CEE_19_02 by Modiconlv

Control, Instrumentation and Automation in the Process and Manufacturing Industries February 2019

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Next generation gateway solutions optimised for the IIoT

SCADA: Keeping pace with the digital transformation

Automating a handcrafted process

Education is key to keeping Industry 4.0 moving forward

CONTENTS AI is set to make its presence felt

Editor Suzanne Gill suzanne.gill@imlgroup.co.uk Sales Manager Adam Yates adam.yates@imlgroup.co.uk Production Holly Reed holly.reed@imlgroup.co.uk Classified Sales Lisa Hales lisa.hales@imlgroup.co.uk Dan Jago David May G and C Media

Group Publisher Production Manager Studio Design

Welcome to the first issue of 2019! I think it’s going to be a very interesting year for us all politically, but at the time of going to press the British Government seem to be no further forward with their plans for Brexit so for now I won’t comment on this depressing subject, as the outcome still remains far from certain. On the subject of technology there is much more certainty! I sat in on a presentation about the rise of cognitive factories and the use of AI on the plant floor. It certainly gave the audience food for thought on what could be the most disruptive technology ever to be integrated into our processes – changing the way we design, produce and sell products in the future (pg 4). AI is already making its presence felt, with a variety of automation vendors now

integrating the technology into their control offerings. There is also an interesting roundup of opinions about the move towards Industry 4.0 in this issue, looking at the barriers to adoption and what is required to remove these barriers (pg 12).

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

INDUSTRY REPORT

EXHIBITION REVIEW

24 We look at some of the highlights of the SPS/IPC/Drives 2018 event, which was held in Nuremberg last November.

AI and the manufacturing industry.

EDITOR’S CHOICE 6

Real-time cavitation detection system; Maintenance support with RFID.

INDUSTRY 4.0: WHERE ARE WE NOW? 10 Suzanne Gill asked a cross-section of automation vendors where they believe the manufacturing sector is on its Industry 4.0 journey and, importantly, what obstacles still need to be overcome. 17 Focusing on the road to Industry 4.0 Maturity.

HAZARDOUS AREAS 28 Ensuring safe operation of flameproof motors in explosive atmospheres.

FINAL WORD 31 It is critical to understand differing OT and IT priorities to achieve collaboration and controls integration argues John Fryer of Stratus Technologies.

SCADA PG 8

18 Suzanne Gill finds out more about the changing role of SCADA systems and asks what features are needed to ensure that this technology keeps pace with the demands of the digital factory of tomorrow.

PG 24

PROCESS CONTROL 16 Automating a handcrafted process has halved manufacturing times and increased productivity. 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

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

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February 2019

INDUSTRY REPORT

AI AND THE MANUFACTURING INDUSTRY In a presentation about the rise of cognitive factories and the use of AI on the plant floor Karthik Sundaram, Frost & Sullivan Industrial IoT programme manager, offered some insight into the potential impact of AI on the manufacturing landscape.

efined as the science behind developing intelligent machines, AI is an advanced form of computer technology that empowers machines to perform tasks that are normally workable only by humans. Also known as cognitive intelligence, AI is the umbrella term used for a variety of underlying technologies including machine learning, deep learning computer vision, speech recognition, robotics, natural language processing, deep learning, and so forth. “Cognitive intelligence is not just about giving manufacturers the ability to gain answers to known questions; it is also about empowering industry to find new answers to emerging questions in a similar way to how earlier revolutions in manufacturing have seen several benefits from lean manufacturing, automation and IT, AI looks very promising as the next lynchpin for Industry 4.0,” explained Sundaram. For manufacturing Sundaram expects deep learning to be the most important AI development as it is about enabling a machine to understand and programme itself using a complex set of algorithms. “This could be the resolution to a big issue currently facing manufacturing today to manage the huge amounts of data that are now being collected from production processes. Deep learning can be used for analysis of this data.” Frost & Sullivan expects that deep learning, along with neural networks, will be the largest contributors to the creation of cognitive factories and we should expect to see such factories by 2020. Frost and Sullivan is seeing a big shift, as Sundaram explained. “Traditionally, sciences have been based on a very

February 2019

simple logic construct – a process resulting in an effect. However, today science is having to confront that fact that there is a complexity of multiple causes having multiple effects. It is no longer possible to simply reduce one cause to a given effect and this is where AI has a huge role to play, helping to resolve this complexity and giving science a whole new dimension.” Sundaram went on to explain that AI could also help manufacturers to improve their processes. “Cognitive intelligence is vital to the future factory architecture – it is one of the central pivots around which the future factory will be built. When it comes to data analytics and predictive maintenance, AI really is the way to go. Siemens, for example, has recently added AI to its Simatic controllers which will allow them to program themselves.” But, what actually happens when a machine gains cognitive functions? Sundaram went on to offer some examples. “A machine with the benefit of computer vision is able to provide remote analysis of product designs and can visually recognise errors. Give a machine the ability to understand spoken commands, in the natural language of the user, and it will offer something far superior to what we have today.” Sundaram also expects AI to change the way that products are designed, produced and sold in the future. “In the manufacturing sector, because AI gives the ability to understand the combination of many causes leading to many effects it will change the very foundation of applied logic as we know it today,” he said. Key applications are expected to be found in quality inspection, navigation

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and movement of goods on the factory floor, just-in-time replenishment of materials in assembly lines, situationbased analysis, cognitive cobots, biometric face recognition and machine part tracking. Offering a real life use case Sundaram explained how Google has used AI technologies to reduce the power costs of its data centres by 40% by improving energy efficiency. He explained that similar techniques could be used to streamline energy efficiency in factories and process plants without the need for changes in the short-term. “It is just a matter of collecting data and applying a certain algorithm to understand how to operate the factory more efficiently. Of course, there are already ways of achieving this, but AI’s benefits are exponential,” he said. It is expected that progress in cognitive applications for the manufacturing sector will be fostered via partnerships between technology vendors and OT companies. Currently investment in AI is higher among discrete industries than in process industries and, as more emerging technologies come to the fore – such a Blockchain, segmented reality and AI – it is expected that there will be a convergence of these trends to facilitate unmanned operations and fully-automated factories. “For cognitive factories to become a reality crossindustry collaboration, and technology partnerships along with mergers and acquisitions will be required,” said Sundaram. Mainstream AI applications are expected by 2021 and a fully-fledged cognitive, lights-out facility is expected by 2023. Sundaram predicts that China Control Engineering Europe

INDUSTRY REPORT will be first to achieve this as it does not have the legacy plant infrastructure and it has the political capability to make it happen. In conclusion Sundaram explained that the current barrier to wider adoption of cognitive technologies in manufacturing is mostly down to the inconsistent data that is currently available. “Unless you harmonised data it is not possible to implement deep learning strategies,”

he said. “There appears to be no limit to what manufacturing will be able to achieve with AI. The technology will be increasingly used for production, quality control, design time and material waste reduction, and predictive maintenance performance. “Factories of the future will continue to learn, develop, and perform better. We have now arrived at a point where it is not difficult to envision factories

as utopian hives of automation. As cognitive technologies mature and costs drop, manufacturers will start discovering new applications of AI that will help them make complex business decisions. Even though there will be some displacement of jobs at the bottom level of automation, businesses will begin to focus on re-training these workers to perform higher levels of design, programming, or maintenance tasks.”

