Cee 18 03

Control, Instrumentation and Automation in the Process and Manufacturing Industries March 2018

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Control voltage distribution solutions: Simplifying selection and configuration

Achieving the goal of profitable efficiency

Mastering the Industry 4.0 security challenge

Mobile robots: Supporting lean objectives

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CONTENTS

Staying safe while getting connected

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 G and C Media

Group Publisher Production Manager Studio Design

I can’t believe it’s almost Hannover Messe time already! I am just starting work on the event preview now which will appear in the April issue. Our flights are booked and, thanks to Airbnb we have also found some reasonably priced accommodation, so I can now look forward to catching up with all the latest technology developments very soon.

Meanwhile, this issue has a focus in cyber security, which has certainly become a big consideration as industry begins to implement Industry 4.0 practices. I spoke to a variety of automation vendors to get their advice on how enterprises can benefit from greater plant connectivity while ensuring the plant and data remain safe and secure.

You can read more about this on pg 12.

Also in this issue we report on the new breed of autonomous robots and look at how they can help support the lean production objectives of today’s more dynamic plant floors (pg 18).

I hope that you enjoy this issue and I look forward to seeing many of you at Hannover Messe in April. Let’s hope it has stopped snowing by then!

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

INDUSTRY REPORT

MOBILE ROBOTS

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18 A new breed of robots are supporting lean approaches to production on today’s more dynamic plant floors.

OPC Foundation sets out secure data exchange guidelines for OPC UA.

EDITOR’S CHOICE 6

PROCESS EFFICIENCY

AI module added to controller to provide diagnostic analytics solutions; PLC moves to the edge.

22 Achieving the goal of profitable efficiency by ceding profitability control to process control.

CYBER SECURITY

ENERGY MANAGEMENT

10 Mastering the Industry 4.0 security challenge.

24 Efficient steam system offers more sustainable operation.

12 Connectivity is often seen as a significant challenge to plant security. Suzanne Gill finds out how this issue can be overcome.

14 IT and OT collaboration is vital for a secure Industry 4.0

26 A recent whitepaper discusses the most common considerations when calibrating pressure gauges.

MACHINE VISION 16 We look at the importance of lighting control in machine vision applications.

17 Machine vision programming: There’s an App for that!

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

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

Control Engineering Europe

CALIBRATION

FINAL WORD 26 Scott Keller, founder and CEO at SignalFire Wireless Telemetry, offers some advice on determining the best wireless frequency for remote monitoring and control systems.

Control Engineering (USA) Frank Bartos, Mark Hoske, Renee Robbins, Vance VanDoren, Peter Welander Circulation Tel: +44 (0)1732 359990 Email: subscription@imlgroup.co.uk Completed print or on line registration forms will be considered for free supply of printed issues, web site access and on line services.

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Paid subscriptions for non-qualifying applicants are available for £113 (U.K.), £145 (Europe), £204 (rest of world); single copies £19.

March 2018

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INDUSTRY REPORTS

Secure data exchange: OPC UA guidelines

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whitepaper entitled ‘Practical Security Recommendations’ offers guidance for industry on ensuring secure data exchange and communication.

Published by the OPC Foundation the document offers practical and easy to understand advice for the secure configuration and use of OPC UA in industry.

Rapid growth in the networking and digitisation of industrial systems brings new security challenges which must be addressed systematically. In particular, beyond the need for implementing secure network infrastructures, it is essential to protect product and production data.

“Currently, users and developers are overwhelmed with making security decisions. Incorrect use of security features causes many security vulnerabilities, due to software difficulties and a lack of security knowledge. Documentation, tutorials, and good examples are often missing,” said Prof Dr Eric Bodden, professor of Software Engineering at Paderborn University and director of Software Engineering at Fraunhofer IEM. To help address this challenge, the OPC Foundation established a security user group with the aim of developing best practices and guidelines for typical

OPC UA security use cases.

The document is available on the OPC Foundation website (located at: opcfoundation.org/ security/) The German government sanctioned organisation, Intelligent Technical Systems OstWestfalenLippe (it’s OWL) supplied the group with key use cases and requirements to help ensure output addresses users’ realworld orientation and practical knowledge needs. “OPC UA is secure by design, but you actually have to use the security features it provides to reap the benefits,” said Erich Barnstedt, principal software engineering lead, Azure Industrial IoT at Microsoft. “The security configuration task can be simplified dramatically when an OPC UA server is secure by default, i.e. all security features are already turned on when the customer takes the server out of the box for the first time. It is also important for the device vendors

to make the security configuration as simple as possible, for example by providing wizards and easy to understand guidelines. We can’t expect OPC UA server users to be security experts.”

A second whitepaper presenting best practices and selected use cases for a secure implementation and operation of OPC UA is expected to be released later in 2018.

Online guide to strain measurement HBM Test and Measurement has launched a strain measurement online guide which focusses on the selection, installation, data acquisition, and analysis of electrical as well as optical strain gauges.

The portal also contains useful information about measuring strain, including valuable tips from strain measurement experts who

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have provided answers to a variety of frequently asked questions about strain measurement – either performed with strain gauges or with fibre optical strain sensors.

The new web pages help users learn more about strain measurement and related-technologies, including the definition of strain, tips for selecting and installing gauges and sensors, guidelines

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to acquire data, types of applications, among many others.

The journey starts at the strain measurements basics page: From there, users can choose to explore the world of strain gauges or the field of optical fibre sensing in more depth. www.hbm.com/en/6896/strainmeasurement-basics/ Control Engineering Europe

INDUSTRY REPORTS

OT vulnerabilities on the rise A recent report from cybersecurity management company, Skybox Security, identified a 120% increase in new vulnerabilities specific to operational technology (OT) compared to the previous year.

According to the report, this increase is of particular concern as many organisations currently have poor or non-existent visibility of the OT network, especially when it comes to vulnerabilities because active scanning is generally prohibited.

“OT is too often in the dark, and that means security management isn’t getting the full picture of cyber risk in their organisation,”

said Marina Kidron, senior security analyst and group leader of the Skybox Research Lab. “Even when patchable vulnerabilities are identified, OT engineers are understandably hesitant to install the update, as it could disrupt services, cause equipment damage or even risk life and limb.

Organisations with OT networks need to have strategies in place not just for OT vulnerability assessment and patching prioritisation, but also to unify such processes with those in the IT network to truly understand and manage risk.”

To read the full report go to: www.skyboxsecurity.com/tcvm.

Achieving top quartile performance Chemical manufacturer, Covestro, has selected Emerson to provide it with IIoT technologies to help it minimise risk and improve uptime across nine highutilisation plants.

Emerson will provide remote monitoring and predictive maintenance to help the company optimise its manufacturing facilities for improved production, safety and reliability.

The programme is a tenet of Covestro’s digitisation programme called Digital@Covestro that considers and implements new Industrial IoT strategies and operating procedures to deliver improved performance and meet defined financial targets.

Its reliability programme will use strategies, solutions and technologies from Emerson’s Operational Certainty programme designed to help manufacturers achieve Top Quartile performance.

Make your journey to Industry 4.0 a success.

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Achieve optimal performance with e-F@ctory. Visit our website for more information.

Hall 17 stand D40

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EDITOR’S CHOICE

Updated enterprise-level pipeline management solution Yokogawa Electric Corporation has introduced a new version of its Enterprise Pipeline Management Solution (EPMS) R1.03, an enterprise level pipeline applications suite.

Developed for deployment within the pipeline operations management environment, the EPMS supplements a core SCADA platform with specific gas and liquid applications that enable a pipeline operator to manage delivery contracts and associated logistics in a safe, cost-effective, and efficient manner.

Many pipeline SCADA systems are tailored to suit a specific set of circumstances and often lack both a standard system foundation for supporting pluggable application modules and a core design that ensures interoperability with enterprise IT environments and policies. The maintenance and upgrade of tailormade applications, that often have

a complex system architecture for protection from security breaches, poses increasing challenges for pipeline operators.

The EPMS suite offers a sustainable solution made up of pipeline applications that can be used in combination with common supervisory and monitoring functions, and is based

PLC moves to the edge Opto 22 has introduced a new industrial system to address the changing needs of automation engineers and developers. groov EPIC combines I/O, real-time control, local and remote HMI, and industrial/IT data exchange in a compact, industrial package.

IIoT solutions typically require multiple moving parts, including stitchedtogether software technologies, boltedon communications protocols, legacy controllers

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March 2018

and I/O, and a medley of gateways. The groov EPIC system is said to offer a better solution, combining I/O, control, data processing, and visualisation into one secure, maintainable, edge-of-network industrial system.

The solution gives the ability to connect legacy systems, control processes and automate machines. Users can subscribe to web services and create mashups, acquire and publish data, visualise that data wherever it is needed, and to mobilise operators.

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on a secure modular platform. The EPMS suite allows for simple modification of templates and functions. It can be offered in combination with advanced pipeline simulation solutions.

New functionality added to the latest version of EPMS includes enhanced interface management; shared use of physical devices for the delivery of products to different tanks; and enhanced batch management for greater flexibility, continuity, and energy efficiency.

One sensor measures speed and temperature M8-rotational speed sensors and ABZ sensors from RHEINTACHO are also able to offer temperature signals.

With its ABZ-sensor, RHEINTACHO has added the ability to record rotational direction and position too.

The temperature recording capability can be customised to meet the needs of the application. Depending on the application, the evaluation of the temperature signal has to be adapted to the differing installation conditions.

In hydraulic applications, the homogenising effect is supported by the hydraulic fluid. In electro-motors, the use of a temperature signal side in a speed sensor requires more adaptation as the installation position has very different ambient conditions from the common installation position of the temperature sensor.

Control Engineering Europe

EDITOR’S CHOICE

Speaking the same language as Universal robots SensoPart has added a new robotics vision sensor to its VISOR Robotic series. The use of URCap software allows the sensor to communicate directly with Universal Robot (UR) systems.

The sensor converts data and supplies all information in robot coordinates for immediate use by the robot systems.

This is achieved via one-time calibration using the calibration plates available as accessories, or with the aid of a point-pair list. Complex programming in the robot control system is not required.

Alongside the live image display and job management features that are already possible with existing VISOR products, the URCap software provides preprepared programme routines for calibration and pick-and-place tasks. It allows common robotics applications, such as collecting and positioning parts or robotcontrolled component inspections, to be set up manually without the need for programming.

Further simplifying the deployment of automated test and measurement systems NI has released a new version of its LabVIEW NXG engineering system design software which allows engineers to more quickly set up instruments, customise tests and view results from any web browser, on any device.

This latest version of LabVIEW NXG introduces introduces the WebVI, for building web-based user interfaces (UIs) that can be deployed to any web browser – PC, tablet or phone – with no plug-ins or installers.

Additionally, to reduce hardware configuration time, the new SystemDesigner feature automatically discovers connected hardware, displays installed drivers and directly links to available NI and third-party instrument drivers if they are not yet installed.

The new release expands hardware support to thousands of box instruments and NI’s PXI modular instrumentation. It also delivers programming capabilities such as object-oriented programming and integration with TestStand test management software.

Speak the same language as robots • VISOR® vision sensor for 2D robot applications • Easy interface with the robot • Finding parts with just a few clicks thanks to easy configuration

www.sensopart.com

COVER STORY

CONTROL VOLTAGE DISTRIBUTION SOLUTIONS: Simplifying selection and configuration As automation systems and control panels become more complex, the challenges associated with designing and implementing effective and convenient control voltage distribution systems increase. However, recent developments in terminal technology and design software provide the answer, says Peter Croucher of Weidmüller.

A

control voltage distribution (CVD) system needs to be compact because of pressure to either install more equipment or minimise the size of control panels, yet connections must be fast and easy to make, clearly identifiable and readily accessible to facilitate testing and fault finding.

A straightforward, three-step approach, makes things much easier.

The first step is to decide on the type of terminal products to be used as the basis for the CVD system. The second requirement is to design the system, and the third is to assemble it.

Klippon® Connect AAP modular potential distribution terminals provide large space savings compared with conventional feed-through terminals, without sacrificing accessibility or versatility. Their use of innovative push-in technology for connections means there are no screws to loosen and tighten and no spring clamps to release, resulting in potential savings in wiring time of 50% or more.

Weidmüller offers AAP potential distribution terminals in two versions: grouped and alternating. With grouped terminals, there are two feedin terminals, one each for the positive potential and negative potential. With alternating terminals, the positive and negative potentials are located on one terminal. Both types of terminals are complemented by a wide selection of push in cross-connections, and a

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March 2018

comprehensive range of markers.

Sometimes, there’s an extra level of complexity – the need to provide overload and/or short-circuit protection for the outgoing supplies from the CVD system.

Weidmüller’s maxGUARD solution offers terminals with integrated electronic protection. Products in this range cut space requirements in the control panel by up to 50% compared with using separate terminals and load monitoring modules, and dramatically reduce wiring time. maxGUARD terminals offer benefits that include pre-trip indication, easily accessible test points and a built-in isolation function to facilitate testing.

Designing the system But what about designing the CVD system? It’s one thing to choose the product range, but quite another to work out the optimum terminal arrangement for a particular project and to order all of the components needed to make up the assembly.

Weidmüller’s Configurator software supports structured selection and configuration of terminal systems, and provides 3D views that make it easy for designers to be confident that the finished assembly will accurately meet their requirements. It also automatically generates full parts lists and, of course, it never forgets an end stop, endplate or other tiny but vital items.

