with Schneider Electric, we realised that the technology used in manufacturing enterprises is rarely standard, is highly complex, and often unique. This would mean that a malicious attack on industrial processes would have to be very specific in order to do harm. But the status quo is about to change. A new virus, Industroyer, recently came to light and reports have indicated that it has the power to seriously damage or compromise industrial control systems. This virus can speak four industrial languages and is highly customisable, and the likelihood is that it would be used in targeted attacks. To what end? If not to extort money from individuals, then more likely to create nation state attacks that disrupt vital infrastructure. Ukraine has been on the receiving end of attacks of this nature, with two widespread blackouts occurring in the winters of 2015 and 2016, both of which left 700,000 homes without power or Control Engineering Europe
CYBER SECURITY water in Western Ukraine. The 2015 incident is believed to be the first example of a hacking attack deliberately targeted at a power grid and was attributed to state-sponsored hackers in Russia. So, for all their robustness, industrial operational systems are not safe from attack, nor are they compatible with today’s interconnected environment. Now, as OT and IT systems converge, there is an urgent need to find a balance between ensuring availability and securing themselves against cyber attacks.
Changing mindsets Observing the industry, we have seen that change has to happen between departments and people before any change can be made to technology. Engineers literally speak a different language to IT managers, and they need to agree a common approach and strategy. This becomes more important every day. The influence of Industry 4.0 on
automation is bringing about huge changes and greater adoption of cloud and cognitive computing. With this comes a need for massive computer resources to support the flow of data to and from the cloud via IoT connected devices. In adopting Industry 4.0, factories are communicating in real-time across networks and that means they need to be secure. Standard firewalls and security software are not enough. The project with Schneider showed that, when challenged, existing solutions lacked the necessary characteristics to be effective in industrial environments. So, as well as working harmoniously alongside industrial hardware, next-generation firewall hardware needed to be built to adapt to the industry prerequisite such as DIN rail mounts. These solutions would be ‘hardened’ and ruggedised according to key criteria including temperature, dust and humidity. In order to provide the same
level of security, the firmware would be the same as other firewalls, but include specific industrial protocols. And, in addition, they would be sensitive to the need for safety. Ordinarily, in an IT setting, if a firewall crashes, the network stops functioning. In an industrial setting, however, safety modes enable a packet to go through regardless of whether there is power, because for OT systems, availability and safety are the priorities and the factory has to be stopped in a safe position. A key finding from this joint project was that compromise is the way forward. Both OT and IT need to work together to combat the risks, regardless of what those risks are. The threat to the new generation of manufacturing enterprise does not come from within if appropriate consideration is given to safety, availability and security. Robert Wakim is the industrial offer manager at security solutions company, Stormshield.
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WIRELESS SENSING
Putting wireless sensor networks to work As wireless sensor networks become more reliable, their applications continue to grow, says David E. Capano.
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. Many will already understand 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.
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, 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 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 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
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Control Engineering Europe
WIRELESS SENSING 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 data standard to ensure seamless interoperability.
Applying wireless sensor technologies
Brandon Hobusch
November 2017
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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 inter-networked 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 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 in www.controleng.com Control Engineering Europe
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SPS PREVIEW
The reality of digital transformation on show The SPS/IPC/Drives exhibition will take place at its usual venue in Nuremberg, from 28-30 November, showcasing all aspects of industrial automation – from simple sensors through to intelligent digital solutions.