OPC UA: More than just a protocol In recent years, OPC UA has become a real ‘movement,’ that appears to be bringing industry together. There are currently around 50 industrial groups working on companion specifications. The goal is for the creation of plug&play standardised information, which can then then exchanged via the OPC UA mechanism – optionally also with determinism at field level (but not into the public cloud). There is still work to do to achieve this but the will and spirit for a common solution has become clear, as was evidentat the SPS/IPC/Drives 2018 event (for more information go to pg24 of this issue). The real challenge for the OPC Foundation, however, is in the harmonisation of information models in order to avoid conflicts of information models. It recognises this and its public roadmap reflects this need.

Moving towards the field In the past two years the use of OPC UA for communication right up to the field devices has been a topic of discussion and which led to the foundation of the new initiative ‘Field Level Communication’ (FLC) under the umbrella of the OPC Foundation. The vision of the initiative is to work towards an open, uniform, secure and standards-based IIoT communication solution between sensors, actuators, controllers and the cloud that meets all the requirements of industrial automation – both in factory automation and process automation. Control Engineering Europe

Michael Schweiger (right) of Volkwagen with Stefan Hoppe, president of the OPC Foundation.

Following a public call for participation, 23 globally active OPC Foundation member companies have jointly coordinated the requirements and roadmaps and have provided the necessary budget, in addition to the membership fees, for financing. Today, OPC UA is considered to be key when it comes to secure, standardised information exchange from the sensor to the cloud in the area of Industry 4.0 and related markets and this has resulted in more end-users joining the OPC Foundation – for example Samsung, Volkswagen and Miele. This allows them to influence the direction of the specification and to ensure that the technology delivers real value for their needs. Commenting on this, Michael Schweiger, account & demand manager at Volkswagen, said: “With OPC UA at the heart of Industry 4.0,

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adopting the OPC UA technology and using it to its full potential in our factories is a natural progression. Being a member of the OPC Foundation guarantees early information to upcoming key technologies like the OPC UA Companion specifications which provide secured and standardised information and interfaces for assets.” OPC UA has become more than just a protocol – it offers secure transport of data via diverse and expandable protocols. But who defines the meaning of the data? Associations such as AIM for the auto ID industry, VDMA technical groups for injection moulding machines, robotics or machine vision and 35 other VDMA industries already define their information in OPC UA servers in the form of OPC UA companion specifications. February 2019

EDITOR’S CHOICE

Wireless connectivity solutions go the distance Advantech B+B SmartWorx is expanding its range of wireless connectivity solutions with the launch of LoRaWAN wireless solutions. Advantech’s LoRa solutions are designed to give users better control and management of applications in remote areas and in harsh environments – including extreme temperatures and high humidity. LoRaWAN solutions utilise LoRa wireless sensing technology to maximise monitoring efficiency and overall productivity. The key benefits of LoRa are said to include operation over distances of from

5 to 15km. A single base station can provide deep penetration in dense urban and indoor regions and can connect rural areas up to 30 miles away. With a protocol designed specifically for low power consumption battery lifetime is extended over years of operation while providing high capacity capable of supporting millions of messages per base station.

EtherCAT motion controllers With its EPOS4 series of motion controllers, maxon motor is addressing the needs of system integrators and fulfilling the requirements of applications such as industrial automation, apparatus engineering, and robotics. Two new Compact EtherCAT models have recently been added to the

range. At the same time, the company is upgrading the capabilities of the entire platform by enabling dual loop control which allows simultaneous control of the motor and load feedback for optimum performance. The EPOS Studio software ensures the minimum possible set-up times with its automatic Regulation Tuning feature.

Safety exhaust valve for emergency stop and fault conditions A new safety exhaust valve from Parker Hannifin rapidly exhausts compressed air in the event of a fault condition or when a machine has an emergency stop. The P33 safety valve is designed for two-channel control architectures and is externally monitored. It features a fail-safe design and is suited to use in applications up to Category 4 performance level e. The P33 safety exhaust valves are optimised for long service life (B10d), very high flow rates, high faulted flow rates, and high mean time to failure (MTTF) values. Connectivity is via two M12 connectors that provide solenoid and pressure sensor interfacing. Compatibility with devices from popular manufacturers

February 2019

ensure versatility and flexibility of the valves. Being externally monitored gives greater control at the safety device for the customer’s application. It also reduces the complexity of the machine for startup or resetting of the valve. The fail-safe design of the P33 family is maintenancefree and requires no additional silencers or mufflers that can clog creating potentially unsafe exhaust conditions.

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RFID antennas over IO-Link The onward march of IO-Link seems unstoppable and for good reason, with advantages such as much more data and diagnostics for minimal extra cost. Ifm electronic offers IO-Link sensors and an established range of RFID systems which combine the technologies. The latest range of RFID antennas from ifm electronic is suited to a range of applications. The range covers nine housing variants, including robust designs for harsh industrial environments with ratings up to IP69K, and temperature resistance from -20º to 60ºC. The range is said to be suited to the identification of workpiece carriers in conveyor technologies where only a small amount of data needs to be transmitted. In machine tools the new IO-Link enabled antennas can be used to confirm correct selection and monitor usage of magazines and component moulds as part of a QA and preventative maintenance process. In automotive production, body components or engines are compared to order numbers via RFID in order to control processing steps, or to check the final assembly.

Control Engineering Europe

EDITORS CHOICE

Real-time cavitation detection system Yokogawa Electric Corporation has developed a cavitation detection system which, by detecting cavitation, quantifying information, and displaying the data in realtime, provides an early indication of conditions that can result in degradation of pump performance. This can improve the efficiency of plant maintenance. Cavitation in fluids can cause damage to pumps. Minimising damage relies on detection at an early stage so that corrective measures, such as adjusting the flow rate, can be taken. However there has been no way to quantify cavitation and as cavitation occurs inside equipment, it is impossible to do a visual check. In its analysis of this problem, Yokogawa focused on the principle that there is a direct relationship

between differential pressure and cavitation, and has created a condition monitoring solution that involves the quantification of cavitation based on pressure data. The system developed consists of a STARDOM FCN-500 networkbased control system, a Yokogawa cavitation detection logic program, and an accurate (±0.075%) DPharp EJX110A differential pressure transmitter. It relies on the FOUNDATION Fieldbus industrial digital communication standard to link these components. At 100ms intervals, the DPharp transmitter measures the pressure inside the target equipment, and this data is transmitted via the fieldbus network to the STARDOM FCN-500 system for processing in real time by the logic program. This system is, therefore, able to detect cavitation issues early.

Hose maintenance support with RFID handheld devices To ensure safety transport of process media in chemical processing plants, regular inspection and maintenance of hoses is required. RFID handheld devices from Pepperl+Fuchs and ecom – paired with ‘hose-manager’ software from Neoception – are helping enable maintenance processes to be efficiently performed and documented. Using the glove-operable RFID handheld and the software the auditor is guided through the maintenance procedure step-bystep. Automatic identification and user-friendly software virtually eliminate errors. The results of the test can be seamlessly transferred to a back-end system and serves as the documentation and proof that the tests have been carried out.