The Weidmüller Configurator simply

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asks the user to specify the number of positive and negative supplies to be distributed, and to select the required marking schemes. The software then automatically generates a suggested solution showing all of the necessary components and accessories.

But what about the third and final step of building the CVD system? The components have been designed with ease of use and assembly in mind, but the configurator provides further benefits at the assembly stage by offering two options.

Either the finished drawings and parts lists for the CVD system can be printed out directly for use in the workshop, or they can be exported to an E-CAD system, such as EPLAN, for seamless integration with the full cabinet design. In both cases, the technicians assembling the CVD system receive detailed information that’s not only easy to understand and work with, but also guaranteed to be error-free. www.weidmuller.co.uk Control Engineering Europe

Safe power supply to equipment in the panel Klippon® Connect and maxGUARD for integrated load monitoring and control voltage distribution Let’s connect.

As the number of power consuming devices in the panel increases so does the complexity of the power supply and fusing concept. With maxGUARD you save up to 50 percent of the space and 20 percent of the time compared to existing wiring solutions. The unique concept combines potential distribution and electronic load monitoring in a complete solution.

If you prefer separate fuses, use our tailor-made Klippon® Connect control voltage distribution terminal blocks. You will benefit from an extremely clear and compact design for your potential distribution.

Sales: 0845 094 2006 Tech: 0845 094 2007 Email: marketing@weidmuller.co.uk www.klippon-connect.com

CYBER SECURITY

Mastering the Industry 4.0 security challenge Factory and process automation are reaching new levels of integration which opens the way to higher degrees of efficiency, process control and flexibility.

However, it also calls for increased security to protect Image thesupplied factory from malware courtesy of and unauthorised intrusion, says Maximillian Korff.

AEMT.

A

s industry strives to reach new levels of efficiency in industrial production systems and process plants, automation systems and information technology will merge, while remote access, process monitoring, control and maintenance will reach new levels.

With increasingly more connected devices in the Industrial Internet of Things (IIoT), islands of automation will disappear – which is why reliable, secure and future-proof industrial communication networks are crucial.

Cyber-attacks cannot be taken lightly. Siemens, therefore, has adopted a philosophy that actively addresses this issue. It has embedded system security into its product design, system development and services. For example, with its security integrated components the company has not only integrated communication functions but also special security functions such as firewalls and VPN. It is also collaborating with customers to address any vulnerability

and effectively respond to any system intrusion.

For automation system providers and plant operators alike, system vulnerability will always be a delicate subject but it is vital that, with technology partners this issue is dealt with in an atmosphere of mutual trust and open communication.

In addition to security, another important product attribute is that commissioning and maintenance work must be possible without requiring any on-site engineering skills. This can be achieved by integrating all hardware configurations into either the engineering software or intelligent plug-ins – eliminating the need for manual configuration on site. Service technicians only have to unplug, replace and reconnect a defective component, without having to worry about configuration issues and potential errors.

Taking a holistic approach System security needs to go far beyond an effective firewall. Considering the ever-present threat of cyber attacks, Plant security Physical access protection Processes and guidelines Holistic security monitoring

Security as a quality standard

Network security Cell protection and perimeter network Firewalls and VPN

System integrity System hardening Patch management Detection of attacks Authentication and access protection

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Security threats demand action

With defense in depth, Siemens provides a multi-faceted concept that gives plants and systems both all-round and in-depth protection. The concept is based on plant security, network security and system integrity – in-line with the recommendations of IEC 62443.

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a holistic approach is required that extends from physically protecting facilities based on an effective access control system, all the way to addressing software issues, such as frequent security patches and updates.

Siemens has established the secureby-design hardware and software development process which actively integrates all relevant security issues right from the start. In all development projects, the project manager works with a dedicated security expert who is responsible for a comprehensive security review of the requested features and design, and also conducts security testing prior to the release of any product on the market. The security expert is authorised to stop the release of any project if serious security breaches are identified.

The security process must assess and evaluate in detail all threats and risks to the industrial environments where the products will be used. Siemens is also a member of ISA 99, the standardisation body of the international Industrial Security Standard IEC 62443, so the company has a clear objective of fully complying with established industry standards.

As part of the secure-by-design development process, all newly developed hardware components and software are analysed by a team of security experts who look for issues that could make the component vulnerable to external attacks, and thus compromise the security of the overall automation system. This research continues even Control Engineering Europe

CYBER SECURITY after the product has been launched into the market.

This is why Siemens security experts collaborate with security researchers at universities, security service providers and CERT organisations. They are able to access the latest security-related information. Any vulnerability that is identified is resolved as quickly as possible by a task force drawn-up specifically for this purpose. Product updates are developed and verified – and security patches are provided to all customers that might be affected.

In other words, these hardware and software products reflect a standard of quality where the emphasis is placed on product security rather than time to market. With the objective of establishing itself as a trusted long-term partner for its customers, based on its secure-by-design development process, Siemens puts far more emphasis on launching a secure product into the market than being the first to introduce

a new technology.

Cyber attacks can shut down a complete process plant or manufacturing system. This results in substantial capital loss for the company involved, but also – depending on the industry – it could lead to a great loss of reputation and expose the company to costly liability claims. The goods may even be blacklisted, if they are part of a public infrastructure. As a consequence, more companies are willing to invest in the security of their automation systems. Although investing in hardened products is costlier, it will greatly contribute to lower cost of ownership over the complete system life cycle.

Security lifetime services According to Helmuth Ludwig, chief information officer at Siemens, the increasing number of cyber attacks is a fact that cannot be overlooked.

However, it must not be seen as a reason to forego the digitalisation of

industrial production. Instead, cyber security should be seen as a competitive advantage rather than a cost factor.

Industrial Security is a strategic concept designed to help pave the way to the Digital Enterprise of tomorrow.

It is based on the defense-in-depth concept that is proposed in IEC 62443.

Industrial Security includes securityrelated product features and also the design of automation systems with the help of pre-defined and security-tested software components. It also provides a range of security-related services that continuously monitor automation systems and the development of preventive security measures.

Industrial cyber security is a challenge, but it can be mastered with concerted effort, open communication and dedicated services.

Maximillian Korff is product sales development for Siemens Process Industries and Drives.

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CYBER SECURITY

OVERCOMING SECURITY CHALLENGES

Connectivity is often seen as a challenge to plant security, and in the era of IIoT, it is vital that security considerations are prioritised. Suzanne Gill reports.

W

ith each new connection comes another potential point of entry for a security threat – be that physical, digital, internal, external, malicious or unintended. “With every part of the enterprise now connected in some way to the whole, the risk at every point of ingress is now also a risk to the whole enterprise,” said Mike Loughran, field business leader architecture & software sales at Rockwell Automation.

A range of security concerns need to be addressed, including the safekeeping of Intellectual Property and market sensitive data; protection from intrusions that might negatively affect throughput, employee safety or the environment; keeping critical public infrastructure, such as wastewater treatment systems, online and operating safely; keeping enterprise systems online and not causing network related downtime; and allowing selective remote access to industrial operations.

“With all of this in mind, the commitment to industrial security must be renewed regularly and must evolve constantly with the ever-changing

threat environment. The worst thing to do is become overwhelmed by the possible threats,” warns Loughran. “A good approach is to start by focusing on the probable threats, which will help create better security practices in general.” There is no single standalone product, technology or methodology that can protect from the wide variety of possible threats. The days of securitythrough-obscurity are also gone – it is hard to measure success and therefore efficacy of that kind of approach.

“Proprietary networks that rely on one vendor fall short when they don’t use other available IT tools, innovations and security features.

“Security should encompass everything – from the enterprise level, through the operational level and all the way to each and every enabled device,” continued Loughran. It must take into account risks from staff, processes and technologies alike. It requires IT and OT operatives commitment and collaboration – each has a vital role in establishing and maintaining a secure network infrastructure. A holistic approach can start with three simple steps: To understand the risk undertake a security assessment; deploy a multiIt is vital that critical public infrastructure stays online and operating safely.

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March 2018

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layered security approach – ‘Defence in Depth’; and verify that your automation vendors follow core security principles when designing your products.

Getting the balance right Niklas Mörth, project manager cyber security at Westermo, agrees with Loughlan. He believes that one of the biggest challenges presented by an increasingly connected industrial landscape is achieving the right balance between security and operations. He said: “The security measures that a plant implements can, potentially, make life difficult for its operators. For example, you could implement network segregation to filter out all the traffic that does not belong to your network, but if you do not keep the network segregation up-to-date, you could block valid and important operational data.

In a worst-case scenario, the mechanism that was supposed to protect against external threats could be the very thing that halts operations.”

With plants under constant pressure to maximise availability, an operator might decide to disable network segregation and filtering, in the belief that this will help to maintain production. However, it is there for a good reason. “Its purpose is to prevent a hacker from breaking into the network and carrying out an attack which could have even more serious consequences,” said Mörth. “It is vital to have a sustainable security posture.

Network segregation and other security protection features, such as perimeter protection, intrusion detection, spoofing protection and network-tonetwork protection are all important.

However, if they are to function properly, it must be understood Control Engineering Europe

CYBER SECURITY that cyber security is not only about technology but also about people.

“A crucial aspect of cyber security is keeping your defensive mechanisms up-to-date. Create your security baseline and then constantly reassess the defence, adjust it, and have plans in place for what to do if something happens. That requires technology, people and knowledge, and is the core of a sustainable security posture. Cyberattack threats are constantly evolving, and therefore so must your defences,” concludes Mörth.

decision makers from industrial companies about their approach to the IIoT, and their use of industrial cyber security technologies and practices.

Over 50% of respondents reported working in an industrial facility that has already had a cyber security breach, while 45% reported that they still do not have an accountable enterprise leader for cyber security and only 37% are monitoring for suspicious behaviour.

Although many companies are conducting regular risk assessments, 20% are not doing them at all.

Slow takeup

Some good news

Worryingly, a study entitled ‘Putting Industrial Cyber Security at the Top of the CEO Agenda’ conducted by LNS Research and sponsored by Honeywell, found that industrial companies are not moving quickly enough to adopt cyber security measures to protect their data and operations.

The survey polled 130 strategic

The good news is that, while Honeywell’s study highlights the slow rate of adoption of cyber security measures, Sanjin Biševac, service sales manager Europe at Emerson Automation Solutions, has identified that the implementation of a range of cyber security measures is now more prevalent within manufacturing and

Defence-in-depth for SMEs A Whitepaper from Wago, entitled ‘IT Security in Production Facilities,’ highlights some of the main threats to automation systems used by small and medium sized enterprises (SMEs). It goes on to offer a 10-point plan to protect information technology (IT) and operational technology (OT) from cyber intrusion.

A ‘defence-in-depth’ approach can help analyse where threats are likely to come from and taking appropriate and proportionate measures to protect against them.

Defence-in-depth involves taking a holistic approach to cyber security, considering human, procedural and structural factors as well as technical ones. It is predicated on the notion that if one layer is breached, others can either thwart an attack outright, or detect and respond to it.

The first step could be to guard against physical intrusion. A security fence may seem primitive, but it may be enough to deter an attacker. Access control for restricted areas is another option.

The second step might be to use additional firewalls to establish virtual barriers between each section of the facility. The plant floor can be further subdivided using more firewalls to isolate them from the control room, which can in turn be isolated from the back office. A third step could be network monitoring. One way of doing this is to set up a honey pot – an isolated point on the network which is kept deliberately accessible. This can lure attackers in with the bait of seemingly valuable resources, which can be used to monitor unauthorised activity, see how attackers behave, and improve security accordingly.

There is no single magic bullet for effective cyber security, and there are many other options and types of protection available, but just with these three simple steps, a multi-layered defence-in-depth strategy has been created.

The whitepaper can be downloaded at: www.wago.com/digital-future/en/ Control Engineering Europe

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process companies than it was just a few years ago. So, maybe adoption is now starting to speed up. Biševac points to two key drivers for this change – regulation and digital transformation.

“Several government bodies across Europe are now encouraging the adoption of cyber security measures, especially within critical infrastructure,” he said. To a certain extent, these bodies form their requirements based on recommendations provided by a single series of international standards – ISA/IEC-62443. With this unified standard comes guidance that helps process and manufacturing companies strive for improved cyber security practices.

“Starting to implement cyber security measures can be relatively inexpensive, beginning with workstation hardening, user-account management and patch/ security management,” said Biševac.

“These measures can reduce the surface for potential attack and increase security at the interfaces of devices.”

Firewalls can be used to segment automation systems internally and to isolate them from Level 3 and other external networks. Firewalls can ensure that only authorised devices/ applications can communicate with each other and protect the integrity and confidentiality of messages exchanged between communicating applications.

“Protection against intentional violations can be increased with Security Information and Event Management (SIEM) and Network Security Monitor (NSM) solutions. SIEM deals with realtime monitoring, correlation of events, notifications, analysis and reporting of log data. NSM monitors traffic on automation system networks to identify suspicious content and malicious activity.

“With new security threats constantly arising, cyber security should be considered as a continuous activity. A company’s appetite for cyber risks and its budget availability will determine which security levels it will try to attain,” concluded Biševac.

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CYBER SECURITY

IT AND OT COLLABORATION

IS VITAL FOR A SECURE INDUSTRY 4.0

Machine security loopholes often originate in remote maintenance and update interfaces.

Increasing connectivity of machines and equipment is offering manufacturers competitive advantage by producing goods more efficiently. However, the only way that Industry 4.0 can succeed is when IT and OT collaborate on an overarching security approach, argues Anja Dienelt.