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ith digital transformation now becoming a reality, IT and automation is growing more intertwined than ever and this trend will be reflected throughout this year’s SPS/ IPC/Drives event, in addition to a host of product innovations and applications. In the automation industry today more attention is being paid to digital transformation. As a result, the topics covered in the exhibition halls have been reorganised. This year, for example, Hall 6 will be entirely dedicated to Software and IT in manufacturing. Microsoft Germany, SAP Germany, and other IT providers will be exhibiting on subjects including industrial web services, virtual product development and design, digital
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business platforms, IT/OT-technologies, fog, edge and cloud computing. Cyber security solutions will also be presented by exhibitors including Kaspersky Lab UK. Meanwhile, providers of industrial communication technology will this year, be housed in Hall 2 and in the newly added Hall 10.1. Visitors will also be able to take Guided Tours on IT-Security in automation, Smart production, and Smart connectivity which will focus on secure communication solutions and products that can help achieve intelligent manufacturing operations. Siemens will, once again, be prominent at the event, taking over the whole of Hall 11, where visitors will be able to see its entire Digital Enterprise portfolio which offers scalable digital
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solutions. The MindSphere Lounge will take visitors on an immersive journey through this open IoT operating system, to find out how data can be used to best advantage. Presentations from Siemens and its partner companies within the MindSphere Lounge will provide an opportunity for an open exchange about topics such as digitalisation, Industry 4.0, and IIoT. Visitors to the Siemens stand will also be able to find out more about the benefits of digital twins for both machine building and plant engineering. The Digital Enterprise for the process industry, with the digital twin at its core, can speed up the digital transformation of facilities. “Our domain expertise creates the foundation for optimising every process across the entire life cycle – even in already existing plants,” said Jürgen Brandes, CEO of the Process Industries and Drives Division. “A concrete example of this is the new IoT-capable drive concept Simotics IQ. Equipped with functions capable of capturing motor data and integrated MindSphere connectivity – Simotics Connect – enables data-based services, for example in the field of predictive maintenance, which opens up scope for new business models for customers, such as the sale of compressed air instead of compressors.” The digital twin also offers benefits when it comes to plant optimisation – from the engineering stage through operation to maintenance. The latest version 9.1 of the Simit simulation software enables the virtual > p28 commissioning of plants to be even Control Engineering Europe
Due to faster time-to-market requirements, I need one supplier who can take the headache I have of reducing engineering time and costs on my projects away from me. At Emerson we have the expertise to look at your application requirements and provide you with a fully tested and certified turnkey solution, ready to install. This frees up valuable resources, enabling you to meet your project deadlines, with savings of up to 30% in costs through engineering, sourcing and installation. For more information visit www.asco.com.
The Emerson logo is a trademark and a service mark of Emerson Electric Co. © 2017 Emerson Electric Co.
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SPS PREVIEW
< p26 more simply combined with operator training. This allows users to speed up the actual commissioning process by as much as 60%, and particularly for plant conversion or migration projects, to reduce downtimes to an absolute minimum. Siemens will also be showcasing the use of IT technologies which enable existing plants to be recorded, digitalised using imaging software and then optimised – for instance through the use of drones. This creates the conditions for an entry into the world of digitalisation tailored precisely to individual needs, benefitting particularly customers in the process industries, where there is a predominance of brownfield plants designed for long-term use. In the field of industrial communication networks and industrial security, featured innovations will include new security network components known as Cyber Security Appliances. These are used as part of the comprehensive Siemens security concept to help minimize cyber risk for industrial enterprises. PROCENTEC will be demonstrating its solutions for Profibus, Profinet and Industrial Ethernet. In addition to presenting its Atlas products – which offer network diagnostic solutions to