Free yourself from repetitive tasks Meet Omron’s TM collaborative robots Omron’s new TM series collaborative robot family realizes an innovative manufacturing environment where humans and machines work in harmony. Our TM series provides a unique solution to easily install a robot to automate applications such as picking, packing, and screwdriving. With the various vision functionalities and simple, intuitive programming environment of the TM collaborative robots, we will further enable safe, flexible, and collaborative manufacturing between human and machine. • Human-machine collaboration • Incredible versatility • Mobile-ready Pick up the phone or email for a quote! +44 (0)1908 258258 uk@eu.omron.com Industrial.omron.co.uk

COVER STORY

GATEWAY SOLUTIONS OPTIMISED FOR THE IIOT Although the progress has been slow, manufacturers at different stages of their IIoT transformation are already beginning to experience the benefits of digitisation, says Matthew Lee, product manager at Moxa.

key factor in the success of digital transformation is the deployment of intelligent edge-computing solutions that can bridge the gap between the operation technology (OT) and the information technology (IT) worlds by providing the following benefits: Reduced latency: Manufacturers are expected to be more responsive to customer needs with customised products and services on a global scale. In addition, time-sensitive applications need immediate processing of device data to be able to take timely corrective actions and enable quick decision making. Edge intelligence facilitates intelligence at the field site as opposed to sending all the device data from the edge to the cloud for processing, thereby enabling quick decisions. Independent remote operations: The edge-computing platform enables

February 2019

remote locations to reduce downtime and operate independently when the central system is inaccessible. For example, if there is a network outage and connectivity to the cloud system is lost, field sites can use local computing power to process and analyse data. Processed data can then be sent to the cloud for long-term storage when the connection is restored. Ensure data security: Sending sensitive operational data from the edge to the cloud puts the data and your edge devices at risk. Multiple levels of security need to be put in place in an edge device to ensure that the data is securely transferred to the cloud. Processing data at the edge helps prevent data breaches and enables faster responses. Reduce data-transfer costs: Transferring large volumes of data from the edge of the network to a cloud

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server can be prohibitively expensive. Manufacturers are looking for optimised computing solutions for their industrial-automation applications to intelligently process large volumes of data received from the sensors and field monitors, and send only critical data or a summary of the data to the cloud. Compact-sized, ruggedised industrial Arm-based computers, designed for low power consumption, are at the heart of these solutions and make edge-side computing more reliable and cost effective.

Arm-based Linux solutions Arm-based Linux IIoT Gateway solutions provide industrial-grade security, manageability, performance, and reliability while still maintaining extensibility. These platforms combine the hardware, OS, and software functions listed below to provide an optimised edge-computing solution for IIoT applications. Longevity: Industrial products are usually in place for 10 to 15 years. Arm-based CPUs typically come with a minimum lifespan of 15 years and Armâ&#x20AC;&#x2122;s commitment to long-term support and access to their future enhancements, make Arm-based solutions an ideal choice for industrial applications. Low power consumption: Lowpower processing is a requirement in many industries to ensure that the equipment does not overheat. Fanless equipment also mitigates the effects of dust in industrial environments. Arm Cortex-A processors are optimised for performance and power efficiency. Scalability: Linux is eminently scalable Control Engineering Europe

COVER STORY and is able to run on a variety of platforms, and its basic functionality – command line tools, configuration, and code – are compatible with any Linuxbased device. This flexibility allows for easier upgrades and compatibility between different systems. Enhanced security: While manufacturers are reaping the benefits of digitalisation, they are also faced with data security risks and softwareintegrity issues. A Trusted Platform Module (TPM) can be deployed to guarantee the physical security of edge devices. In addition, Arm’s TrustZone can be used to create an isolated secure world, which can enhance security and maintain the integrity of edgecomputing solutions. Most IIoT Gateway Solutions also come with edge-side preprocessing tools that have built-in interfaces to cloud services to help accelerate development of industrial IoT applications.

Ready-to-run solutions Moxa’s UC series IIoT Edge Gateways are industrial-grade, wireless-ready Arm-based computing platforms are designed to operate reliably in a wide temperature range of -40 to 85°C. These gateways are built around the Arm Cortex-A processor and come with Moxa Industrial Linux (MIL), a Debian-based distribution with 10-year support, to address the need for extended lifecycle of computing systems. Industrial-grade Linux: Moxa Industrial Linux (MIL) is a highperformance industrial-grade Linux distribution developed by Moxa to help accelerate your industrial projects. A 10-year long-term Linux support that includes security patches and bug fixes, to address the need for extended life cycle of computing systems in industrial automation applications, makes your industrial projects secure and sustainable. Moxa is working with industry leaders, such as Codethink, Hitachi, Plat’Home, Renesas, Siemens, and Toshiba, through the Civil Infrastructure Platform (CIP) project hosted by The Linux Foundation, Control Engineering Europe

to create an open-source platform for managing and monitoring IoTenabled civil infrastructure and make it safe, secure, reliable, scalable, and sustainable. Low power consumption: Build on the Arm Cortex-A processor, Moxa UC series gateways provide industrialgrade intelligence at the edge in power budgets under 10 W. Secure platform: The UC series IIoT Edge Gateways are the only Armbased computers that support TPM v2.0. Bringing TPM and Arm-based computers together gives system integrators and industrial engineers a powerful new tool in their security arsenal. By creating a specific cryptographic key for each individual device, which is hardcoded within the platform itself, the data stored on the computing system is secured and protected from being read by an unauthorised party. Moreover, the OS on the system can be locked from being overwritten to secure edge devices and data in distributed areas. You can use the Moxa Security Utility to conveniently build up the protection mechanism on the Moxa Industrial Linux platform to meet your cybersecurity requirements. This security utility is developed in accordance with Moxa’s product development guide for cybersecurity, which ensures compliance with the IEC62443-4-2 standard and recent ICS-CERT alerts, to provide an adjustable security protection level for systems and applications. Support for multiple interfaces and protocols: The UC series IIoT Edge Gateways come with multiple interfaces such as serial, CAN, Ethernet, Wi-Fi, and NB-IoT. The IIoT Edge Gateways are 4G LTE-ready and come with Verizon/ AT&T certification and industrialgrade CE/FCC/UL certifications. An edge-side software, ThingsPro, accelerate configuration, DAQ, and device management. ThingsPro enables Modbus connectivity for data acquisition and processing and MQTT support for lightweight edge-tocore data transmission. RESTful APIs

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and Modbus APIs are provided for implementing all ThingsPro Gateway software functions in your IIoT applications. Easy connectivity from the Edge to the Cloud: The UC series IIoT Edge Gateways are the first Azure IoT Edge certified Arm-based computers. Integrating Azure IoT Edge with Moxa’s IIoT gateways benefit customers, especially those operating on Linux platforms, in a number of ways. The benefits include secured remote connections to enable deployment in remote locations, connectivity to allow existing brownfield applications to share data with the cloud, and device management and product longevity to ensure customers can deploy, scale, and maintain IIoT applications.