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or IIoT to succeed, network issues and cyber attacks need to be systemically detected and blocked. To achieve this, security measures specifically designed for Industry 4.0 must be taken on all automation levels and this requires close collaboration of information technology (IT) and operational technology (OT) to proactively combat the ever-growing risk of cyber attack.

Today many enterprises consider security as being the biggest obstacle on the Industry 4.0 journey – as a survey on Industry 4.0 by IDG Communications Media AG revealed. The report highlighted the fact that enterprises fear hacker and DDoS attacks the most, followed by industrial espionage and the resulting loss of competitive advantage.

However, for many it remains unclear

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who, within an enterprise, is responsible for securing production sites and processes – is it IT or OT? In 2017, automation and IT experts and security specialists met at the ‘IT meets Industry’ conference in Germany, where it became apparent that responsibilities concerning Industry 4.0 security have not yet been clearly defined. A survey concluded that many operational technicians feel like it is their responsibility.

To date OT has focused on production and industrial equipment availability, but without connection to the Internet.

IT, however, takes care of data security and has little or no experience in dealing with industrial systems.

Working together Traditional automation technology continues to evolve with development

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being heavily influenced by digitalisation and increased connectivity. IT and OT must collaborate closely to secure Industry 4.0 and this necessitates a change in organisational structures: IT and OT must intertwine their processes to profit from each other’s expertise. That is why IoT security cannot be achieved solely by using suitable technology. It is also important to clearly define the roles and responsibilities of OT and IT individuals and departments.

Machines security loopholes often originate in remote maintenance and update interfaces. Information can leak or malicious external data may infiltrate a company through these weak spots.

In most cases, controlling devices used in production networks are not able to fight such threats because they were designed to ensure a network’s Control Engineering Europe

CYBER SECURITY availability, not its security. In addition, mainly heterogeneous data flows through industrial networks – unlike the homogenous traffic of office networks.

That way, a network turns into a black box: It becomes home to an opaque flow of information and commands, used for remote machine maintenance, for sending product information to production systems, for ensuring constant site monitoring and for synchronising logistics. More often, external partners have access to these networks.

Suppliers usually integrate their own IoT solutions into their machines, often leaving production owners without knowledge of what happens inside their own network. Yet they depend on production to run smoothly and it is only when it does that Industry 4.0 is able to deliver on its promise. The plant needs a multi-layered approach to data protection to enable users to leverage the advantages of secure IP-based networks for production and automation processes.

at numerous positions, it analyses network traffic, revealing processes in the field or control networks and potential attacks. A core feature of the analysis is a technology called deep packet inspection (DPI). Instead of classifying traffic by analysing which port is used, DPI gives insight into the data’s contents. This accurate decryption allows for the detection of cyber attacks hidden in permitted protocols, even if sophisticated obfuscation and encryption techniques are employed.

The reporting system accumulates and correlates the information obtained on all levels of industrial automation. It assesses the network’s status, the communication relations within it or the communication behaviour of individual machines. Event monitoring can even visualise anomalies as they occur in the network. The data obtained by the system provides the crucial basis for securing continuous operation, and for network capacity planning and load balancing.

A multi-layered concept

Based on network analytics, necessary precautionary measures can be taken.

These measures, however, require new technologies. Up until now, processing and controlling networks were mainly protected by classic firewalls which protect the company network as a whole from external attacks (first line of defense). Such perimeter firewalls are no longer sufficient for complex industrial networks. Instead, additional firewalls must work inside the network and segment it.

Currently, several security solutions for securing industrial systems are available.

Dependable security products work on all levels of automation across IT and OT systems of a manufacturing site and consist of network sensors, reporting tools, firewalls for industrial sites and Ethernet encryption – while being fast enough to not slow down production processes.

How does it work? By inserting the network sensor into the network Close collaboration of IT and OT is vital to proactively combat the ever-growing risk of cyber attack.

New defence technologies

DPI technology should be part of it too, in order to defend against unknown attackers. Unlike the portbased approach, DPI technology is able to immediately identify and validate any kind of traffic, even down to individual applications, devices or users. DPI technology, therefore, provides proactive protection through whitelisting. This process ensures that industrial networks can be accessed only by authorised users using predefined commands. To achieve this, the network administrator can allow or block individual protocols. This is possible by applying restrictive rules to data traffic between machines or between a machine and a user. Port-based firewalls, on the other hand, use blacklisting, which only allows for identifying and blocking viruses or spyware after adding them to the blacklist.

Industry 4.0 also creates new requirements for industrial communication. Security is in the spotlight as company facilities get more and more interconnected and automation systems are connected to ERP systems in private or public clouds. Functionalities such as integrity protection and encryption with strong authentication gain importance.

Therefore, high performance encryption devices protecting connections between data centers and locations (WAN, Wide Area Networks) from interception and manipulation are also key for a dependable solution.

Anja Dienelt is solution manager IoT at Rohde & Schwarz Cybersecurity.

MACHINE VISION

CONTROLLING MACHINE VISION

LIGHT OUTPUT INTENSITY Jools Hudson explains the importance of lighting control in machine vision applications.

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ighting control is vital for machine vision systems. The intensity of illumination influences how an object appears to the camera, and will affect all subsequent measurements and inspections based on the image.

Dedicated lighting controllers can provide the control needed for consistent illumination, and can offer enhanced capabilities which can facilitate applications that might otherwise be impossible or reduce the cost of ownership of a vision system.

in silhouette and the background illumination is bright; for brightfield illumination of highly reflective objects; transmission inspection of transparent objects; and test equipment for high-sensitivity sensors.

Accurate control of LEDs is achieved by regulating the current applied, rather than the voltage, because the light output from an LED is directly proportional to drive current, not the voltage. Indeed, a small change in voltage will cause a much larger change in the current through the LED, resulting in a large change in Precision control brightness. Even when using current For many machine vision applications control, regulating very low light the challenge is delivering enough light output is a challenge because LEDs to the object to allow the acquisition respond to very tiny currents. of a reliable, measurable image, Just 10µA of current can cause especially in high speed inspection an LED to illuminate and create a applications. However, there are proportionally very large change in numerous requirements where very low output intensity when low intensities illumination levels are needed to avoid are needed. It is, therefore, important saturating the camera sensor. These to control all light leakages and typically occur in backlit applications prevent the LED from illuminating at where work pieces are being imaged the wrong time.

Control systems must have very low noise and achieve an output that is stable within a few µA. This performance is orders of magnitude better than most electronics can achieve and gets close to the limits of physics. In addition, the controller must have all of the functionality of a traditional lighting controller, with multiple Precise lighting control was needed tion to inspect electronic output channels, fast components with variations in surface finish. Shiny parts required accurate pulsing and very low lighting to prevent the camera from saturating, while parts with a dark matt finish required much brighter lighting. safety features.

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The S106 low power lighting controller from Gardasoft, for example, is designed to minimise the effect of noise, errors and crosstalk and achieves accurate ultra-low light control in continuous or pulse modes. It offers 16 constant-current output channels which each have two current ranges that are software-configurable. The low current range operates from 7 µA to 10 mA in increments of 3.5 µA and the high current range operates from 25 µA to 90 mA in increments of 25 µA.

Control in action One application involved inspecting batches of components with very large variations in surface finish. Shiny parts required very low lighting to prevent the camera from saturating, while parts with a dark matt finish required much brighter lighting. The lighting controller was configured in the low range to supply a stable drive of only 90 µA for inspection of the reflective parts, and to operate at 10 mA in the high range for inspection of the matt parts.

Variations in light intensity can have an impact on machine vision measurement repeatability. Both internal factors, such as the age and temperature of the LED, and external factors, such as dust and dirt, can affect LED intensity. Even with a simple caliper measurement, a 10% reduction in light level can cause a change of up to 0.5% in the measured values.

So, when developing machine vision solutions which require very low and precise lighting levels do consider the use of lighting controllers designed specifically for the job.

Jools Hudson is marketing manager at Gardasoft Vision.

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UK INDUSTRY REPORTS

Industry 4.0: time to start thinking small!

The debate surrounding Industry 4.0 is too theoretical and risks leaving lower tier suppliers and smaller manufacturers behind, argues Steve Askins, UK engineering director at ERIKS. The Made Smarter Review, published late last year, outlined an initial strategy to engage Government and industry in harnessing Industry 4.0 by 2030. Despite the recommendations, which ERIKS supports, there is some concern that many manufacturers, particularly those on lower levels of the supply chain, still feel daunted by the task being set, and require more practical advice.

The review was the result of a welcome debate, but what is now needed is actionable advice that businesses can implement, particularly those with limited financial and technological resources.

Much of British manufacturing is made up of lower tiers of the supply chain and smaller subcontractors, who

are either not engaging in the current Industry 4.0 debate, or are daunted by the prospect. While it offers an exciting opportunity, it is a significant undertaking, particularly for smaller manufacturers.

We need to start talking about Industry 4.0 in terms of small, but meaningful, changes that can be built upon gradually, not as an entire allencompassing philosophy.

A potential big win for manufacturers is maintenance strategy – the Industry 4.0 low hanging fruit in terms of helping organisations better understand Overall Equipment

Effectiveness (OEE) and the real cost of downtime. Ultimately, Industry 4.0 should simply be considered to be about better use of information which can be used to upgrade maintenance from a reactive stance to a more proactive, planned or preventative strategy.

Multipix Imaging announces distribution agreement Multipix Imaging has entered into an agreement with Photoneo, Slovakia, to distribute its 3D scanner products within the UK & Ireland. The company’s advanced 3D vision technology is helping drive the future in autonomous systems, working in areas such as collaborative robots, drones and

self-driving vehicles.

Photoneo PhoXi 3D scanners use a laser light pattern projector that emits a set of coding patterns onto the target scene, interpreted by a single camera it constructs a point cloud. It is capable of delivering 16 million measurements per second – either in 3.2 megapixels at 5fps, or

Secure and seamless communication with POWERLINK and OPC UA An announcement by the OPC Foundation and the Ethernet POWERLINK Standardization Group (EPSG) confirmed that an OPC UA companion specification is now available for POWERLINK. The companion specification describes how payload data is exchanged between POWERLINK and any OPC UA platform to enable Control Engineering UK

integrated communication from the sensor to the cloud.

Thomas Burke, president of the OPC Foundation, said: “OPC UA and POWERLINK complement each other perfectly. POWERLINK is among the leading real-time bus systems used in plants and machinery. Together with OPC UA, POWERLINK networks can now communicate seamlessly and securely

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0.8 megapixels at 20 fps.

The scanners are suited to use in robot handling applications for bin picking, where randomly placed, semi-oriented objects can be picked from a container or pallet and placed on a conveyor belt. The scanners are also compatible with multiple industrial robot brands. with the IT environment and into the cloud.”

Stefan Schönegger, managing director of the EPSG said: “This specification allows OPC UA and POWERLINK to fuse into a single network. We are then able to join devices from different manufacturers and across different levels of the automation pyramid into a single, cohesive system. A joint working group between the OPC Foundation and the EPSG has been working on the specification since 2016.

March 2018

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FOOD INDUSTRY FOCUS

Addressing old challenges with new controllers Suzanne Gill looks at the features of modern machine controllers that can offer benefits in food industry applications.

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ight across the food industry there is a need to eliminate downtime, reduce waste, increase throughput, increase production flexibility and optimise asset usage.

John Rowley, industry manager at Mitsubishi Electric, argues that all of these issues can be addressed through automation. He said: “Look beyond traditional SCADA/PLC based systems and turn your attention towards the machine controllers that define the production efficiencies of individual lines and which can also help manage the flow of data.”

Most PLCs today include features that can directly address current food production challenges. “Take batch control as an example,” said Rowley.

“Recipe creation and management, automatic execution of recipes and the simultaneous execution of multiple recipes on a single line can all be accomplished without ever leaving the familiar PLC environment, eliminating a layer of PC complexity.”

Further PC middleware can now

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also be removed, with the PLC linking seamlessly to higher-level management systems. “These PLC edge computing functions have the ability to pass data to and from higher level databases or management systems directly from the plant level control system and this can open-up a whole new level of visibility on production processes,” continued Rowley.

Today’s PLCs also offer data logging capabilities, the incorporation of robot CPUs to ease the transition into robotics, and a platform to address cyber security. The PLC can also become a hub for condition monitoring activity, driving an environment of predictive maintenance and asset optimisation.

Many of these PLC capabilities are recent additions. Traditionally, control requirements in the food and beverage industry have been stable with multi-functionality being the norm, with PLCs needing to offer PID, implement recipes, and the ability to handle processes based on weight/ pressure and temperature. In addition, HMI panels need to comply with spray

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& wipe standards IP66/IP65/NEMA4.

Added value “The lengthening chain of supply has highlighted food safety issues and the importance of traceability, said Cara Bereck Levy, a Unitronics’ spokesperson.

“So, the ability to securely log production data is now critical. A PLC capable of logging, manipulating, and securely sending data has added value for food applications. Some PLC manufacturers now enable their controllers with SQL support.”

Embracing standards According to Darren Reeves, consumer goods manager at Lenze, the demands being placed on the food and beverage industry is leading end users, machine builders and system integrators in a few clear directions. “They want to embrace standards for communication and data sharing. That makes new systems easier to integrate, and simplifies their adaptation, improvement and management in operation. For many of our customers, considerations like the PackML standard are becoming increasingly important.