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help avoid downtimes – the company will be will showing the HE+, the latest addition to its ComBricks family, which offers a Profibus and Profinet-based automation system that unites repeaters and permanent monitoring in a web browser to offer a solution that allows for the remote monitoring of Profibus installations. The new HE+ device is designed for use in harsh environments. Experts will also be available on the stand to discuss the company’s online technical support offering, which ranges from troubleshooting to network audits and from consulting to network certification. PROCENTEC is an accredited Training Center and can provide courses in Profibus and Profinet. TE will demonstrate how its engineered solutions can enable industrial data driven applications to accelerate performance. Visitors will be able to learn about the company’s product portfolio and its latest product offerings. which include Intercontec M12 Motorconnector, a robust metal connector with IP66/67 protection that can provide power and signal connectivity in one, enabling efficient installations based on one-cable solutions. With rotatable angled receptacles for flexible mounting in combination with its fast locking system,
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the connector enables fast termination and the flexibility to save time and cost. As motors continue to get smaller, this connector will meet the need for a compact and powerful quick-connect. TE will also show its RJ45 jacks with integrated magnetics which are specifically designed for industrial applications. These new jacks support voltage mode as well as current mode PHY chips, providing customers with solutions for almost every industrial Ethernet application, including PLCs, motion controllers and industrial computers. B&R will be unveiling a new solution that, it says, will be instrumental in the coming era of mass customisation. “We are revolutionising the way that materials move through the manufacturing process, said Hans Wimmer, managing director at B&R. The B&R stand will also feature a live demonstration to showcase its industrial IoT and cloud connectivity solutions. OPC UA TSN will enable real-time access to cloud-based digital twins. The stand will also showcase the latest addition to B&R’s mapp technology, which consists of modular software blocks to simplify the development of new programmes and reduce the development time for new machines and systems by an average of 67%. mapp now also offers intelligent, readymade software blocks for crane control and hydraulics applications. Belden will demonstrate how it can deliver connectivity solutions to help users see the the benefits of IoT. A number of new products and technologies will also be on display, from its Belden, Hirschmann and Lumberg Automation product ranges, designed to enhance the productivity of industrial systems and machines. Hirschmann, for example has designed a next generation Layer 3 Ethernet backbone product family – DRAGON MACH4000/4500 – to meet the need for increased network bandwidth and flexible future-oriented solutions. Available in two open variants, they offer a maximum of 80 x 1Gb/sec modular ports and 8 x 10G fixed ports. Control Engineering Europe
SPS PREVIEW The Lumberg Automation brand will also introduce a number of industry firsts. These include Lumberg Automation LioN-Power μDCU, the first device to combine the benefits of a field I/O and a PLC providing multiprotocol support with M12 power L-coding technology; Lumberg Automation LioNPower Universal 16DIO, the world’s first I/O modules to support all three standard Industrial Ethernet protocols PROFINET, EtherNet/IP and EtherCAT in one single device; and Lumberg Automation LioNPower IO-Link, the first LioN-Power IO-Link I/O Hub with 16 digital inputs, featuring IO-Link V1.1 specification and port type Class A, so it can be connected easily to all IO-link Masters. The Ethernet POWERLINK Standardisation Group (EPSG) will be showing how the open, standardised protocols POWERLINK, openSAFETY and OPC UA TSN dovetail with each other to create state-of-the-art communication architectures with advanced safety and security features. It will demonstrate how interfacefree communication will soon provide seamless connectivity from the sensor layer to the ERP layer and into the cloud. The foundation for this has been laid with the companion specification for OPC UA and POWERLINK. Also on display at the EPSG stand will be new products from the group’s members featuring IEEE 61158
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POWERLINK interfaces, including a managing node solution from IBV for the QNX operating system. Robodev will show how it integrated POWERLINK into the open source Robot Operating System (ROS) and what types of projects it can be used for. An interactive demo cell will demonstrate how ABB robotics mesh with SPINNER infrastructure components. With its networking automation products and solutions, Softing believes it is able to close technological gaps between OT and IT, and create the conditions for seamless exchange of digital data in Industry 4.0 applications. A highlight in the area of data integration is the new ‘Industrial IoT Starter Kit’, which will be presented as a live demonstration. The starter kit is said to offer a fast and easy way to securely link the production line to the cloud. This plug-and-play solution brings together the power of HPE hardware, Softing software, and Microsoft Azure. The company will also be showing a complete solution for OPC communication and IoT cloud communication with version 4.45 of its dataFEED OPC Suite which offers direct symbolic data access to optimised blocks in Siemens SIMATIC S7-1200 and -1500 controllers. The suite combines a package of components for OPC communication and cloud connectivity within a single product.