A wireless solution It can be a challenge to find an IIoT gateway that easily connects geographically dispersed devices to the cloud, especially in outdoor or rugged environments. The IIoT gateway must be easy to deploy and easy to maintain over an expected operational life of at least five years. The UC-8200 industrial computing platform is designed for embedded data acquisition applications. The computer comes with dual RS-232/422/485 serial ports, dual 10/100/1000 Mbps Ethernet ports, and one CAN port as well as dual Mini PCIe socket to support WiFi/cellular modules. These versatile capabilities let users efficiently adapt the UC-8200 to a variety of complex communications solutions. The UC-8200 is built around an Arm Cortex-A7 dual core processor optimised for use in energy monitoring systems but is widely applicable to a variety of industrial solutions. With flexible interfacing options, it offers a reliable and secure gateway for data acquisition and processing at field sites as well as a useful communications platform for many large-scale deployments. Wide temperature LTE-enabled models are available for extended temperature applications. ! February 2019

Sponsored article

Highlight 1: Personalised USB-stick production This modular demonstration machine uses cyber-physical systems and decentralised automation inside each cell/ module. With the new Festo CPX-E PLC, including EtherCAT master, Festo offers solutions for complex gantry or handling systems with complete motion control functionality. All motion is programmed in the subsystem with Codesys and then integrated in the host system either as a slave on PROFINET, EtherNet/IP, or peer-to-peer e.g. via Modbus. Major benefits: • Faster selection, set-up and commissioning with Festo free of charge software selection tools. • Easy programming inside the new Festo Automation Suite ensures electric axes are integrated into the sub system with just two clicks and are up and running in less than five minutes. • A complete, single source solution! No risks due to integrating many suppliers – first class technology in mechanics, pneumatic, electric and software from one source; seamless connectivity.

Highlight 2: Four years Industry 4.0 experience in the Festo Technology Factory Scharnhausen An outstanding engineering reference. Five assembly lines full of products from the Festo Automation Platform. And all connected to the future via OPC-UA. These five production lines are completely modular, flexible in use and produce all lot sizes our customers demand: down to batch size1 if necessary. And they generate big data which have been recently analysed – and which led to a 15% increase in productivity after optimising the bottle necks identified. This use case shows exactly how you can benefit from the Festo I4.0 knowledge, experience – and our products and (digital) services.

Fig. 2: Personalised production, modular machine and automation concept, IoT inside, digital services integrated including cloud connection. In short: Industry 4.0 ready demonstrator – see at Hannover fair from 1-5 April in Hall 15

Faster. Better. Connected. Only with Festo: Seamless connectivity from the workpiece to the cloud

Fig. 3: Small and flexible lot sizes, modular machine and automation concept using Festo products and services to a large extend - the latest assembly lines at the Festo Technology Factory in Scharnhausen, Germany clearly show I4.0 at its best.

Highlight 3: Smart Maintenance = Smartenance Four years ago Festo introduced a mobile maintenance concept in its Scharnhausen factory. The results had been overwhelming: better team utilisation, quicker repairs, higher OEE – and an ROI below six months. Now Festo has turned its learnings and experience into a digital product called Smartenance: all our customers are now able to optimise their maintenance teams and infrastructure by our well-experienced solution. !

Join Festo at Hannover fair from 1-5 April, Hall 15 and see all details, and many more. Control Engineering Europe

Fig. 4: Smartenance – the mobile maintenance app from Festo is tested in its own factory (e.g. in the machines shown above), with an ROI in less than six months. Now for sale and available via www.festo.com/appworld

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February 2019

INDUSTRY 4.0

Education is key to keeping industry 4.0 moving forward Suzanne Gill asked a cross-section of automation vendors where they believe the manufacturing sector is on its Industry 4.0 journey and, importantly, what obstacles still need to be overcome.

ccording to the CLPA (CC-Link Partner Association) one of the key requirements for enabling Industry 4.0 is bandwidth, to cope with the explosion in data that comes with the IoT. “There is growing market acceptance that the previous standard of 100Mbit Ethernet is no longer going to be sufficient going forward and that gigabit Ethernet will become the norm,” said John Browett, general manager at CLPA Europe. Other technologies key for Industry 4.0 success include Time Sensitive Networking (TSN), along with OPC UA and major steps forward were taken for these technologies at SPS/IPC/Drives 2018 when key global automation players announced plans to support them. Browett believes that the two main barriers to adoption of Industry 4.0 are skills and finance. He said: “Companies need to have a good understanding about what kind of improvements they want to make to their operations. In general, these are going to be based on how they can increase the business by serving customers better. Then it’s necessary to determine if Industry 4.0 techniques can actually deliver these improvements – this will demand a broad range of skills from engineering, to process management, and an understanding of the role of workers. Some companies struggle to find the right blend of expertise to cover all these bases, especially now that IT has become a key part of automation. “The financial aspect will be the final make or break hurdle. There’s no doubt that eventually an engineering and operational solution to most challenges

February 2019

Image courtesy of Harting

can be found, but if it bankrupts the company, then clearly it’s useless,” continued Browett. Management has a role to play to see how the investment required can be supported by the overall financial picture of the business. In many cases, implementation will take a step-by-step approach, building a series of successes along the way to justify further investment.”

A sweet spot Improving maintenance strategies and efficiency have presented a particular sweet spot for Industry 4.0 technologies, according to Nick Taylor, marketing director Europe for Emerson. “Augmented reality, for example, is being used within process applications to send repair instructions to maintenance teams in the field and in the future Emerson believes that it will be used more extensively to provide real-time information to improve decision making and work procedures.” Data analytics applications are also helping improve maintenance strategies through the use of preconfigured

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algorithms to translate data into actions for specific asset classes or devices. “This type of application is being used to provide in depth monitoring of critical pumps and heat exchangers, identifying failed steam traps and continuously monitoring pipework metal loss caused by corrosion or erosion. By analysing data from wireless instruments, realtime pump status and health can be established, and alerts created that provide warning of cavitation, plugged strainers, early bearing wear and seal leaks. Data analytics can also provide insight into plant health, performance and energy consumption and access to the information can be enterprisewide,” said Taylor. He went on to highlight the need for executives to harness innovation to improve performance. “Manufacturing is now focused on digital transformation, leveraging new technologies to boost operational performance. But there is no consensus on how to get there and little understanding of what success looks like. With no industry standard, it is Control Engineering Europe

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e: New Initiativ mmunication Field Level Co UA over TSN including OPC

The Industrial Interoperability Standard

www.opcfoundation.org

OPC UA: Set for IIoT & Industrie 4.0 OPC UA is the world largest eco-system for Industrial Interoperability Key Features: ➞ Modeling of data and interfaces for devices and services ➞ Integrated security by design with configurable access rights for data and services Validated by international security experts ➞ Extendable transport protocols: Client/Server and Publisher/Subscriber and roadmap for TSN ➞ Scalable from sensor to IT Enterprise & Cloud ➞ Idependent from vendor, operating system, implementation language and vertical markets Information models of different branches are mapped onto OPC UA to make them interoperable with integrated security. The OPC Foundation closely cooperates with organizations and associations from various branches:

Practical Security Recommendations opcfoundation.org/security 1

Practical Security Recommendations for building OPC UA Applications

OPC Unified Architecture Interoperability for Industrie 4.0 and the Internet of Things

VDMA-Guideline OPC UA ISBN 978-3-8163-0709-9

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Version 08 // January 2018

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UPDATE

Update including IIC / China2025 opcfoundation.org/ resources/brochures/

Industrie 4.0 Communication Guideline Based on OPC UA

IoT Industrie

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M2M Whitepaper Security Working Group

in cooperation with

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VDMA’S ACTIVITIES DEFINING OPC UA COMPANION SPECIFICATIONS OPC UA CS under development ➞ Food Processing Machinery and Packaging Machinery ➞ Integrated Assembly Solutions ➞ Machine Tools and Manufacturing Systems ➞ Machine Vision ➞ Measuring and Testing Technology ➞ Plastics and Rubber Machinery ➞ Power Transmission Engineering ➞ Pumps and Systems ➞ Robotics ➞ VDW: Machine Tools ➞ Weihenstephan: Food and Beverage Awareness existent ➞ Electrical Automation ➞ Fluid Power ➞ Foundry Machinery