“There is also a need for greater customisation to help companies differentiate their offerings and gain competitive advantage.” As production machinery becomes more sophisticated, automation systems have a larger software component, which has become a larger portion of overall system costs.

Rapid development environments can cut the time and cost involved in the production of software, allowing system designers to spend more effort on the features that truly differentiate their machines.

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FOOD INDUSTRY FOCUS

Finding the key to PRODUCTIVITY IMPROVEMENT Suzanne Gill reports on the productivity conundrum facing the food industry and looks at an OEE tool which can identify areas where improvements can be made.

Achieving 30% OEE improvement Wagg Foods, a producer of pet food, has increased its OEE efficiency by 30%, secured its packaging lines from errors and ensured compliance with retailers’ codes of practice through the use of a modular suite of packaging line software.

The company was looking to eliminate human errors and improve its operational efficiency. It was attracted to the OAL Connected system as it offers label and date code verification with the option to easily expand functionality. The automated system verifies the labels, packaging and date codes on every product. The same system can then be used for factory performance monitoring, offering the realtime data and metrics required to implement a continuous improvement, OEE programme. Additional functionality also includes paperless quality checks and checkweigher links to ensure full traceability.

The OAL Autocoding label and date code verification module places control of the packaging line with Wagg’s technical team, rather than operators on the line, ensuring compliance with retailers’ codes of practice.

The automated system links a master database of products, scanners, printers and touchscreen PCs on the production line. The same touchscreen PC on the production line can then record product counts and downtime reason codes, replacing existing manual production logs. As part of a continuous improvement strategy, Wagg Foods used this accurate and reliable data and reporting to drive improvements. Operational managers can then predict and plan their factory more efficiently using the collated data.

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T

he UK’s productivity figures do not make for comfortable reading. Data from the Office of National Statistics shows that the UK produces no more in an hour of work today than it did in 2007. Indeed, productivity has fallen in every quarter since 2008, with the UK now 18% below its 2007 high.

For the food processing industry the lack of productivity is having a negative effect on profitability and until this issue is addressed it will be difficult for the UK food sector to remain competitive with other, more productive regions.

One route to increased productivity is through improved production performance and this requires the collection of line data to help determine Overall Equipment Effectiveness (OEE), a best practices metric which is able to identify the percentage of planned production time that is truly productive.

It can be used to track the elimination of waste from production assets to increase productivity.

“Continuous improvement managers and production managers in the food sector need to take data and turn it into meaningful information to help root out the cause of inefficiencies,” said John Roberts, director at Idhammar.

“Often this data is being collected anyway to meet food traceability demands.” Roberts believes that the easiest way to turn data into useful information is to run it through optimised OEE software to gain insight into problem areas across the plant.

Such a solution is offered by Idhammar’s OEE System which is able to automatically manipulate raw data and turn it into graphical visualisations, providing the basis for real-time analysis and reporting. The data can be held locally on site or remotely in the cloud.

“Of course, security of data will always be a vital concern,” said Roberts.

Idhammar systems are ISO 27000 accredited. This is a rigorous information security management systems standard which the company adheres to because of its work for the Environment Agency where this standard is a prerequisite.

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FOODINDUSTRY INDUSTRYFOCUS FOCUS FOOD The easiest way to collect data for Idhammar OEE is via a tablet or smart device if the plant already has wifi installed, or via hard-wired data capture devices. A simple solution, for example, could be a sensor placed at the end of a line to count products as they leave. This can provide information about the rate at which products are being made. Even such a simple setup will also be able to give near real time information about the reasons for line stoppages.

Inputting data manually Data can even be input manually into Idhammar OEE if automated solutions are not an option to make it possible to periodically identify where line stoppages are occurring.

“Industry needs to grasp the nettle and look for small productivity improvements wherever they can across the plant,” said Roberts.

Within days of installing Idhammar OEE one food industry customer was able to very quickly identify that it was losing up to 30 minutes of productivity on every shift due to the fact that a small conveyor needed to be lifted up and down for staff to gain access to the line.

At a beverage production plant information from Idhammar OEE was used to embark on an OEE improvement project, which resulted in its being able to cut out weekend shifts while also increasing productivity.

“Getting to that point, however, did require a great deal of hard work and manpower. Idhammar OEE provides the information but it is still up to the company to act on this to achieve the possible efficiency and productivity improvements,” said Roberts.

Idhammar is working with another food customer in the UK, as a part of a wider global campaign to implement world class manufacturing, to help it completely eradicate line stops. “We are developing software to help the company achieve this goal. It requires detailed analysis of every stoppage of longer than five minutes so we need to capture data about the product on the line as well as shift information to allow for analysis of all the relevant data.

Acting on the information provided by Idhammar OEE the company then needs to take steps to ensure that the causes of any downtime are not repeated. This could require line setup changes or staff training, for example. This analysis happens for every single breakdown, helping the company move towards its zero downtime target.

OEM benefits Idhammar OEE can also offer benefits to OEMs supplying the food industry. One packaging equipment company, for example, which provides both the machinery and the raw materials for production of drinks containers, wanted to be able to measure and improve the performance of its equipment in-situ at customer sites.

It is important that complex filling machines are correctly operated and maintained in order to ensure they operate Control Engineering Control Engineering UKEurope

at peak performance. In certain circumstances the company is contractually obliged to ensure machine performance, so it needed to be able to verify that the customer was correctly using and maintaining the machinery.

Idhammar OEE offers omnipresent software embedded in the equipment to monitor all of the company’s machines globally, providing data about how customers are utilising the machines.

The software is now being installed in all new filling machines and the customer is retrofitting it into existing equipment to provide it with information to demonstrate whether or not the machinery is being deployed and maintained properly.

“For this company, having data about the performance of the machine allows them to track critical control points (CCPs) to identify any circumstances where the machine has been running outside of its recommended limits which can result in poor performance,” said Roberts.

In conclusion, Roberts said: “While the deployment of robust, fully functional OEE software will be an important step towards operational improvement, crucially it will be the absence of accurate and reliable, real-time data that will undoubtedly prevent line operators and management from making informed decisions quickly. Don’t get caught in the data gap.”

The WTX110-A Industrial Weighing Terminal: The latest addition to HBM’s world-class WTX series Designed for static and dynamic filling or dosing tasks, the WTX110-A is encased in robust stainless steel housing and is certified to IP69, making it suitable for industrial and legal for trade weighing applications in harsh environments or for products with strict hygiene requirements.

Featuring a large easy to read back-lit display, push buttons and simple text navigation, the durable WTX110-A allows for effortless on-site operation and has been designed for optimal ease of maintenance.

Enabling easy configuration or calibration, as well as other servicing measures, to be performed conveniently on-site or in a distributed system using PanelX software, the WTX110-A enables remote calibration to be performed via the internet quickly and cost-effectively.

An encrypted connection ensures secure data exchange through remote access, via both PanelX software and the WTX Mobile App, which makes HBM one of the very first manufacturers of weighing technology products to offer this highly innovative option.

With state-of-the-art functionality, industrial interfaces, software, and design HBM’s products are ideally suited for dynamic and static weighing applications. Whether it is for filling, dosing, check weighing, or sorting tasks, our weighing terminals, weight indicators, and weighing electronics are robust and durable even in harsh environments. From sensors to software, HBM offers a complete range of weighing solutions which can be adapted to suit a variety of requirements.

For more information, contact HBM on +44 (0) 208 515 6000 or visit www.hbm.com

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MARCH March 2018 2018 UK5 UK5

FOOD INDUSTRY FOCUS

SPEEDING UP PRODUCTION LINE DESIGN TIMES In just eight months, a machine manufacturer, together with its chosen automation partner, were able to equip a new teabag production line to achieve Industry 4.0 production.

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hen Twinings set out to develop a new production line to help it reinvent the heatseal teabag, it turned to machine manufacturer, IMA. The company was interested in implementing emerging technologies and Industry 4.0 methodologies to help acheive its potential. The biggest challenge was the timeline for the installation of the new line, and it was the use of innovative technologies which allowed IMA to speed up its product development time to ensure that this deadline could be met. It made use of B&R’s ready-to-use software modules, while the simulation features in Automation Studio allowed critical parts of the machine to be accurately sized early in the conceptual design phase.

Sauro Rivola, automation manager at IMA explains more about the

machine control and automation solutions specified for the line. “The compact dimensions and significant use of electrical axes that had been specified, B&R’s fully integrated control system – including the motion platform and Automation Studio development environment – made a big difference.”

Other time saving features offered

by B&R included its drive-integrated safety technology and single-cable hybrid motor connectors, which helped IMA reduce the time required for wiring and obtaining CAT3 (EN 13849-1) certification for safety applications, as specified by Twinings. Finally, the use of an energy recovery system helped achieve a significant reduction in both energy consumption and heat dispersion in the electrical cabinet.

Simulation of the dynamic behaviour of the system – including drives and loads – allowed each mechanical component to be precisely dimensioned

to optimise the relationship between inertia and resistance to breakage.

The ability to complete this step directly in the development environment before constructing a prototype was fundamental to IMA being able to complete the project on time.

Simulation also ensured a good level of accuracy in sizing the electric motors.

Correlation between the theoretical torque curves, obtained through motor simulation, and those achieved by measurements on the machine itself, were observed. Machine development time was reduced as there was no need to replace any mechanical or electrical components due to errors that were not revealed prior to operation.

This approach also enabled IMA to perform tests on mechanism geometry and motion profiles in advance, helping predict their dynamic behaviour with a minimum margin of error. The meant that commissioning could proceed more smoothly.

Power distribution from the smallest to the largest.

ENCLOSURES

POWER DISTRIBUTION

See us on stand D720 Drives & Controls 10 - 12 April NEC Birmingham

CLIMATE CONTROL

FOOD INDUSTRY FOCUS

Bringing an outdated operating system up to date without disrupting production When a UK-based manufacturer of chilled and fresh food recognised that its flagship premium soup lines were becoming vulnerable to failure in the production system it set out to find a solution.

Because the company’s XP legacy operating system was no longer being supported by hardware vendors it was no longer able to maintain or expand the SCADA system and was also unable to carry out security updates.

To make matters worse, obtaining the correct level of support for the system was proving very difficult, leaving it vulnerable to system failure.

The company recognised that it urgently needed to replace its outdates system.

However, due to its existing configuration, it was a time consuming and complicated task, requiring additional support from in-house IT resource.

The priority was to address and reduce the immediate risk of computer failure, while operating within budgetary constraints. A pragmatic and targeted

solution was essential to ensure objectives were met and project overrun was avoided. The company called in Astec Solutions to provide a solution.

The first step for Astec Solutions was to first stabilise the system. The existing operating systems were virtualised to enable them to continue to run in the current configuration on modern server hardware, which came with a replacement guarantee. Next the non-industrial PCs were replaced with rugged thin-client workstations, which do not need to carry an operating

IT INFRASTRUCTURE

system themselves.

The existing SCADA computer hardware was also replaced with a redundant, centralised virtual host, with links to the virtual clients at the appropriate plant locations.

Removing the server from the working environment makes it much more stable, robust and reliable. If a shopfloor workstation fails it can simply be unplugged and replaced with a new unit from the store. Once it is confirmed that the IP address is correct, operations can be resumed.

Astec Solutions was able to deliver system virtualisation, replacement and commissioning – without disrupting production – by working overnight and at weekends, during scheduled downtime. The outcome of the project was that the food manufacturer now has a modern, stable and supportable system, increased flexibility and a greater level of redundancy and resilience.

At the same time, its reliance on the IT department has been reduced and the company is now well placed to embark confidently on enhancements to its SCADA solution.

SOFTWARE & SERVICES

www.rittal.co.uk

CALIBRATION

CHECKING THE CHECKWEIGHER

Colin Maher explains, in simple terms, how to precisely measure the accuracy of any inline checkweigher, using the method required by the Package Goods Regulation.

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t is estimated that in the UK alone there are 4.9 million products checked by inline checkweighers every minute. Despite this, there is still widespread misunderstanding about how to measure the accuracy of a checkweigher and even greater confusion relating to regulation compliance.

Unlike most of Europe, the UK has no requirement for a checkweigher to be trade approved, so a checkweigher placed on the UK market is not required to have any guaranteed accuracy. For this reason it is essential that the accuracy is checked to ensure it complies with all the regulations and countless codes of practice. Often literature about this is overly complex and can be easily misunderstood. There

are many publications available today that offer information and guidance on inline checkweighers.

On any weighing instrument, there are two areas for error that will determine the accuracy of the equipment. The first is the repeatability and the second is exactness to a known mass, such as calibrated weight. These two factors are the only similarity between dynamic weighing (inline checkweigher) and static weighing (scales).

Misunderstanding The most common misunderstanding is that an inline checkweigher should be calibrated the same as a static scale, meaning you stop the transport system, place weights on the weighing

Example of dynamic versus static weighing.

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conveyor and if this is OK then the checkweigher is accurate. This is not true as you need to consider the additional errors introduced when you start the conveyor and the checkweigher is working with additional vibration and in motion.

This is a big factor and fundamentally only a checkweigher that has a weigh cell designed to work in this way will meet the required accuracy.

While static calibration as the only form of calibration is pointless, for the service engineer a starting reference should be used to determine the dynamic weight. For example, the checkweigher can weigh a product at 500g statically but when in motion the display shows 502g, the checkweigher would need to correct the dynamic by -2g. Ideally, a checkweigher’s auto dynamic calibration will adjust for this by taking a static reference first and then measuring the difference and adjusting.