Hall 7A Booth 330
Beckhoff will be presenting all the products and systems in its range of PC-based and EtherCAT-based control technology. Consolidating control intelligence in software, PC-based control incorporates all functions – PLC, motion control, IoT and more – within a single platform. This year’s trade show presence will focus on the integration of image processing, process technology and high-precision measurement technology into the central control system. Turck will be previewing a new IP67 I/O module for serial interfaces on its stand. The TBEN-S-2COM connects RS232, RS485 and Modbus RTU devices to Ethernet networks, directly in the field via Turck’s multiprotocol standard. The module connects devices with an RS232 or RS485 interface directly in the field, to controllers with the Profinet, Ethernet/IP or Profinet protocols. This is said to save users from having to run long wiring routes to the control cabinet. The user can choose between RS232 and RS485, as required for the characteristics of the two serial ports. The module also offers four I/Os that can be used as inputs or outputs without any configuration. Use in very demanding environments is possible thanks to protection to IP65, IP67 to IP69K standards, as well as the extended temperature range from -40 to +70°C.
ENERGY MANAGEMENT
Overcoming the barriers to energy efficiency The drive towards energy efficiency is not as straightforward as it might appear and it is important to recognise and overcome any barriers in order to reap the benefits, says Heikki Kervinen.
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hen considering an energy saving project it is important to first look at the drivers for energy efficiency in business. A shift away from the status quo for any business must make sense commercially. Equally, a commerciallydriven decision from the top must be supported by employees at every level throughout the business – and that means tapping into the things that matter most to them, and ultimately connecting the two. One of the greatest barriers, in my experience, is when the ambitions of management do not align with the everyday experience of people on the front line. Let’s look specifically at industrial productivity. A shift to greater energy efficiency can make a manufacturer more productive and more attractive to customers with a sustainability agenda. An energy efficient plant may also mean a quieter and more pleasant working environment for those on the shop floor as well as more reliable process equipment requiring fewer late-night maintenance call outs. Ultimately, improving energy efficiency might even secure the future of that plant, and the jobs that go with it. Recently, I visited an automotive engine factory in the UK that is part of a global business, and I was completely blown away by the attitude of the engineers who were singing the praises of the energy-efficient measures that have been installed. That is because they understand that energy efficiency
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is integral to the future success of their plant. The main reason being that the company’s global plants are effectively in competition with each other. When there is a new product to be manufactured, the plant that bids the lowest cost to produce it gets the project. And the lowest bid is driven by the ability of that factory to be as efficient as possible. Of course, winning bids means job security. So it is in the interest of every employee to support the drive for efficiency in everything they do, every day. It is ingrained in their culture. This is a great example of a company getting it right.
Why fix what isn’t broken? A challenge that we sometimes face is the sentiment that, as the saying goes, ‘if it isn’t broken, don’t fix it’. Particularly in North America, the received wisdom
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is that you simply use existing machinery until it breaks. I believe that this is a false economy that will damage competitive advantage in the long run. But how do we get that message across? Ultimately, it all comes down to money, and the cost of the investment required to become more energy efficient. Manufacturers of energy efficient drives and motors always want to talk about how they can result in a lower total lifecycle cost. But customers for those products usually focus on the initial purchase cost. To overcome this barrier manufacturers need to be able to demonstrate an effective return on investment (ROI) in the very short term. Essentially, the financial drivers that speak to the end user must be recognised and arguments for energy efficiency must be presented in the same language.