INDUSTRY 4.0 hard for companies to know whether they are on the right track or to know when they have arrived! Operations technology (OT) and information technology (IT) leaders are often siloed, not collaborating toward one central mission to achieve digital transformation. “Implementing digital transformation projects and adopting new technologies can be challenging and there is a need for manufacturers to increase their practical understanding about digital technologies and applications and with that knowledge they must formulate a digital manufacturing strategy.” To support companies Emerson has developed a Digital Transformation Roadmap with consulting and implementation services to help its customers develop and execute a tailored transformation plan. Emerson recently carried out a study of industry leaders responsible for digital transformation initiatives and found that only 20% of respondents had a vision, plus a clear and actionable roadmap for digital transformation. Responders stated that a clear practical roadmap was important and the absence of one was the major barrier for digital transformation projects. Cultural adoption and business value were identified as other leading barriers to progress. “We found that while all respondents were actively conducting pilot projects, only about 20% of those had moved beyond that stage into new operating standards,” continued Taylor.

February 2019

Daniel Rossek, regional marketing manager at Omron Industrial Automation Europe, believes that the market is in varying states of adoption of industry 4.0 principles – from the extremes of firmly ‘burying one’s head in the sand’ to the process of developing the ‘factory of the future’, to somewhere in the chasm that exists between the two. In general, however, making a comparison to the Gartner hype cycle, Rossek believes that industry has now moved past the ‘peak of inflated expectation’ and that more realistic and practical approaches are now being investigated and deployed by many companies. While Rossek acknowledges that Industry 4.0 technologies can provide tangible solutions to real-life issues he believes that in the real world most manufacturers are more focused on simply improving productivity and efficiency to increase competitiveness or are busy reacting to socio-economic issues like labour shortages. “The main hurdle for most manufacturers is that they are often not working from a blank canvas, so are restricted by the existing infrastructure of legacy machinery and plant, with little or no standardisation of system architecture,” he said. “For many, the Industry 4.0 concept can appear somewhat overwhelming, and defining a process or starting point for implementation can be challenging. “A recommended starting point is to deploy a system that can monitor machinery or plant effectiveness. These types of solutions can be used to monitor productivity and downtime, linking back to a central dashboard. Systems like this are relatively simple and cost-effective to deploy, but provide valuable

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line level information to permit more informed decisions about possible areas of additional investment in critical areas or bottlenecks. “In addition these types of solutions, provide a platform for data gathering at line level and can be upscaled in the future to capture more information, paving the way for more advanced industry 4.0 benefits like predictive maintenance or condition based monitoring,” concludes Rossek.

The right direction Siemens believes that German industry is now moving in the right direction when it comes to digitalisation. Commenting on this at the 2018 SPS/ IPC/Drives event Klaus Helmrich, a member of the management board of Siemens AG, said: “An ever-increasing number of industrial enterprises, particularly SMEs, are well on the way towards Industry 4.0, and are already improving their competitive standing with digital solutions. This applies to all sectors of industry with rapidly changing market demands in which products have to be manufactured ever more quickly, flexibly and in diminishing quantities.” Earlier in 2018, at the Hannover Messe, Siemens announced that ‘the hour of implementation has arrived’. Helmrich said: “By implementing Digital Enterprise solutions, users and customers can now tap into the full potential of Industry 4.0 to achieve greater flexibility, shorter times to market, higher efficiency and better quality.” Helmrich believes that greater cooperation is necessary to ensure the success of Industry 4.0 and to this end Siemens has joined forces with Aruba, a Hewlett Packard Enterprise, in a strategic partnership for integrated networks. On the basis of their complementary product portfolios they are providing support to customers in the implementation of integrated communication networks, all the way from factory floors to corporate offices. Siemens is also working closely with Control Engineering Europe

INDUSTRY 4.0 Bentley Systems on a joint development of PlantSight Cloud Services which will give users access at any time to 1D/2D/3D data using a simple web portal – making a continuously updated digital twin of a plant available to all users. Industry 4.0 has been a buzzword for some time but many organisations in the UK still have a long way to go in their journey according to Martin Walder, VP Industry at Schneider Electric. “Manufacturers need to take every opportunity to embrace smarter, connected technologies now – whenever a new piece of equipment is purchased it should be connectable even if at first it is not connected,” he said.

Moving to the edge Gavin Stoppel, a product manager at HARTING says that, from a manufacturing perspective, much of the key technology driving Industry

4.0 is focused on data analytics and he believes that to enable this compact edge computing devices will play an important role in opening up gateways to cloud and data analytics solutions. “Edge computing devices are low cost and easy to implement with a range of different platforms, providing flexibility for the user,” he said. “It is possible to retrofit these edge devices to legacy machines to access vital machine data and ultimately help extend machine lifetime.” Stoppel is also of the opinion that one of the biggest barriers to adoption of new technologies is a lack of understanding about how to implement Industry 4.0. He said: “There is a lot of information out there that is conflicting and confusing. Many companies know what they want to achieve from Industry 4.0, but do not know the best solution to implement in order to achieve these goals.” Stoppel cites cost of implementation

as another stumbling block to adoption so it is important that vendors are able to demonstrate to businesses that, despite the initial costs, they will see a return on investment in terms of more efficient production planning and energy use.

Varying pace According to Steve Sands, marketing manager at Festo UK, the pace of Industry 4.0 varies from country to country and also between industry sectors. However, in general, he says most businesses are aware that there is a major change coming and that they need to be ready to capitalise on it. Sands suggests a good starting point for information on the subject would be to read the Aspects of the Research Roadmap in Application Scenarios paper (available at www.plattform-i40.de). Sands explained that a fundamental requirement for Industry 4.0 delivery is having the ability to communicate

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February 2019

INDUSTRY 4.0 according to a set of common standards. “These standards are essential to enable the open exchange of information throughout product lifecycles that can deliver significant improvements in manufacturing and production,“ he said. “To deliver real benefits, the terminology has to be in place to ensure a common language is being spoken and that the machine conversations make sense. Digital twins from one manufacturer need to be formatted and compatible with another’s, allowing a smart machine to be assembled from a number of smart devices. The system will only operate effectively when the data is uniform, consistent and coherent.” Sands went on to explain that while there are some excellent proposals for standardisation, the adaptation of frameworks like AutomationML (including by the diverse providers and users of the technology) requires consideration of the natural conflicts. For example, is it better to gather a high quantity of excellent data but accept compromises to speed? What about the increased cost of creation, storage, transmission and utilisation of large quantities of data in the Cloud? What type and depth of data is right for everyone? Can a standard be flexible enough to meet everyones needs and still be a standard? “In total, working groups have identified more than 20 technology areas that would need to be addressed. These issues are being approached pragmatically, because it is better to agree to something than to wait until everything is defined and agreed.” Although Sands accepts that much remains to be done, he pointed out that we are really only three years into a 20-year journey – and progress is being made. “There are excellent demonstrators of IIoT / Industry 4.0 technologies working today. There are many more examples of the excellent use of digitalisation, cloud-based technologies, big data gathering, visualisation and analysis using clever predictive and artificial intelligence,” he said.