The other misunderstanding is passing a known weight across the checkweigher, such as a calibration weight. Even if it is the same weight as your product this calibration weight will have a different dynamic effect as it is transferred across the weighing conveyor.

It will give different results, mainly due to its difference in length and > UK10 shape.

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| PC11-48E |

Minimised size with maximised application flexibility.

The ultra-compact C6015 IPC.

www.beckhoff.co.uk/C6015 With the ultra-compact C6015 Industrial PC, Beckhoff is again expanding the application possibilities of PC-based control. Wherever space or cost limitations previously prevented the use of a PC-based control solution, this new IPC generation offers an excellent price-performance ratio in an extremely compact housing. With up to 4 CPU cores, low weight and unprecedented installation flexibility, the C6015 is universally applicable in automation, visualisation and communication tasks. It also makes an ideal IoT gateway.

Processor: IntelŽ Atom™, 1, 2 or 4 cores Interfaces: 2 Ethernet, 1 DisplayPort, 2 USB Main memory: up to 4 GB DDR3L RAM Housing: Die-cast aluminium-zinc alloy Dimensions (W x H x D): 82 x 82 x 40 mm

Flexible installation with rear or side panel mounting.

CALIBRATION The Zone of Indecision One of the first checks is to determine the Zone of Indecision (ZoI) which is globally accepted as a calculation that factors for the uncertainties attributed to dynamic weighing. This test will determine the repeatability of the checkweigher with the product. The same product needs to be passed 10 or 20 times over the checkweigher in the usual direction of travel during production.

The individual values need to be recorded. Some checkweighers include a function to automatically record and even display the required standard deviation. If not, Excel has a built in formula to do this called STDEV. Once you have the standard deviation multiply it by six and this is your Zone of Indecision. From Table 1 you will then be able to calculate your Tolerable Negative Error (TNE) (-T1). For example if your product is 200g then your TNE (-T1) is 5% or 9g.

Next, calculate one-quarter (0.25) of this 9g, 0.25 of 9g = 2.25g. This value is your repeatability limit. If the Zone of Indecision is greater than the 2.25g (one-quarter of TNE) then the checkweigher cannot be used with the set points, (reject limits) shown in Table1.

This test should be done and recorded for all product types and weights used on that checkweigher. It

is good practice to repeat this test over a period and build up a trend analysis to indicate how variable it is over time and this will help determine how frequently you need to perform the test in the future. These records, along with the trend analysis, form the proof of the risk assessment detailed in the retailer’s code of practice.

Exactness The second test is for the exactness to a known mass, which is also done using the product along with a static scale, calibrated to national standards.

The static scale should be capable of reading to the same resolution as the checkweigher or better.

These checks should be done before, during and after a batch. By recording the weights a trend analysis can be made which can form the data for a risk assessment as required in some of the codes of practice. The test includes: • Using a calibrated weight traceable to national standards and as close to the product weight as possible check that the static scale is weighing correctly.

• Note the weight of a pack as it passes over the checkweigher and then weigh this on the static scale. If the difference is within one-fifth TNE then the checkweigher is suitable for use. Some checkweighers have a built in weight check function and will

Table 1: Calculating your Zone of Indecision.

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reject a product and hold the weight of that product on the screen • In order to make a check on the repeatability of the checkweigher at that time it is good practice to repeat this test at least once.

For example, a product with a nominal of 200g, when we weigh this on the checkweigher it reads 200.4g.

Weighing this same product on a static scale, it shows 199.7g a difference of 0.7g. We know the TNE for a 200g product is 9g and one-fifth of this is 1.8g. The 0.7g is less than 1.8g limit therefore this checkweigher is accurate enough to comply.

The Package Goods Regulation and Codes of Practice state: “Any measuring equipment used for quality checks must be suitable for the purpose to which it is used”. While this statement remains open to interpretation, the regulation references a minimum resolution of weighing equipment that must be used and trade verified for offline static weight sampling of product.

Colin Maher is sales manager at Minebea Intec.

Table 2.

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Control Engineering UK

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Safety laser scanners benefit from safe network integration SICK has expanded its microScan3 family of safety laser scanners with the addition of EtherNet/IP and PROFINET compatible variants to enable simple integration of safety laser scanners into a safe network.

The move also facilitates simultaneous field evaluation of up to four fields, instead of the single field offered by standard I/O scanners.

The SICK microScan3 Core – EtherNet/ IP is believed to be the first safety laser scanner to support CIP Safety over EtherNet/IP and the microScan3 Core – PROFINET enables safe and reliable bus

communication using the PROFIsafe protocol over PROFINET. The network-compatible scanners are said to be particularly useful in applications where having multiple single field scanners would require costly, complex wiring and control. They are suited to use for access protection where material is transferred across sections of the production line and for presence detection to prevent an accidental restart of a machine if personnel move out of one field and into another.”

Turning a cooling unit into an IoT device Rittal has added a new IoT interface to its cooling units and chillers to enable integration into Industry 4.0 applications. This addition enables continuous communication, from the sensor to the cloud – the interface also supports connections to superordinate monitoring or energy management systems.

A great deal of information is generated by modern enclosure climate control solutions. However, until now, it has only been practical to record operating hours and the current temperature inside the enclosure.

Modern devices, such as the new cooling units and chillers in the Rittal Blue e+ range, allow a multitude of values and other information to be

measured and recorded. This includes the temperatures inside and outside the enclosure, the evaporator and condenser temperatures and, where appropriate, measurements from additional sensors located inside the enclosure. In addition, instead of a simple operating hours meter, the run-times of the compressor and internal and external fan can be recorded separately. It also provides system messages, data for capacity utilisation and the current parametrisation information.

The IoT interface can be mounted either on a top hat rail, or directly on the cooling unit, or chiller. The protocols supported are OPCUA, Profinet, SNMP, Modbus and CANopen.

High-precision positioning encoder The ENX 16 RIO high-resolution encoder from maxon motor offers a resolution of up to 65,536 counts per turn in a compact and rugged housing.

The new maxon ENX 16 RIO encoder (Reflective, Interpolated, Optical) fulfills all the requirements for a high-resolution optical encoder in a compact design. The resolution can be configured at the factory or online. The

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March 2018

operating temperature range for the robust unit is from -40°C to +100°C. The encoder can be combined and configured with matching drives online.

It fits the new brushless EC-i 30 motors and the brushed DCX motors (diameters of 16mm and up). The counts per turn and the electrical interface of the ENX 16 RIO encoder are also configurable online.

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Zero leak check valves for extreme conditions New valve configurations, manufactured from materials which are compliant with NACE specification MR0175/ISO 15156, have been added to the range of zero leak check valves from LEE PRODUCTS. Suited to use in tough conditions, the valves can be used in gas wells as well as oil wells.

The MP35N bodies and poppets offer durability and custom polymeric valve seats ensure zero leakage of fluids at pressures up to 1034 bar and at temperatures of up to 200°C. Seat materials are also available to ensure compatibility with typical subsea and down hole fluids and also gas exploration and production applications.

The zero leak check valves are said to exceed the performance requirements necessary for oil tool operation under the extreme environmental conditions found in deep wells.

The valves are also self-retained without the need for O-rings, facilitated by the use of the innovative and field-proven Lee locking end which securely locks the valves in place and prevents any bypass leakage.

Control Engineering UK

MACHINE VISION

MACHINE VISION PROGRAMMING:

THERE’S AN APP FOR THAT! Neil Sandhu takes a look into the future of machine vision programming; and sees a more flexible, cost-effective solution appearing on the horizon.

I

n today’s information-rich world, there is an App for just about everything. All the hard work has been done for us – and there is no need to understand the programming that goes into creating the eye-catching user interface.

Could the same ever be possible in the field of machine vision? Will you be able to configure, commission and monitor a sensing application just by finding a ready-made App? Well, in fact, that technology is already on its way. In the not too distant future, a sensor manufacturer’s ‘App Store’ could be the go-to source of ready-developed application-specific solutions for programmable devices.

Machine builders, system integrators and developers will soon have the facility to access ‘Apps’ to easily set-up and configure the required software for their systems by using or adapting existing applications.

SICK recently launched AppSpace, a concept that allows free and flexible customisation of applications on its range of programmable sensors and devices with ‘click and drop’ ease.

Rather than being restricted to the available pre-developed proprietary software, AppSpace’s open software platform enables system integrators and OEMs to develop – and even share – their own tailor-made solutions.

Developers working for SICK and for its customers have already formed a dynamic community that is collaborating and perfecting new ideas.

In AppStudio developers are able to create customer-specific applications easily, use the AppManager to import Apps into the sensor and adapt them to the task in hand. The AppPool cloud service then makes it easy for endusers to install, manage and allocate Control Engineering Europe

uploaded sensor Apps to programmable SICK devices anywhere in the world. Sales engineers can build configurations for customers using AppTemplates, without the need for programming skills, and integrators can quickly accomplish feasibility studies.

The first ‘App’ The first application to be developed in the AppSpace programming environment is now complete, following work with a European confectionery manufacturer to create an ‘off-theshelf’ label reading and verification solution. Developed initially for the customer’s high-speed chocolate packing line, SICK engineers perfected the all-in-one LabelChecker with the ability to read and verify text, numbers bar codes and 2D codes, as well as inspecting label design and print quality.

The SICK LabelChecker’s capabilities encompass OCR and OCV in multiple regions and lines, including overlapping characters, as well as dot matrix printed and indented (peened) text. In addition, many standard types of 1D and 2D code can be read and verified including multiple codes in one image and comparison with alphanumeric print.

Label design quality control includes type checking, print quality, shape, rotation, tilt and location checking and comparison with pre-learned label images with compilation of quality statistics.

LabelChecker is now available to any end user, system integrator or machine builder as a ready-to-use package.

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The future?

Traditionally, machine vision has required specialist programming expertise, huge processing power and bulky complex hardware. AppSpace offers more flexibility for vision engineers and programmers because they can customise a camera or sensor for themselves and, with full access to standard image libraries, such as Halcon, can adapt them for their own needs. It turns programmable devices into easily-configurable ones, even when for complex applications.

The beauty of AppSpace is that it enables applications to be developed that can then be made available off the shelf and easily adapted for a specific need.

The potential for advancement of sensor technology will eventually reach the limits of what is practical from a hardware perspective. However, the opportunities for software application developments are almost limitless Neil Sandhu is UK product manager – imaging, measurement, ranging & systems at SICK UK. March 2018

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MOBILE ROBOTS

MOBILE ROBOTS:

SUPPORTING LEAN OBJECTIVES Control Engineering Europe finds out how a new breed of autonomous mobile robots are supporting lean approaches to production on today’s more dynamic plant floors.

A

s manufacturers embrace lean approaches to their operations, there is continual evaluation of any opportunities to optimise production. Even in highly automated facilities, material handling often remains a manual, inefficient process and automating material transportation to reduce production bottlenecks and deploy valuable human workers more effectively has remained a challenge.

Automated guided vehicles (AGVs) are no longer able to provide the flexibility needed in today’s agile manufacturing processes. However, new sensor and software technologies are making autonomous mobile robots (AMRs) a good solution for often unpredictable and changing production layouts and dynamic work environments.

Manual transportation Manual transportation requires workers to leave their stations to push carts loaded with materials between manufacturing processes and the stockroom, and can result in production backlogs and idle workers as they wait for assemblies and parts to be delivered. Plant set-up is often dynamic, with new production cells and processes that must be supported so people, equipment, pallets, and other obstacles can unexectedly appear in what used to be open passageways. Any automated material transportation approach needs to be flexible and adaptable without adding cost or disruption to processes.

They must also be safe for operation around employees. That flexibility

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also means that automated material handling must be easy to learn, programme, deploy, and redeploy in-house to ensure that the chosen approach can stay up-to-date with requirements cost-effectively.

Traditional automated guided vehicles (AGVs) move materials using fixed routes guided by permanent wires, magnetic strips, or sensors embedded in the plant floor. However, those systems are inflexible and do not fit with the trend for more dynamic manufacturing floors. If manufacturing processes change, the facility must be updated again and if people or material temporarily blocks the AGV’s route, it simply stops until the way is cleared. In contrast, autonomous mobile robots (AMRs) are designed to work within dynamic and changing environments.

They offer the flexibility, safety, and cost-effectiveness that allows companies of any size to automate and optimise material handling.

An AMR navigates via sensors, cameras, and software built into the robot

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itself, without the need for any external sensors or guides. Once the robot has learned its surroundings – either by uploading a facility blueprint or by piloting the robot around the plant to develop its own map – it will recognise its surroundings and can take the most efficient route to its destination autonomously, safely avoiding obstacles and people.

Magna-Power, a US-based manufacturer of power products, deployed two Mobile Industrial Robots (MiR) AMRs to move parts and assemblies from the stockroom and through its vertically integrated manufacturing floor. “One thing that was pretty astonishing for me is that the MiR robot was delivered and 15 minutes later it was unpacked and on the floor,” said Adam Pitel, VP of operations at Magna-Power. “In another 15 minutes, I’m controlling it with my mobile phone, and within two hours it is travelling from point to

Control Engineering Europe

MOBILE ROBOTS point in our building, after uploading a schematic of our facilities,” he continued.

The fast and easy integration of AMRs make them capable of adding new efficiencies almost immediately. With low initial costs and fast optimisation of processes, they can offer a remarkably fast return on investment – often in less than six months.