Control Engineering Europe
ENERGY MANAGEMENT No matter what the sector, energy efficiency must be addressed at both the operational and financial level. Many companies are committed to making energy efficiency part of the fabric of their business, setting annual goals at the highest level. I believe that, ultimately, these are the businesses that will be more successful. It is often a question of getting every part of the ecosystem on board. Let’s think about the construction industry. When a customer puts out a tender to construct a new building for business or commercial use the cost of actually running it year on year is often overlooked in the bidding process. The result is that the cheapest builder might win, but poor energy efficiency might see a dissatisfied customer over the longer term (and make it a less successful facility) simply because the running costs are so high. There are similar – though industry specific – challenges across many sectors.
In every industry, we need to understand the cost of energy and how it fits into the overall picture. On a positive note, energy efficiency mitigates a company’s exposure to energy price fluctuations. Historically the argument has been that energy efficiency is good because energy prices keep increasing. Even if that is not always the case, if you use energy efficiently, you lower your risk of exposure in this area.
The role of regulation Needless to say, regulation has a significant role to play – and the regulatory environment can vary greatly from country to country. I believe regulation is a positive force, but the focus must remain on communicating the commercial benefits of energy efficiency beyond the basic legal requirements. There also needs to be political drive – not only regulation, but incentives such as tax breaks, rebates and funding programmes to encourage
businesses to adopt energy efficient technologies. The key to overcoming the barriers is in helping industry understand that adopting energy-efficiency measures creates a ‘win-win’ situation all-round. It is good for the environment and it also contributes directly to their bottom line through enhanced productivity. Overall, energy efficiency must become deeply rooted in the approach that industry takes to business. A trend in its own right, rather than the result of an external force. There is significant movement in that direction, and to maintain the momentum all players – suppliers, industrial operators and regulators – must help build the energy-efficiency ecosystem: learning, educating, and communicating in support of the single message that the drive for energy efficiency is built on a valid commercial business case. Heikki Kervinen is energy efficiency sales and marketing manager at ABB Drives.
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PRODUCT FORUM • 1/8 DIN UNIVERSAL PANEL METER OMEGA’s new universal panel meter delivers high performance in a 1/8 DIN size for panel mount, and integration in a wide range of applications. The DP20 accepts universal inputs, including thermocouple, RTD, process (mA & Vdc), resistance, and true RMS voltage and current. By configuration, it will work as an AC and DC voltmeter (up to 400 V) and AC and DC ammeter (up to 5 A) offering application flexibility for process control and industrial requirements. A single universal power supply allows this unit to be suited for global use. The optional relays, analog output, and Modbus® RTU serial communications provide customization, control and communication capability. Additional features of the economical DP20 panel meter include scaling, IP54 protection, and programmable decimal points. • Fast Access Menu—Front Key Access to Modify the Alarm Setpoints and Max/Min
Memory • External Control Function—Contact at Multifunctional Terminal 5 (Second Scaling, Decimal Point Change, ‘Hold’ the Reading or Activate the Max/Min Memory) • Automatic, Power Saving Eco Mode Alarms 1 or 2, Independent, Configurable as Max/Min, with Setpoint and Hysteresis • Reading Offset—Configure a Fixed Number of Counts to be Added to the Reading • Second Scaling Function—Define Two Scalings for the Same Signal and Control (One is Active with the ‘External Control’ Option) • Recursive Display Filter for Noisy Signals and Configurable Steps for Minimum Predefined Changes on the Reading Omega Contact details Free Phone 0800 488 488 International +44(0) 161 777 6611 sales@omega.co.uk