February 2019

Sands concluded by saying that to maintain momentum, it is important to be clear in terms of deliverables. Potential users need to understand the terminologies involved and to appreciate the timescales.

Where to start? While acknowledging that the IIoT offers many opportunities, a Yokogawa spokesperson said that few companies have really incorporated IIoT into their digital transformation program and many are struggling to determine where to start. While technology is the heart of IIoT it is not enough on its own to make it successful, according to Yokogawa. IIoT will only be successful if the new technology is aligned with existing business processes and the competences of existing employees. The Yokogawa spokesperson pointed out that one of the biggest barriers for full deployment of IIoT are the barriers or silos between technology, process and people in an organisation. Breaking down these barriers requires a change of mindset and culture and therefore strong involvement from senior management to lead the change. Yokogawa advises that companies do not try to do everything at once. Instead, first create a plan which explains why this IIoT revolution can add real benefits the business and how it will help achieve business goals.

Going a step further Per Kloster Poulsen, regional sales director at Universal Robots argues that Industry 4.0 is failing to bring the muchneeded personalisation and flexibility to manufacturing.

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He believes that Industry 5.0 offers an evolution of this approach which seeks to retain efficiency benefits while bringing the human touch back into manufacturing. “Collaborative robots, or cobots, have played a major part in delivering automation with greater potential for flexibility,” he said. These human-cobot collaborations are rapidly becoming a norm in automation, particularly among SMEs who are able to seamlessly implement them into existing production lines with minimal downtime and without the added expense of a robotics engineer. With cobots offering enhanced flexibility, adaptability and affordability, the manufacturing world is embracing the idea of employing cobots to work side by side with humans, taking a step forward towards an industry 5.0.” Implementing cobots into the workforce has already proven to be effective. FT-Produktion, for example, a Swedish machine shop, turned to collaborative robots to boost productivity without needing to hire additional personnel. By implementing cobots into its production, this SME has managed to significantly increase production and efficiency at the factory and it is also now much more responsive to changing customer demands. “What this use case demonstrates is that due to the affordability of cobots Industry 5.0 is in fact achievable for businesses of all sizes, and can even help SMEs become more competitive against larger corporations,” said Poulsen. ! Control Engineering Europe

UK NEWS

UNLOCKING YOUR HIDDEN ASSETS Ian Flaxman argues the need for UK manufacturers to look at their hidden assets as a financing solution to help them grow.

ccording to the United Nations the UK is currently the ninth largest manufacturing nation in the World. So, UK industry is thriving, contrary to public perception – a survey by the manufacturers’ organisation, the EEF, found that the public think the UK sector is 56th in the World. If current growth trends continue, the UK will become the fifth largest manufacturing nation in the world by 2021, according to the EEF. For the sector to continue to thrive it needs access to finance. Research undertaken on behalf of Wyelands Bank revealed that too many firms are not making as much of their hidden assets as they could. This potentially creates a working capital squeeze, limiting growth. Unlocking these hidden assets would help manufacturers to trade, grow and to create jobs.

Hidden assets The Wyelands Bank analysis of 23,000 UK mid-sized manufacturers shows that they have up to £252 billion in assets

that could be used to access working capital to help them grow. It shows that the average business in this bracket has more than £10 million of potential working capital tied up in assets that could be used to raise finance. Typically, this amounts to 25% of turnover. Wyelands Bank used Government data provided by businesses to understand the total stock and debtor assets available to these businesses. The research assesses the working capital potential. Quite often large businesses need less financing because they have more leverage with their customers. Mid-sized businesses, however, can struggle for this reason. Freeing up these potential working capital assets would help provide the finance that businesses need to fulfil new orders and grow. The research looked at businesses turning over £10 million to £300 million across the manufacturing supply chain. This included tier three businesses, or raw material suppliers, and tier two businesses, or manufacturers. It also included tier one businesses, or distributors, and OEMs. The analysis reveals that OEMs have

the highest proportion of working capital assets compared to turnover at 28% on average. Manufacturers have the second highest proportion compared to turnover at 26% on average. Distributors are third with 25% on average. Raw materials suppliers have the lowest proportion of working capital assets compared to turnover at 24% on average. There are some simple ways to fund growth. This might mean raising money against the invoices they have issued, or against stock that they hold. Some businesses might also be able to raise finance against the plant and machinery they have or are looking to get. As the Wyelands research shows, too many manufacturers are not making as much of their hidden assets as they could. Companies need to look at how to unlock their assets to allow the UK to move from the world’s ninth largest manufacturer to the fifth. ! Ian Flaxman is managing director, working capital solutions at Wyelands Bank.

Stages in the supply chain

Tier 3

Tier 2

Tier 1

Turning over £10-300 million

Supplier

Manufacturer

Distributor

Companies that produce raw, or close to raw materials like textiles, metals and plastics

Companies that produce component parts that are not sold directly to the OEM, but to Tier 1 companies, who package the inputs for ultimate sale to the OEM

Companies that supply parts or systems directly to OEMs

Design, manufacture and market the end product, sourcing parts from suppliers/ distributors to assemble the final product

Average turnover

£44,550

£40,982

£40,525

£40,608

Average debtors

£6,208

£5,932

£6,078

£4,916

Average stock

£4,454

£4,904

£4,205

£6,501

Average potential assets

£10,662

£10,836

£10,283

£11,417

Control Engineering UK

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Original Equipment Manufacturers

February 2019

UK1

PROGRAMMING

LADDER LOGIC: FINDING FAULTS In ladder logic, faults are used to capture abnormal circumstances and each cell or station in a program will usually have its own fault routine and can send messages to a HMI or a PLC. Frank Lamb reports.

n ladder logic faults are used to capture abnormal circumstances such as an actuator not completing its motion within a prescribed period of time. Each cell or station in a program will usually have its own fault routine. There is usually one fault for every motion (extend, retract, raise, lower and so on). Other faults may include lack of air pressure, emergency stop actuation, guard door switches and drive or overload alarms. A system fault disables the timer on the fault rung. It serves two purposes: • Only the fault that happens first is enabled – This prevents subsequent faults that may have been caused by the initial fault from occurring. If air is removed from the system several pneumatic actuators may fault within the same event. • After the fault occurs the timer resets allowing a new countdown – This allows physical correction of the cause of the fault by maintenance or an operator. There are a couple of methods of resetting the fault. One is to clear the register word that contains the faults, in this case word 10. This fault word may be for only this cell allowing the system reset signal to reset faults in sections if desired; word 10 for cell 1, word 11 for cell 2, etc. Another method is to reset or unlatch faults individually. These reset signals can also be individually conditioned this way on each rung. Faults can also be used in a permissive rung to prevent actuation of an axis. Fault bits are also used to

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February 2019

activate messages on a touchscreen or human-machine interface (HMI), for instance, bit 10.0 might bring up a message that says, ‘Axis SV1.0 Failed to Extend; Correct Fault and Press Reset’. The message would be cleared when the fault is corrected and the fault reset button pressed. There are several ways to display fault messages on an HMI. Most HMI software allows the user to make a list of faults and then call them by number to display in a banner or other type of text display. Another option is to configure the trigger to display the message by bit number. This also allows multiple messages to be displayed on a timed cycle, unlike if the message were to be displayed by value or placing a number into the message register. The background colour of the message can also be configured so that fault messages and warnings or other informational text can be displayed in the same banner. This is especially helpful if the HMI is small and does not have room for more than one message display. Besides faults and messages, these displays can be used as multi-state indicators to show the mode of a machine or station status. Other properties of the message display can also be configured such as its visibility.