Efficiency gains AMRs can bring efficiency gains to a number of operations related to production and material handling. As businesses grow, AMR implementation can expand simultaneously with minimal additional costs. Moreover, the AMR is collaborative and can be used in nearly any situation where employees are currently spending time pushing carts or making deliveries.

Automating these low-value tasks means that employees can focus on higher-value activities. At Magna-

Power the implementation of the two MiRs has freed the equivalent of three full-time employees, who can now focus all their attention on the tasks they were hired to do. “The purpose of the robot is not to replace employees, but to make them more efficient with their time,” explains Grant Pitel, VP of engineering at Magna-Power. “Now they can focus on the things that we can’t get a robot to do.”

AMRs can perform the monotonous and repetitive tasks of material transportation without breaks that can disrupt the assembly process.

NewForm, a manufacturer of Italiandesigned bath taps and fittings, is seeing these benefits with its two MiR robots.

Damiano Marconi, technical assistant at NewForm, said: “Now our lines are active on a 24/7 ‘lights out’ basis, because they are automatically loaded and unloaded.” Moreover, the MiRs are integrated with the production

planning system and provide a realtime overview of materials. “We can guarantee real-time production control. The very simple integration software can easily communicate with both our machine tools and our data server, so we can easily track every piece, its position and condition in real-time.”

Modern manufacturing environments can no longer be dependent on costly, inflexible legacy technologies. Nor can they afford to continue to rely on unproductive manual transportation of materials, especially in today’s tight labour market. Autonomous mobile robots can offer an agile alternative to AGVs or manual delivery, providing flexibility, cost-effectiveness, return on investment, and productivity optimisation.

MiR AMRs are available in the UK from RARUK Automation.

WIRELESS TECHNOLOGY

WIRELESS AS AN OEE TOOL

Accurate machine run-time data helps determine why production goals aren’t met, says Fritz Cleveland.

F

ield devices make operations visible and support datadriven decision making. Using technologies associated with the Industrial Internet of Things (IIoT), device-level data is accessible to operators and plant managers, offering insight into machine performance and process inefficiencies.

Real-time remote monitoring of machine status helps address issues as they arise, regardless of whether an operator is present. Personnel monitor multiple machines on a factory floor from a convenient location. Operators resolve small issues before they become big problems.

Traditionally, wireless systems were difficult to install and complicated to maintain. However, technology has advanced over the years and today many remote monitoring solutions offer reliable, low-cost wireless communication. These wireless I/O devices are easy to install, and then uninstall and move to a new location as monitoring requirements change.

One wireless I/O device can collect both digital and analogue sensor readings and forward this data to a central collection point for analysis.

Several sensors can connect to a single node, and 47 nodes can exist within a single radio network. This means multiple sensor readings aggregate into a single gateway device before being forwarded to a host-controlled system for analysis.

Serial-data radios further extend this wireless I/O network. These back-haul devices receive serial data from another serial-data radio, or a serial connection to a gateway, and forward it to another remote serial device. Chaining data

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radios expands the network to meet the remote-monitoring needs of many applications.

An efficiency calculation Overall equipment effectiveness (OEE) is a calculation of manufacturing process efficiency involving three primary factors – availability, performance, and quality. The availability factor considers events that decrease total runtime, including planned stops (such as for product changeover) and unplanned stops. The performance factor considers anything that decreases the speed of the manufacturing process while it is running. The quality factor accounts for parts or products that do not meet quality standards.

An OEE calculation, taking these factors into account, expresses its result as a percentage value, with 100% meaning only good parts are made (quality), as quickly as possible (performance), and without any stops (availability). Calculation results provide actionable insights into the critical sources of waste in a manufacturing operation.

The OEE Foundation also identifies 6 ‘Big Losses’ to manufacturing productivity: • Unplanned stops for equipment failure • Stops for setup, adjustments, or changeover • Idling or minor stops (for issues such as a material jam or a blocked sensor) • Reduced equipment speed • Scrapped work • Rework.

To reduce these losses and minimise their impact, visibility into where and when inefficiencies occur is essential.

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This is where access to data from sensors and indicator lights becomes important. Logged data from sensors and indicator lights installed on machines can help calculate OEE and identify steps to improve efficiency of machines, processes, and people.

Runtime trends Tracking machine and process data trends helps identify when and where losses are occurring. However, manually monitoring production machine status is time-consuming. Depending on facility size, it slows down production and requires additional time which could be more effectively used elsewhere.

With a wireless system, using a tower light with a wireless radio base offers local indication of machine status and remote status of each light module. By logging results from machine-status indicators users can track trends in individual machine up-time and cycle counts for timely updates.

Data can be used to identify whether a bottleneck is caused by a machine or personnel issue. Capturing machine status helps users identify causes of production loss. This information, necessary to identify and drive efficiency improvements, was most likely previously unavailable.

For one manufacturer accurate machine runtime data helped determine why production goals were not being met. Operators blamed machine downtime for the failure and maintenance personnel blamed the operators. Based on the data, facility managers identified what exactly was transpiring.

Machine health In addition to monitoring machine performance metrics, wireless sensor networks also check up on machine health. Machine predictive maintenance is challenging because minor performance changes can be hard to detect without the proper tools. Remote condition monitoring using a wireless system plays a key role Control Engineering Europe

WIRELESS TECHNOLOGY so can damage to the machine. By remotely monitoring motors, pumps, compressors, fans, blowers, and gearboxes for increases in vibration, problems are detected before they become severe. A wireless vibration and temperature sensor serves as a ‘check engine light’ for machines by measuring RMS velocity, which provides the most uniform measurement of vibration over a wide range of machine in predictive maintenance and helps prevent costly downtime.

Vibration, for example, is a key machine parameter. It is often caused by imbalanced, misaligned, loose, or worn parts. As vibration increases,

frequencies.

After mounting the vibration sensor, a user must collect enough vibration data to establish a baseline for the machine. Initially set the threshold at 1.5 or twice the baseline. When the

threshold has been exceeded, the wireless vibration and temperature sensor can provide local indication of the problem, the signal can be sent to a wireless tower light on a central location, or an email or text alert can be sent. The vibration and temperature data can also be sent to a wireless logic controller or programmable controller for collection and analysis.

Remote monitoring capabilities are making it easier for manufacturers to identify and remedy causes of waste within their facilities. By using wireless technologies, manufacturers can quickly gather data needed for OEE calculations, as well as gain valuable metrics for predictive maintenance to maximise machine performance.

Fritz Cleveland is product manager, wireless products at Banner Engineering. This article originally appeared on www.controleng.com

PROFITABLE EFFICIENCY

Achieving the goal of

PROFITABLE EFFICIENCY Peter Martin discusses a new approach to achieving profitable efficiency, by ceding profitability control to process control, which is said to realise 100% ROI in a short time, often under six months.

P

rofitable efficiency is profitability control cascaded to process control to maximise operational profitability in real time. While this is a new execution method, its concept is already deeply ingrained within the DNA of process control.

The primary objective of process and logic control is to improve the efficiency of an operation. To improve efficiency, a feedback control loop measures the variables to be controlled, determines the variation from the desired set point and adjusts the variables to move toward the set point.

Since the 1960s process control has advanced beyond single-loop feedback control. For example, multi-loop cascade control, feedforward control, and coordinated multiple variable control utilise dynamic process models to enable sophisticated control strategies.

Fundamentally, real-time control involved making and acting on decisions within the period defined by the time constant of the process being controlled. In other words, the timing is defined by the process being controlled, rather than human time schedules. Decisions being made on human schedules are referred to as ‘management decisions’, while decisions made on process schedules are referred to as ‘control decisions’.

When humans are provided with the information they need to make effective real-time control decisions, as well as the tools they require to act on that information and to realise a positive result, we say they are

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‘empowered’. So, an empowered workforce relies on operators being given the tools necessary to effectively serve as controllers.

It was understood that any improvements in efficiency could be translated directly into improvements in operational profitability. But this is no longer the case. Since the early 2000s, the speed of industrial business has steadily increased, triggered by the deregulation of electric power. As electrical power was deregulated, the supply-to-demand ratio on the grids started to fluctuate. Energy suppliers and grid managers tried to deal with these fluctuations by increasing the price of energy when the demand was high and supply was low and reducing the price of energy when the demand was low and supply was high.

The result was that even though plants might actually increase their energy consumption, their energy bill could increase.

The fluctuations in electricity prices caused a domino effect across other energy sources and raw materials. To deal with the unstable costs, industrial companies started changing the price of their products more frequently. Today, in an increasingly speedy industrial market, not only must plant managers decide how much to produce, but the operators must also determine the best time to produce, which can sometimes diminish the importance of operational efficiency – it might be more profitable to run the plant less efficiently, according to the traditional efficiency measures, to more cost-effectively meet

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market demand and opportunity.

Process control for improved operational efficiency no longer had a direct impact on improved operational profitability and new approaches were required to deal with the everincreasing real-time dynamics of industrial business variables.

The first response was to turn to IT departments and enterprise resource planning (ERP) suppliers for solutions.

Few, if any, realised the desired results, primarily because the IT teams and ERP software were both experienced in solving traditional management problems, but not real-time control problems.

The correct solution involved understanding that, as operational profitability fluctuated more rapidly, management decisions had become control decisions. In other words, the solution had to be approached from the perspective of real- time control.

Real-time control Real-time control is predicated on the availability of real-time measurements. The first problem was measuring operational profitability in real time. Engineers developed a number of engineering-based approaches to solve this problem. New key performance indicators (KPIs) with monetary context were calculated, but they had little credibility with the cost accounting teams who actually measure the performance of the operations because they used different metrics.

The correct approach was found to involve calculating the accounting factors of the operation in real time.

This can be done by using a combination of sensor-based data from the process and financial data to calculate the cost and profit points across industrial processes. This is referred to as real-time accounting (RTA).

Control Engineering Europe

PROFITABLE EFFICIENCY Once these RTA factors became available, they could be used to control operational profitability very dynamically.

Providing real-time feedback to operators allows them to determine the financial impact of their actions and empowers them to learn how to operate the process most profitably. The result is manual, real-time profit control. As engineers gain more insight into the factors that drive the decisions made by operators, automated control will eventually be developed.

The next challenge was determining the relationship between traditional process control and real-time profitability control.

There is a classic control relationship between profitability control and efficiency control. It involves a cascade control strategy with profitability control as the primary loop, cascading set points to the process control, serving as the secondary loops.

Implementing profit control strategies over process control strategies results in a new class of real-time control strategies, referred to as ‘profitable efficiency’. Implementing this throughout an operation drives new and improved levels of operational profitability that can realise 100% ROI in a very short time – often under six months – with sustainable results that last and improve for years.

Making the real-time accounting measures the primary performance indicators of industrial operations ensures their sustainability and often enables continual operational profitability improvements for the life of the plant.

Additionally, embedding the RTA models throughout the operation enables you to measure operational profitability for any initiative that impacts the performance of the operations.

With these measures, managers can learn on how to shift the focus of their resources on activities that add more value.

The field of real-time control is expanding. As new control strategies are applied to new domains, the performance of industrial operations will improve significantly, to levels never before expected. Profitable efficiency, by ceding profitability control to process control, represents one new approach. It has proven to drive strong results because it allows you to keep both your process and profits in control.

Peter Martin is vice president, Innovation and Marketing Process Automation at Schneider Electric.

Improving efficiency & minimising downtime It’s in our DNA

For sixty years our customers have relied on Rotork for innovative and reliable flow control solutions.

Rotork products and services help companies in the oil & gas, water & waste water, power, marine, mining, chemical, pharmaceutical and food industries around the world.

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March 2018

23

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ENERGY MANAGEMENT

Efficient steam system offers MORE SUSTAINABLE OPERATION Following a steam system audit, a complete re-design of a dated system has helped a metal refiner to improve production levels, operate in a more sustainable way, and reduce energy costs by up to 60%.

T

he precious metal refining industry consumes significant amounts of heat and chemicals to extract impurities from noble metals. As a large user of chemicals and energy, Londonbased Vale Acton is always looking for ways to reduce its carbon footprint and to speed up process efficiency while reducing energy consumption.

Over the years Vale Acton has gradually updated specific sections of its steam system to suit the various changes in production requirements.

However, the majority of its steam network was in the region of 45 years old. This not only limited process efficiency but the ageing pipework was compromising safety and costing the business a significant amount in maintenance.

Recognising that improvements were needed to uphold the company’s commitment to the environment, Darren Matthias, project manager at Vale Acton, engaged with Spirax Sarco to find a solution.

While the refinery primarily uses steam for process heating, it is also critical for many production processes too, including reactor vessels – both coil and jacketed – which are used to control the temperature of reactants, heater battery and tank heating applications, unit heaters, direct injection systems and steam hose stations for cleaning tanks, vessels, and process equipment.

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Unfortunately, processes were impacted by both an out-dated condensate return system and boiler house which, in turn, were causing knock-on effects to other plant equipment.

“The condensate return system was inefficient and costly to operate which was becoming a major issue, with corrosion to pipework, as well as inconsistent water and blowdown quality problems,” said Matthias.

“Condensate was returned to a common tank located in a tank farm which is extensively cooled by a plate heat exchanger before finally being sent to the effluent plant.

“We were using two boilers – one oil and one gas – to generate steam for the entire plant. Steam was generated in the boiler house at 3.8 bar g and the two boilers in question were operating at half the efficiency they should have been. This, coupled with an unreliable condensate recovery system, spelled a toxic combination of unsustainable operation and high costs”.