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DRY BLOCK TEMPERATURE CALIBRATORS AND MICRO-BATH CALIBRATORS A temperature calibrator today needs to be versatile and meet a wide range of requirements. It should be an easily portable device to cope with frequently changing operation locations, as in multiple test bays or in production locations. A calibrator should also be equally suitable for stationary use in the measurement lab or in testing and inspection. To meet these demands, these calibrators are lightweight and easy-to-use at each site. Five temperature calibrators are available to cover the range from -35 to 650°C (-31 to 1202°F) and wet or dry calibration requirements. • Dry Block Calibrator: TCL-650S-D, ambient to 650°C (1202°F) • Dry Block Calibrator: TCL-165S-D, -35 to 165°C (-31 to 329°F) • Micro Bath Calibrator: TCL-M165S-B, -35 to 165°C (-31 to 329°F) • Micro Bath Calibrator: TCL-M255S-B, ambient to 255°C (491°F) • Multi-function Calibrator: TCL-3M165E, Dry Bath, Micro Bath, Infrared Blackbody, and Surface Temperature
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Why calibrate? Temperature sensors are subject to mechanical, thermal and chemical stresses. This results in a drift the longer the sensors are in use. Only the regular calibration of the sensors provides information on the difference between the actual temperature and the measured temperature and makes the specific drift visible. This data can be critical to maintaining a stabile process operation. OMEGA™ Dry block calibrators and micro bath calibrators are one of the best means to check and calibrate a wide range of temperature measuring instruments and temperature sensors. Mechanical, electro-mechanical or electronic measurement equipment can be checked with ease. These compact and durable calibrators are easy to transport, user friendly and offer all the features required for the specific test. Omega Contact details Free Phone 0800 488 488 International +44(0) 161 777 6611 sales@omega.co.uk
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Control Engineering Europe
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PRODUCT FORUM • SENSOPRO COMPLETE CONDUCTIVITY MONITORING SYSTEM To meet conductivity control needs in online water quality and process applications, Sensorex has introduced the Sensorex SensoPro Toroidal Conductivity Monitoring System. The system combines a Sensorex TCS3020 probe, capable of reliable conductivity measurements in even the harshest of environments, with the company’s new EX2000RS transmitter, featuring Modbus communication for robust system integration. Monitoring with SensoPro can prevent scaling and corrosion, reduce excessive water usage, and optimise processes in a range of applications including cooling tower water control, wastewater treatment, brine analysis, desalination, chemical processing, and other harsh or high conductivity environments. The TCS3020 probe used in the SensoPro system measures conductivity using toroidal sensing technology, which is more stable and reliable compared to traditional contacting conductivity sensors.
The Modbus-equipped EX2000RS toroidal conductivity transmitter completes the SensoPro system. The unit includes one analogue output and can monitor conductivity, percent concentration, total dissolved solids (TDS), and salinity. The RS-485 serial interface with Modbus RTU or ASCII protocol provides multiple output options for integration with industrial automation systems. The onboard screen displays measurements in real-time and is capable of showing up to four weeks of historical measured values. The EX2000RS has a small form factor, an IP65/ Nema4X case, weighs just 1.1 pounds, and can be wall or panel mounted. The result is a reliable conductivity and concentration monitoring system, in one simple package. www.sensorex.com, email info@sensorex. com or phone +1 714-895-4344.