Bits versus values There are advantages and disadvantages to using bits versus values. Using bits allows several states or messages to exist at the same time, whereas a value allows only one message to be called. If the HMI does

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not have the ability to cycle through messages with several bit triggers active at the same time, it will be necessary to write code in the PLC that cycles through the messages. Another method that is sometimes used for message displays is to simply place a string display on the screen. While this is simple on the HMI end, it requires the PLC program to cycle through the strings and place them into the message register, which of course must be of the STRING data type. This technique has advantages and disadvantages. On the plus side, the PLC programmer can change string messages dynamically. As a matter of fact, the programmer can give access to the user of the touchscreen by placing links to the locations of the string registers on a screen. This allows the messages to be configured without using the HMI software. On the minus side, it is difficult to manage background or text colors using strings. The background would have to have a color register assigned to it, which would be managed separately. ! Frank Lamb is the founder of Automation Consulting LLC. This article originally appeared on www.controleng.com Control Engineering UK

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NOW. NEXT. BEYOND

WHAT THE FACTORY OF THE FUTURE HAS IN STORE In today’s global manufacturing landscape, competition is more fierce than ever as consumers demand customisation, flexibility and shorter lead times. For manufacturers, that introduces a need to adapt to change, to become more nimble, more efficient and more productive. The advent of Industry 4.0 makes this possible, supporting manufacturers to evolve and realise their full potential.

ith some six billion objects now IoTconnected, we’re already seeing manufacturers taking significant steps towards a digital future. But for some, taking the leap into the digital age isn’t straightforward, with the benefits of Industry 4.0 and the process of implementation not fully understood. To understand where the benefits of digitalisation lie, Bosch Rexroth developed its own Factory of the Future, demonstrating every possibility and exploring how manufacturers can implement them step-by-step for maximum impact.

Digitising your value stream In the Factory of the Future, all hardware modules and functions are represented digitally in real-time. Sophisticated software solutions collect, transfer and process data to analyse, simulate and improve all processes. Putting sensors on key pieces of machinery to provide realtime insights into equipment health and making use of the Internet of Things to collect data, streamline operations and improve efficiency are just some of the benefits. Distributed intelligence manifests itself in all technologies - from cabinet free drives which reduce cabling; low energy, intelligent hydraulic power units; to assembly workstations which provide employees with personlaised work instructions.

to (re)configure production lines and facilities to fast changing requirements. Taking connected hydraulic systems as an example sensors can be added to horizontally and vertically networked machine architectures. By managing functions such as position, velocity, distance/ force in real-time via the software, users can operate more efficiently when producing small batches and reduces the retooling work for new products. The increasing use of wireless technology has the potential to further improve flexibility. Instead of power cables, which tie a machine to a specific place in the factory floor, machines will be powered by inductive charging, with the added benefit of 5G connectivity as a faster, more stable means of data transfer. This functionality simplifies conversion to new processes, making factories highly flexible. Production configures itself independently in-line with the product to be manufactured. Communication between machines

and systems is mainly wireless. Production layouts are optimised and operating data is captured and analysed, producing real-time data which drives continuous improvement and virtually eliminates machine downtime.

Stepping into the future The notion that a process facility is too large or too old to move towards digitisation is a common one. Whether a facility chooses to take a granular approach to getting connected, or prefers the idea of a complete digital overhaul, it is important to remember that digital technologies are highly scalable – making them relevant to any business, of any size, at any stage of the process. In fact, Industry 4.0 presents a host of opportunities for manufacturers to incrementally change how they do things. ! To discover more about the evolution of smart factories, explore Bosch Rexroth’s Factory of the Future at: www.boschrexroth.co.uk/fotf

Maximising your flexibility Smart factories will make it possible Control Engineering UK

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Fenbruary 2019

UK3

TEST & MEASUREMENT

TEST AND THE IOT While the IoT is increasing device complexity and, in turn, increasing test complexity, it can also enhance automated test workflows says Mike Santori.

nternet of Things (IoT) devices and Industrial IoT (IIoT) systems are increasing test complexity. However, on the plus side the IoT is also able to enhance automated test. The application of IoT capabilities such as systems management, data management, visualisation and analytics, and application enablement to the automated test workflow will better equip test engineers to overcome the challenges that the IoT poses.

Managing test systems Connected managed devices are fundamental to the success of IoT and IIoT. Many test systems, however, are not connected or well managed, even as they become more distributed. Test engineers often have difficulty tracing the software running on any given hardware or just knowing the whereabouts of systems, much less tracking performance, utilisation, and health. Fortunately, most modern test systems are based on a PC or PXI and so can directly connect to the enterprise, which enables additional capabilities such as managing software and hardware components, tracking usage, and performing

predictive maintenance to maximise the value of test investments. The business value of the IoT comes from the data it generates. Consuming test data is, however, difficult due to the many data formats and sources – from raw analogue and digital waveforms in time and frequency to parametric measurements often gathered at significantly higher rates and volumes than from consumer or industrial devices. Further, test data is often stored in silos with little standardisation. Consequently, this data is ‘invisible’ to a business, making it easy to miss potential insights at other phases of the product life cycle. Prior to implementing a comprehensive, IoT-enabled data management solution, Jaguar Land Rover (JLR) analysed only 10% of its vehicle test data. Simon Foster, powertrain manager at JLR, said: “We estimate that we now analyse up to 95% of our data and have reduced our test cost and number of annual tests because we do not have to rerun tests.” Applying IoT capabilities to automated test data begins with ready-to-use software adapters for ingesting standard data formats.

These adapters must be built with an open, documented architecture to enable ingestion of new and unique data, including non-test data from design and production. Test systems must be able to share their data with standard IoT and IIoT platforms to unlock value from data at the enterprise level. “It will soon become standard that our customers require the management and maintenance of test assets from around the world,” said Franck Choplain, digital industry director at Thales. “We must reshape our test architectures to integrate IoT technologies, especially to evolve configuration management and data analytics and support the digitalisation of our business for Industry 4.0.”

Visualising and analysing Using general business analytics software for test data is not the best solution as this data is often complex and multi-dimensional. Also, typical business charting capabilities do not include common visualisations in test and measurement, such as combined graphs of analogue and digital signals, eye diagrams, Smith charts, and constellation plots. Test-oriented schemas with appropriate metadata enable tools to provide visualisation and analysis for test data and correlate it with design and production data. Well-

Connected intelligence for automated test.

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February 2019

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Control Engineering UK

??? TEST & MEASUREMENT organised test data allows engineers to apply analytics from basic statistics to artificial intelligence and machine learning. This enables workflows that integrate and leverage common tools, like Python, R, and The MathWorks, Inc. MATLAB software, and generates greater insights from data.