The catalyst A detailed steam system audit helped to identify the specific issues which needed addressing, with its ethos for protecting the environment and staff being a key driver for this change.

“Steam isn’t our core area of expertise so we enlisted the help of Spirax Sarco to conduct a steam system audit,” said Matthias. “After analysing the entire

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system and completing a Hazard and Operability Study (HAZOP), the decision was made to design and supply new process steam, condensate and cooling systems.”

Because of the various uses of steam throughout the facility it was essential that a bespoke solution was developed to meet the exact needs of each production process.

“Working with Spirax Sarco, we identified the problems and created solutions that would support our safety and environmental policies,” continued Matthias. Spirax Sarco recommended a complete redesign and supply of new steam, condensate and cooling water systems which would help streamline the steam network and improve process and production cycles.

New control valves, steam traps and condensate return units were fitted, with the addition of contamination detection systems – to bring the facility up-to-speed with current technologies.

Modular boiler house Following the success of the initial project, the company invited Spirax Sarco to carry out the design and supply of its boiler house, replacing the burners with two efficient gas boilers.

“We were given two options to consider. We could either hire two boilers for a period of time while the upgrade took place in the existing boiler house, or, Spirax Sarco could complete the full design of the boiler house off-site. This meant the new boiler house could be assembled in a separate location so there was no disruption on-site,” said Matthias.

Two boilers fired only by gas were installed, as a more energy efficient and maintenance-friendly alternative to oil. The new boiler house is designed to allow a third boiler to be installed when Vale Acton are ready to increase capacity. An added benefit was that one of the new burners also allows the use of heat from a Combined Heat & Power (CHP) system, for efficiency.

Once built, the modular boiler house was dismantled and delivered to site Control Engineering Europe

ENERGY MANAGEMENT

where it was erected, reconnected and put into operation, before being commissioned and inspected by a thirdparty insurance company.

“The two new boilers are consuming much less energy than before and are operating at approximately 95% efficiency,” said Matthias. “They have been fitted with an oxygen trim, which measures the gas emission in the flue

and automatically brings it back in line with the defined emission level when needed.”

New controls have also enabled staff to take back control of energy consumption. Data is now easily accessible, while improved visibility of energy consumption has allowed the company to track their environmental impact more effectively.

“By replacing the oil and gas burners with two gas boilers we have saved a significant amount in energy. We are achieving 55% less nitrogen oxides (NOx) emissions than we were from our old oil boiler and we are also emitting zero sulphur oxides (SOx),” said Matthias. “Since switching to gas we have seen a 60% cost reduction and a considerable improvement in our operational efficiency. This has resulted in a faster process cycle and production levels.”

Safety is a key priority for the firm so the installation of double, block and bleed isolation valves has been an added benefit, allowing for safe maintenance to take place during production. In addition, employees were provided with an on-site Boiler Operation Accreditation Scheme (BOAS) course to ensure that safety and efficiency is always prioritised by staff.

Using energy management software to lower costs Energy management software is designed to measure costs and deliver quantifiable results for companies. It can also be integrated with the cloud to lower energy costs and provide more immediate, hands-on data for users, according to Melissa Topp, senior director of global marketing at Iconics.

Energy management initiatives can help companies looking for ways to save on operational costs while being more environmentally responsible. Such initiatives need to ensure that all possible energy sources and users are identified and measured.

Energy management software can analyse factors such as: • Consumption rates: For example kilowatt hours (kWh) provided from electric, wind, solar, or cogeneration sources; or l/hr from steam; or cu3/h from gas; or gph from water.

• Costs: Money spent on electricity, steam, water or gas.

• Conditions: Such as people per hour for occupants; hours of equipment runtime; lumens of sunlight; cubic feet per minute (CFM) in air handling units; square metre in zone footage; degrees in outside air temperature; or units in component counts.

• Carbon elements: For example, measured carbon dioxide or methane.

A comprehensive energy analysis tool should be able to deliver the back-end calculations, key performance indicator (KPI) analytics, rapid data historian storage and retrieval abilities, reporting, and visualisation tools to manage and Control Engineering Europe

reduce energy costs and carbon footprint.

Users can receive informative reports covering a number of scenarios, such as the energy cost per square feet, or average kWh based on degree days, or measured CO2 per meter, or energy consumed per unit of product produced.

Real-time views into current energy trends help catch possible problems early, which lead to better power utilisation and potentially costly issues.

Modern energy analytics tools are now available in a software-as-a-service (SaaS) model, which does not require on-premises computing hardware to interpret and analyse energy data. Many cloud service providers have also adopted energy analytics software themselves, within their data centers globally. An organisation’s energy calculations can be computed on a server in a data center being monitored by the same software.

Users of such software solutions have seen savings of between 5% and 25% annually on utility bills without sacrificing building occupant comfort using energy management software.

Adopting an energy management plan – whether installed on-site or connected to the cloud – is a first step towards cost reduction and environmental responsibility as companies continue to strive to do more with less.

This article originally appeared on www.controleng.com.

Edited by Suzanne Gill.

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March 2018

25

CALIBRATION

Pressure gauge

CALIBRATION CONSIDERATIONS As with any measurement device, pressure gauges need to be calibrated at regular intervals. A Beamex Whitepaper looks at the most common considerations when calibrating pressure gauges.

P

ressure gauges are commonly used instruments. As with any process measurement device, they should be calibrated at regular intervals.

When talking about pressure gauges, it is normal to refer to analogue pressure indicators which are provided with a pointer needle and a pressure scale and are often built with a Bourdon tube, diaphragm or capsule – a mechanical structure that moves the pointer across the scale as pressure increases.

Digital pressure gauges have a numeric pressure indication instead of an analogue pointer. While this article focuses on analogue gauges, most of the principles are also valid for digital gauges.

Put simply, a pressure gauge calibration requires a known accurate pressure input to be input to the gauge and read and compared with the gauge reading these. The difference in the values is the error and this should be smaller than the required accuracy for the gauge.

Some of the most common things you should consider when calibrating pressure gauges include: Accuracy classes: Pressure gauges are available in many different accuracy classes, specified in ASME B40.100 (accuracy classes from 0.1 to 5% range) as well as in EN 837 (accuracy classes from 0.1 to 4% range) standards. The accuracy class specification most often being ‘% of range’ means that if the accuracy class is 1% and if the scale range is zero to 100 psi, the accuracy is ± 1 psi. It is important to know the accuracy class of the gauge being

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calibrated, as this will naturally specify the acceptable accuracy level.

Pressure media: When calibrating pressure gauges, the most common pressure media will be gas or liquid. The pressure media during the calibration depends on the media that is used in the process that the gauge is connected to. Media also depends on the pressure range. Low pressure gauges are practical to calibrate with air/gas, but as the pressure range gets higher, it is more practical and also safer to use liquid as the media.

Contamination: While installed in a process the pressure gauge uses a certain type of pressure media, which should be taken into account when selecting the media for the calibration.

You should not use a media during the calibration that could cause problems when the gauge is installed back to process. Also, the other way around, sometimes the process media could be harmful to your calibration equipment.

Height difference: If the calibration equipment and the gauge to be calibrated are at different heights, the hydrostatic pressure of the pressure media in the piping can cause errors.

This should not be an issue when gas is used, but when liquid is used as media, errors can occur. If it is not possible to have the calibrator and gauge at the same height, then the effect of the height difference should be calculated and taken into account during the calibration.

Leak test of piping: If there are leaks in the piping during calibration, unpredictable errors can occur so a leak test should be done prior to calibration.

A simple leak test is pressurising the

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system and letting the pressure stabilise.

Some systems can maintain the pressure even with a leak if it has a continuous controller adjusting the pressure. So the controller should be closed. Adiabatic effect should also always be taken into account in closed system, especially with gas a media.

Adiabatic effect: In a closed system with gas as the pressure media, the temperature of the gas will affect its volume, which has an effect on the pressure.

When pressure is increased quickly, the temperature of the gas will rise, making it expand, resulting in a bigger volume and higher pressure. When the temperature cools, the volume of the gas becomes smaller and causes the pressure to drop. The faster the pressure is changed, the bigger the effect. The pressure change caused by this effect will gradually get smaller as the temperature stabilises. So, if you change the pressure quickly, make sure it is stabilised before deciding whether there is a leak in the system.

Calibration/mounting position: Because pressure gauges are mechanical instruments position will affect the reading so the gauge should be calibrated in the same position that it is used in the process.

Generating pressure: To calibrate a pressure gauge, you need to source the pressure applied to the gauge. This can be done using a pressure hand pump, a pressure regulator with a bottle or even a dead weight tester. A dead weight tester will provide an accurate pressure and you don’t need a separate calibrator to measure the pressure, but it is costly, not very mobile, requires a Control Engineering Europe

CALIBRATION

lot of attention, and is sensitive to dirt.

It is more common to use a pressure calibration hand pump to generate pressure and an accurate pressure measurement device to measure the pressure.

Pressurising/exercising the gauge: Due to its mechanical structure, a pressure gauge will always have some friction in its movement, and may change its behaviour over time, so exercise it before calibration. To do this supply the nominal max pressure and let it stay for a minute, then vent the pressure and wait a minute. You should repeat this process 2-3 times before starting to do the actual calibration cycle.

Reading the pressure value (resolution): The scale in pressure gauges have limited readability. It has major and minor scale marks, but it is difficult to accurately read the pressure value when the indicator is in between the scale marks. It is recommended that the input pressure is adjusted so the needle is exactly at an indication mark, and then the corresponding input pressure is recorded. It is also Control Engineering Europe

important to look at the indication perpendicular to the gauge scale.

Many accurate gauges have a reflecting mirror along the scale, behind the needle pointer.

This should be read so that the mirror reflection of the needle is exactly behind the actual needle.

Number of calibration points: The different accuracy classes of gauges will determine the number of calibration points. For the most accurate gauges (better than 0.05%) you should use the ‘comprehensive calibration procedure’ and the calibration should be performed 11 calibration points across the range (zero point plus 10% steps) with three cycles in rising and falling pressure. For the medium accuracy class gauges (0.05 to 0.5%), use a ‘standard calibration procedure’ with 11 points, but less repeated cycles. The less accurate gauges (class equal or greater than 0.5%) are to be calibrated with the ‘basic calibration procedure’ with six calibration points (zero point plus 20% steps) with rising and falling pressure.

Hysteresis (direction of calibration points): Hysteresis will result in an indication that is not exactly the same when a pressure point is approached with an increasing pressure compared to a decreasing pressure. To find the amount of hysteresis, calibrate the gauge with increasing and decreasing calibration points.

Number of calibration cycles (repeatability): The calibration cycles are repeated several times to determine the repeatability of the gauge

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under calibration. If the gauge to be calibrated has bad repeatability, it will give different results during different calibration cycles. If you only calibrate it with one cycle, you will miss the repeatability information. The most accurate gauges should be calibrated with three calibration cycles.

Adjustment/correction: If the ‘As Found’ calibration is not within the accuracy requirements, something needs to be done. In most cases the gauge should be adjusted so that it will be within the allowed tolerance levels.

After adjustment, the gauge needs to be calibrated again. If it is not possible to adjust the gauge, then a correction coefficient can be calculated and this coefficient must be taken into account in normal usage. If the gauge has a big error, then it is best to repair/replace it.

Calibration certificate: The calibration certificate should document the applied pressure and the indication of the gauge as well as an error calculation. It must contain other information also, as stipulated with standards/ regulations, including calibration uncertainty.

Environmental conditions: Most gauges have temperature effect specified and this should be taken into account. Environmental conditions (temperature and humidity) during the calibration should be recorded in the calibration certificate.

Metrological traceability: As with any calibration, the reference standard used to measure the applied pressure to the gauge must have a valid calibration certificate and its calibration must be traceable to the appropriate standards.

Uncertainty of calibration (TUR/TAR): With any calibration, you should be aware of the total uncertainty of the calibration measurements, otherwise the result will not have much value. The awareness of calibration uncertainty seems to be rising and it is also now included in more relevant standards and regulations. In some areas the TUR (Test Uncertainty Ratio) or TAR (Test Accuracy Ratio) is something that is used instead of the uncertainty calculation.

March 2018

27

PRODUCT FORUM •

www.controlengeurope.com to read the full story

WEB-BASED INTELLIGENT PAC CONTROLLERS`` OME-WISE-7000 Series (Web Inside, Smart Engine) is a product series that functions as control units for use in remote logic control and monitoring in various industrial applications. OME-WISE-7000 Series offers a user-friendly and intuitive web site interface that allows users to implement IF-THEN-ELSE control logic on controllers just a few clicks away; no programming is required. With its powerful and easy-to-use features, it will minimize the learning curve, shorten time to market and dramatically reduce the labor and cost spent on system development. Through a Web browser, users can access the Web Server on OME-WISE-7000 Series controllers to perform tasks such as logic rule edition and download. A Rule Engine will be set up to manage and deploy logic rules for controllers. The Rule Engine will check whether the rules are valid or not and determine the execution of actions under specific conditions, for examples: setting up I/O channel values, perform timer tasks, sending Email message or sending CGI command under a specific condition. With the Advanced P2P function, all OME-WISE-7000 Series controllers in network can freely share their status such as AIO value, DIO value, DIO Counter value or Internal Register value to each other’s. This function greatly enhances the flexibility and boosts accuracy to the logic rule design and makes it easy to

enable the interactions between the controllers. In addition, through MODBUS/TCP Protocol, a SCADA package enables control and monitoring of I/O channels or system status on OME-WISE-7000 Series controller in real time.