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MONITORING GREASE LUBRICATION FLOW IN A WIND TURBINE Titan Enterprises OG2-700 flowmeter is a well-established monitoring device that provides valuable data helping to ensure safe and reliable operation in hundreds of wind turbine installations. Although China leads the world in the amount of power generated from wind, Denmark has the highest generation rate per capita by a long way. In 2015, this small country was generating over 2 megawatt hours per person well ahead of China’s 0.26. This relatively high generation rate has resulted in a local industry which produces large numbers of wind turbines for the rest of the world. One of the fundamental requirements of ensuring reliable and efficient wind turbine operation is to keep the heavily loaded main bearings fully lubricated in all operating conditions. Titan Enterprises were approached to supply a small flowmeter to monitor the grease being supplied into a wind turbine main bearing mechanism. For simplicity the grease mechanism is mechanically driven from the blade rotation and therefore the flow rate is potentially very low if the blades are barely rotating. This grease flow is crucial and an alarm must be tripped and the rotation stopped should the grease flow be insufficient. In addition, if the lubricant supply line became blocked the flowmeter should be able to withstand pressure that could potentially rise to several hundred Bar. An extra requirement for the required flow measurement device was for a low power system as the backup system was battery powered. Drawing upon its proven OG2 flowmeter that fulfilled the low flow measurement specifications on lubricating viscous fluids, Titan Enterprises redesigned this meter to
operate at 700 Bar in a small body and fitted a miniature reed switch detector to keep the power requirements to a minimum. Fully IP67 / NEMA 4 compliant, the OG2-700 flowmeter is optimised for measuring the flow of viscous fluids and liquids at pressures of up to 700 bar and temperatures up to 150°C. With a standard flow range from 0.03 to 4.0 litres / minute on 30Cstk oil the OG2-700 can routinely achieve outstanding accuracy (0.5%) and repeatability (0.1%). Combining robust 316 stainless steel construction and proven technology ensures that OG2-700 flowmeter provides reliable, accurate operation over an extended product lifetime. At the heart of the OG2-700 flowmeter are a pair of toothed oval gears one of which contains chemically resistant magnets, the gears rotate freely on robust bearings. Rotation is detected through the chamber wall by a Hall effect detector or a reed switch giving approximately 1100 pulses per litre passed. The output is an NPN pulse or a voltage free contact closure either of which is readily interfaced with most electronic display or recording devices. This combination of materials and technology ensures a long-life product with reliable, accurate operation throughout. For further information on the OG2-700 flowmeter please visit www.flowmeters. co.uk/og2-special-700-bar-high-pressure-oval-gear-flow-meter/ or contact Titan Enterprises on +44-1935-812790 / sales@flowmeters.co.uk. i More info - Enter Link code 140383
ADVERTISE YOUR BUSINESS IN THE PRODUCT FORUM SECTION Contact Lewis Atkinson on 01732 359990 or email lewis.atkinson@imlgroup.co.uk USB_card_85x55mm_final.indd 2
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PRODUCT FORUM • INTRODUCING SICK’S SURESENSE – THE FLEXIBLE FAMILY OF CUSTOMISABLE SENSORS SICK has developed the SureSense family of user-customisable photo-electric sensors - a concept that enables machine builders and plant engineers to specify from a wide-range of sensing options all within a standard technology, set-up, mounting and housing. The durable SureSense sensors can reliably detect nearly any object in any environment – ensuring machines and lines stay up and running at full capacity. David Hannaby, SICK’s UK product manager for presence detection, explains why SICK developed the technology. “We are seeing more companies looking to use a hybrid sensor that allows flexibility in mounting either from the side or from the front. During installation and operation, SureSense’s signal strength bar gives clear indication of the sensor’s performance and making set up and operation easier for engineers. “The SICK SureSense enables machine builders and plant engineers to standardise on one single sensor family for the most basic to advanced applications. Users can literally build their own sensors online, expect prompt delivery and quickly commission their sensors for optimal performance “As a result, machine design variables, plant maintenance costs and stores inventories can be all be dramatically streamlined.” Intelligent Sensing Technologies SICK SureSense offers either laser light, red or infra-red LED in the same housing, multiplying the number of potential applications from one sensor family. SICK SureSense also incorporates a facility, not seen on conventional sensors, that helps users achieve rapid set-up and ongoing high performance. A signal strength light bar on the back of the sensor housing enables the alignment to be optimised, increasing performance consistency and stability, even when faced with mechanical stress or contamination. SICK SureSense sensors draw on a comprehensive toolbox of innovative SICK technologies to compensate for the wide variety of shapes, colours and tones, transparency or reflectivity of objects to be detected. Excellent background suppression means the effects of changes in colour or materials, or by reflections from the surrounding production environment are minimised. In applications to detect clear objects such as bottles or food trays, the sensors automatically compensate for dust and dirt contamination using Sick’s renowned Auto-Adapt technology. Challenging Products and Conditions
David Hannaby continues: “The SICK SureSense family benefits from all the SICK technologies you would expect to simply detect any object. For example, built-in sensor intelligence compensates for the high light absorption by dark or matt black objects, by adjusting and optimising the emitted light intensity and signal strength. “SICK SureSense is also available with a laser LED emitter that enables superior performance in applications such as counting small objects, detecting small holes, sensing objects through small openings and detecting product defects.” SICK SureSense’s tough VISTAL housing and IP69K/Ecolab rating ensure rugged durability and resistance to vibration, chemicals and moisture for a long reliable life. The -40oC to +70oC range means the sensors can be used reliably without risk of failure in a wide variety of temperatures. For more information about the SICK SureSense photo-electric sensor family, please contact Andrea Hornby on 01727 831121 or email andrea.hornby@sick.co.uk.
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FINAL WORD
TESTING: collaborate for better design outcomes Andrew Newton, MD of electromechanical design company, Magnet Schultz, shares his advice on testing within collaborative development projects.
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s an outsource partner for electromechanical development teams, we supply specialist technology expertise, typically to customers for whom this function is just a small part of their development project. Recent projects include an access ramp solenoid bolt on a hovercraft; a locking mechanism for cash-in-transit security cases; and a lock for a fridge onboard a sports boat. Our collaborations usually proceed smoothly from the outset with prototype designs sailing through the test process. But occasionally, a test initiative will reveal something vital. In each case, our engineers will create a specification from the customer’s brief which includes all known aspects of the application: operating environment, life expectancy, etc. Solenoid functionality is something that is often oversimplified. From experience, we recognise gaps in the brief and draw out requirement details such as Failure Mode Effect Analysis (FMEA) and risk-based analysis. But we can’t imagine every eventuality – which brings us to testing. Testing is the one development process that should never be underestimated. The danger of testing inadequately, or in a way not representative of the application, is that system limitations or weaknesses may not be revealed before production parts are ordered and installed. When our customers engage with us, they get testing as part of the development support package. Initially, it’s a lab bench test. We can, for example, Control Engineering Europe
soak test for the million cycles required by the spec, confirm voltage ranges, check power consumptions or verify that solenoid stroke forces meet the spec. But we cannot replicate the end-use environment – and that is critical.
Filling the gap Real-life testing fills the gap that inevitably arises during development – the gap between our knowledge of solenoid and actuator capability, and the customer’s understanding of the challenges faced in the application’s environment. When collaborative testing is undertaken thoroughly, it brings both parties together in an exercise that everyone understands. We often uncover things we would have liked to know sooner but forgot to ask, or that the customer neglected to mention. In the sports boat example, we designed a robust electric lock mechanism for a drawer-style onboard fridge. Bolt strength was a key feature. We couldn’t quantify the true forces in the lab, and nor could the customer prior to taking the craft to sea. During the real-life test (a sea trial) with the boat wound up to around 50 knots, our prototype lock gave way under the pounding of the hull over the water. The test resulted in a stronger bolt being designed. With the cash-in-transit case lock, our design met stringent usability conditions, and delivered the impregnable security required. The live test programme comprised extensive field trials with security operatives using the new case, fitted with pre-production lock units. Reports soon surfaced of some cases
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Andrew Newton is MD at Magnet Schultz.
springing open when dropped. G-force hadn’t been factored into the brief, but careful planning and execution of the field trial picked it up. We were quickly able to put it right. Sometimes an application’s environment can change through unexpected third-party behaviour. During sea trials of the hovercraft, it was noticed that the maintenance crew routinely sprayed everything visible with a Waxoyl-type substance to inhibit corrosion. It began to clog the solenoid locking bolts, causing them to stick. Thanks to the test, we could prevent this from occurring by advising the maintenance crew and recommending new procedures. I’m certain these experiences parallel those of other specialist outsource partners. My advice to the customers of those expert companies is to recognise that collaborative testing is vital and do ensure that you make use of all the test expertise that is offered to you. November 2017
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