Features include: IF-THEN-ELSE Logic Rules Execution Ability, No More Programming, Recipe Function for Grouping a Series of Actions, Timer Operation, Remote Monitoring and Alarm via Email, CGI Command Sending for Surveillance System Integration, Advanced P2P for Controller’s Resource Sharing and Offer Various Options for Channel Seamless Integration with SCADA OME-WISE-7000 supports MODBUS TCP Protocol for users to perform realtime monitoring and control of the controllers. Through MODBUS TCP, it allows a SCADA package to seamlessly integrate with OME-WISE-7000 and enables total solutions for remote monitoring and control.

Free Phone 0800 488 488 International +44(0) 161 777 6611 sales@omega.co.uk

HIGH ACCURACY DIRECT-TO-SENSOR USB DATA ACQUISITION SYSTEM The iNET-600 Series A/D module provides 16SE/8DI voltage input channels (Ch#1...#16), each of which are independently software programmable with Windows software that support the direct connection to many common sensor types. Voltage input range on each channel is independently software programmable to

one of: ±20 mV, ±40 mV, ±80 mV, ±150 mV, ±300 mV, ±600 mV, ±1.2V, ±2.5V, ±5V, ±10V. Included is a mating Hd44 Female Connector and Cover. Alternatively, one can attach iNET-600 Series to the following optional wiring boxes: iNET-500, iNET-511, iNET-512.

If one is working with thermocouples, an iNET-510 wiring box is required due to its internal cold junction compensation. iNET-600 Series is a stand-alone USB data acquisition system. No additional components, such as external power supply, are required. Included in the box: iNET-600 Series Hardware Device, USB Cable, Software on CD, Mating Hd44 Female Connector and Hd44 Cover. Digitize at a maximum sample rate of 160K sample/ sec for 1 channel, 12Ks/sec/ch for 2 channels, 6Ks/ sec/ch for 4 channels, and 3Ks/sec/ch for 8 channels.

For more details, see Voltage Accuracy. Each channel provides the following software programmable parameters: A/D Signal-Averaging-Per-Point (0 ... 100 mSec), Sample-Rate (samples-per-second-per-channel), Digital IIR Filter (Low Pass, High Pass, Band Pass, or Band

Stop), Voltage Measurement Range (±20 mV to ±10V), Sensor Type, and Single-Ended or Differential Wiring.

Excitation power (+3.3V ±0.2V, <80 mA, 28 mA per sensor max) is provided for sensors, along with other End User Power voltages. This 3.3V, which is referenced to instruNet Ground, is automatically read back by A/D when calculating sensor values.

The 4 mA sink/source digital I/O port consists of 4 individual TTL compatible lines (Ch#25...#28), each of which can be configured as: input or output bit. When configured as an input, a channel can be used to sense a digital high (2 to 5.5V) or digital low (0V to 0.8V).

When configured as an output, a channel can be set high (e.g. >2V) or low (e.g. <0.8V). These I/O pins are short-circuit protected against high voltages up to 6.0V and down to -6.0V. Free Phone 0800 488 488 International +44(0) 161 777 6611 sales@omega.co.uk

FOOD PROCESSORS BENEFIT FROM HOSOKAWA’S SMART MANUFACTURING JOURNEY The government’s Made Smarter call for increased adoption of industrial digitalisation, to boost UK manufacturing has launched process technology experts, Hosokawa Micron Ltd on an Industry 4.0 journey that

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March 2018

will allow them to deliver advanced solutions to their existing customers and a broader industry base.

‘Our smart manufacturing journey started in our own contract manufacturing facility in Runcorn, within the dedicated food processing unit, where we support customer requirements for the processing of niche ingredients under food accredited quality control systems.

From ultra-small batches for customer R&D projects or for customers lacking appropriate systems to handle certain foodstuffs, such as those containing allergens, to bulk processing to meet peaks in demand, Hosokawa work with a wide range of customers to meet the specific requirements of each.

Additionally, our contract manufacturing team often engage with customers to support the development of bespoke processes or machine acquisition to deliver competitive advantage.

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We have committed to a major digital strategy for contract manufacturing, making significant investment to further optimise production and processing performance through the application of industrial internet of things (IIOT) technologies, always in conjunction with our human expertise.’ explains Hosokawa Micron Ltd, MD, Iain Crosley.

Hosokawa Gen4 Global Business Manager, Paul Gilroy says, ‘If you want to find out more about our solutions and how Hosokawa Gen4 can help increase plant availability, maintainability and reliability, I will be happy to speak with you and share our experiences.

Download our free Remote Monitoring App and see for yourself how new digital technologies are applied in our own contract processing facility.’ http://www.hosokawagen4.com/rems-app-forfree-download/ Fax:+44 (0) 1928 714325 Email: info@hmluk.hosokawa.com www.hosokawa.co.uk

Control Engineering Europe

Enter Link Code on www.controlengeurope.com to read the full story to read the full story

PRODUCT FORUM •

SG TRANSMISSIONS SIGNS AGREEMENT WITH LEADING SOUTH KOREAN ROBOTIC MANUFACTURER SG Transmission has recently signed an agreement with a leading South Korean robotic manufacturer, to provide a permanent magnet brake which is small, lightweight and has a relatively high torque.

The UK Company, which designs and manu factures a range of electromagnetic clutches and brakes at their factory in Bishop Auckland, was approached by the organisation with an enquiry at the end of last year. The company was looking for a supplier of permanent magnetic brakes which were of high quality that would be fitted in a variety of collaboration robots.

The SG Transmission engineers designed and developed a bespoke fail-safe brake, which has now been used widely in the robotics industry, within a range of their collaboration robots which are designed to work alongside humans performing tasks such as laser eye surgery, “Pick and place” and even welding applications.

Due to the high accuracy of the work the robots are required to carry out, our customer needed a high quality brake that did not affect the cr fety functions, coming to an immediate stop in any scenario, while also retaining the load.

SG Transmission could deliver as a trusted UK manufacturer.

Neil Cook, Sales Manager at SG Transmission says “Following testing last year, the finalised brake solution is now successfully incorporated within in the robot”.

01388 770360 sales@sgtransmission.com

SKF ‘OPENS THE DOOR’ TO AN ENGINEERING TREASURE TROVE New advanced simulation software from SKF gives customers access to a powerful engineering tool used by its own application specialists.

Luton, United Kingdom, 27 February 2018: SKF SimPro Expert is an advanced simulation software tool developed in-house by SKF to maximise support for, and co-operation with, its customers. SimPro Expert gives customers greater freedom of choice and flexibility when incorporating SKF bearings into their machine designs, but more particularly it gives them the power to evaluate the performance of SKF bearing arrangements in minute detail across a wide range of applications and service conditions, in the virtual world.

Effectively placing the breadth of SKF engineering knowledge into the hands of the customer, SimPro Expert gives the user an extremely accurate means of evaluating bearing performance in any given machine model. Its enhanced application modelling capabilities and detailed SKF bearing geometry, performance data and in combination with more then 100 years of developing bearing theories verified and validated by our extensive testing capabilities and real field experience, gives the user a world leading engineering tool.

As the software is practically the same as that used by SKF engineers, SimPro Expert allows seamless interaction between the customer and the SKF Application Engineering team.

Moreover, it encourages the customer to tackle more complex engineering challenges, confident in the knowledge that the support and guidance of SKF Application Engineering is ready to hand. +44 (0)1582 490049 www.skf.com

ADVERTISE YOUR BUSINESS IN THE PRODUCT FORUM SECTION Contact Lewis Atkinson on 01732 359990 or email lewis.atkinson@imlgroup.co.uk Control Engineering Europe

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March 2018

29

PRODUCT FORUM •

www.controlengeurope.com to read the full story

TITAN ENTERPRISES ANNOUNCES NEW VERSION OF ATRATO ULTRASONIC FLOWMETER Titan Enterprises announces the availability of a new version of its Atrato Ultrasonic flowmeter designed to deliver precise flow measurement of fluid flows from -10 to +110 degrees centigrade.

Ruggedly constructed with PEEK pipe connections and either a glass or 316 Stainless Steel flow tube the compact Atrato is compliant to IP54 standards.

Utilising patented time-of-flight ultrasonic technology that enables it to operate with unmatched accuracy over very wide flow ranges, the Atrato range of inline flowmeters has set a new standard in flowmeter technology. Its rugged, clean bore construction makes the Atrato ideal for a whole range of low flow applications. Its signal processing system permits flow measurement across the whole Reynolds number range allowing both viscous and non-viscous products to be metered accurately.

An integral USB interface makes it extremely easy to install and enables users to directly monitor flow volume and rate on an external PC as well as altering operating conditions.

Drawing upon over 40-years of flowmeter innovation - Titan Enterprises Ltd are a manufacturer of high performance solutions including the Atrato ultrasonic flowmeter, Oval Gear flowmeters, low flow Turbine flow meters and a flow instrument range.

Titan’s company philosophy of “pushing the envelope by trying to do things a little different and better” has resulted in sales of over 500,000 products into 50 countries worldwide and a repeat purchase percentage of 95%. All flow meters produced by Titan Enterprises are designed and manufactured to ISO9001 and calibrated to an uncertainty of ±0.25%.

For further information please visit http://www. flowmeters.co.uk/atrato-ultrasonic-flowmeters/ or contact Titan Enterprises on +44-1935-812790 / sales@flowmeters.co.uk.

ADVERTISE YOUR BUSINESS IN THE PRODUCT FORUM SECTION Contact Lewis Atkinson on 01732 359990 or email lewis.atkinson@imlgroup.co.uk 30

March 2018

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Control Engineering Europe

FINAL WORD

Scott Keller, founder and CEO at SignalFire Wireless Telemetry, offers some advice on determining the best wireless frequency for remote monitoring and control systems.

R

emote monitoring and control systems rely on radio communications to integrate a variety of sensors, nodes and gateways to a wireless network for the transmission of data.

A large number of radio-based telemetry systems use communication networks based on a 2.4GHz frequency band. Zigbee, WirelessHART, ISA 100 and other 802.15.4 systems, for example, operate in the 2.4GHz wireless frequency spectrum. While this is suitable for short range building and plant environments, 2.4GHz systems have limitations when performing in outdoor applications and a lower frequency is a better option. A 915MHz system, for example, will provide a more reliable data transmission over longer ranges in challenging environments.

The operating range, or distance over which the wireless system must perform, will determine the best frequency band.

When assessing the use of a 2.4GHz or 915MHz system, consider transmitter power; radio antenna design; interference; and data rates.

In the US and Canada, 915MHz systems can transmit powers up to 1 Watt and have antennas that can double that range (+6dB). While 2.4GHz systems can operate at the same power levels in the US and Canada, most do not exceed the global requirement of 0.1 Watts.

Global restrictions on 2.4GHz frequency further limit performance by measuring radiated power – no antenna gain is permitted for a full power (0.1 Watt) system in most countries.

With operating parameters being equal, a 915MHz system offers about 2.6 times the range of a 2.4GHz system.

In most cases, the 915MHz supports Control Engineering Europe

Finding the perfect

WIRELESS FREQUENCY

longer range between nodes, beneficial for wireless sensor control networks that cover large geographic areas of hundreds of square miles.

Most wireless sensor control systems are subject to two types of interference – physical and electromagnetic. Physical interference can be broken down: Building attenuation: Either a 2.4GHz or 915MHz solution works efficiently.

Vegetative attenuation: The impact of trees and other vegetation can significantly impact link quality.

Evergreens are worse than deciduous trees and wet foliage will degrade link quality even further. A 2.4GHz system will experience significant foliage attenuation problems due to the moisture in vegetation as it operates close to the frequency that vibrates water molecules.

Rain attenuation: Rain attenuation is modest for both a 2.4GHz and 915MHz frequency. Fog and snow are slightly lower. Rain, however, will significantly exacerbate the foliage attenuation at 2.4GHz due to the high absorption of the 2.4GHz energy by water.

Electromagnetic attenuation Both frequencies use standard techniques to manage radio interference. The choice will depend on system design.

• Zigbee, WirelessHART, and ISA 100 at 2.4 GHz use Direct Sequence Spread Spectrum (DSSS) as a method of using multiple frequencies to avoid

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narrowband interference. This technique preserves high data rates until the interference band spreads to a point where data rates degrade quickly.

• While DSSS works at 915MHz, SignalFire implements a Frequency Hopping Spread Spectrum (FHSS) that ‘hops’ over narrowband interference.

This technique assures communications, where DSSS fails.

Data rate Data rate will impact range. Most 2.4GHz systems transmit at 200–500Kbits/sec, while a SignalFire Remote Sensing System operates at 915MHz transmits at 10Kbits/sec. Doubling the data rate causes a 3dB loss in link budget. When compared to a 200Kbits/sec system, this provides an advantage of about 12dB (6dB= a doubling of range).

While no single frequency will provide the perfect solution to support the communications of a wireless telemetry or mesh network. While working well in building and plant environments at ranges measuring tens of meters, a 2.4GHz frequency poses limitations in longer ranges and under certain outdoor conditions.

A 915 MHz frequency offers a more reliable data transmission platform for outdoor applications where data must be reliably transmitted hundreds to thousands of meters under different weather conditions. The choice will ultimately depend on system operating requirements.

March 2018

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