Test software The world is moving from exclusively using desktop applications toward augmenting with web and mobile apps. This transformation can be difficult to realise for test. Computing at the device under test (DUT) is needed to process large amounts of data and make real-time pass/fail decisions, and local operators need to interact with the tester and the DUT. At the same time, companies want to remotely access testers to see results and operating status. To address this, some companies have built one-off architectures to manage

software centrally, and they download software to testers based on the DUT. But because of this, they must maintain their custom architecture, which requires additional resources that could be applied to activities with higher business value. Higher level test management is a good candidate to move from the local tester to a cloud deployment. Web-based tools allow for viewing tester status, scheduling tests, and examining test data pushed to a cloud or server. Higher level management capability complements existing test systems built with common tools such as NI LabVIEW, Microsoft .NET languages, NI TestStand, and Python. A modular test software architecture (test management, test code, measurement IP, instrument drivers, hardware abstraction layers) enables companies to evaluate the tradeoffs of moving different software capabilities from local to server or

cloud-based execution. Leveraging the IoT for test can be achieved today. An organisation’s ability to do so depends on its current automated test infrastructure and most pressing business needs. Some common areas to consider are improving test system management, increasing test equipment utilisation, gaining better insight from test data, and remotely accessing shared test systems. A software defined approach with a high degree of modularity allows businesses to focus on the areas of greatest value without having to make an all-or-nothing decision !. Mike Santori is an NI Business and Technology Fellow. This article was taken from the NI Trend Watch 2019 To read the original document go to: www.ni.com/en-gb/innovations. html#trends

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MACHINE VISION

LASER EYES FOR ROBOTS Laser profile sensors act as the â&#x20AC;&#x2DC;eyesâ&#x20AC;&#x2122; of a robot and are now being used in a variety of applications, says Chris Jones.

s well as inspecting onedimensional parameters, there is now an increasing need for multi-dimensional quality control in industrial production. Laser profile sensors (laser line scanners) are designed to carry out complex 2D/3D measurement tasks in robotics and other automated, high speed production environments, where the sensors are increasingly used to measure profiles and contours. The operating principle of a laser line scanners is based on the laser triangulation technique for twodimensional profile detection. They detect, measure and evaluate the profiles on different object surfaces.

By using special lenses, a laser beam is enlarged to form a static laser line instead of a point and is projected onto the target surface. An optical system projects the diffusely reflected light of this laser line onto a highly sensitive sensor matrix. In addition to distance information (z-axis), the controller also uses this camera image to calculate the position along the laser line (x-axis). These measured values are then output in a two-dimensional coordinate system that is fixed with respect to the sensor. In the case of moving objects or a traversing sensor, it is possible to obtain 3D measurement values. Laser line scanners are equipped with an integrated, highly sensitive receiving

scanCONTROL laser profile sensors are equipped with a Gigabit Ethernet interface for transferring profile data

UK6

February 2019

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matrix that enables measurements on almost all industrial materials, largely independent of the surface reflection. A typical application for laser profile scanners can be found in the inspection of adhesive beads in smartphones. The challenge here is the very fine contours inside the smartphone and extremely thin, semi-transparent adhesive beading. Here, absolute reliability and 100% control of the completeness of the beading, the height and width of the applied adhesive are required. This also applies to logos on tablets and laptops: grooves are milled into the aluminium housing, in which the logo elements are glued afterwards. The latter must be flush with the housing. Haptics (touch sensation) is a critical factor, as the customer would immediately feel any protruding logo or depression. Using laser line scanners, these depressions can be measured to determine the planarity as well as the depth. The parts being glued are also measured in order to ensure a perfect fit. Laser line scanners are also carrying out important inspection tasks in the automotive industry. For example, airbag covers on steering wheels should be functional and not impede the airbag, while opening during an accident. They also form part of the interior decor of the car. As interior parts, the covers must therefore harmonise with the overall appearance. The high aesthetic requirements placed on the cockpit, seats, interior trim and steering wheel are particularly important for this functional component. While assembly gaps cannot be measured prior to installation, like many other elements of a car, the airbag stitching can be inspected during production. Guided by robot Control Engineering UK

MACHINE VISION arms Micro-Epsilon scanCONTROL laser profile sensors can evaluate several features synchronously. The laser scanner continuously inspects the distance between the stitching and the separating point between the single stitches and outputs the evaluation directly as ‘O’ (NOK) or ‘1’ (OK) via its Ethernet interface. Beyond that, the height difference between two single stitches is directly inspected in order to recognise any faulty assemblies immediately.

Gap monitoring Car interiors present a number of gaps, for example, between the single cockpit elements such as the centre console or door trim. From a technical point of view, it is often irrelevant if the width and height of a gap are constant. However, the interior is an area of the car that the customer sees first. Even minor faults can therefore catch the buyer’s eye and negatively

influence their purchasing decision. The gapCONTROL profile scanner can inspect the gaps of all parts in the car interior during final assembly. Depending on the inspection situation, a single scanner applied on a robot arm can measure different gaps in a static or dynamic mode; alternatively, a special frame on the robot arm can be used to enable the scanner to detect a number of different gaps in the interior in static mode within fractions of a second. The sensor then evaluates the measurement values and sends a signal to the control system if the values measured lie within the tolerances defined by the customer.

Robotic weld inspection systems Laser profile sensors have also been installed on an automatic weld inspection system that is designed to inspect thin section steels and thin gauge welds on ships and other

marine vessels. The system inspects the weld and classifies it by means of laser, ultrasound and electromagnetic methods. The system uses a crawling robot that deploys remote volumetric surface and visual inspection to verify the integrity of welds on the hull plates of ships during manufacture and in the servicing of shipping vessels. Other inspection techniques have proven to be disruptive to the manufacturing process and are far from cost effective. New generations of ships are being built from thinner section steels in order to lower the cost of build and ship operations and so typical assessment methods are not as effective as they were for thicker sections. There is, therefore, a genuine need for a more reliable, faster, cost effective and safer inspection technique. Chris Jones is managing director of Micro-Epsilon UK.

Pushing the boundaries of 3D vision inspection SICK has launched the SICK Ranger3 camera which is its first to use the CMOS ROCC (Rapid On-Chip Calculation technology) which is said to be faster than any comparable device on the market. This next-generation technology is capable of capturing 7,000 profiles per second at full sensor acquisition. The camera is able to extract the true 3D shape of an object, regardless of its contrast or colour and as a result achieves an accurate 3D measurement, enabling operators to achieve reliable quality inspection at more rapid throughputs. The SICK Ranger3’s performance on light, dark, reflective and contrasting surfaces makes it suitable for a range of inspection duties. ROCC technology is said to enable faster and more precise shape, volume and position measurements even for large depths of field or height variations. By having analogue to digital conversion of the signals on the CMOS sensor itself, and sending the accurate data directly to a controller or a standard PC, the ROCC process increases the application possibilities for high speed 3D inspection. The Ranger3 camera delivers a continuous stream of GigE and GenICam-compliant data with a variety of 2D and 3D data generation options, as well as measuring reflectance and scattered light. The camera can be built into standalone inspection units or integrated into automatic quality control systems with other sensing devices, such as encoders, photoelectric switches, light curtains and scanners. The camera is available with either IP65 or IP67 rated housings and has M5 mounting points on four sides, and M12 industrial connectors with GigE and power I/O.

Control Engineering UK

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February 2019

UK7

NEW PRODUCTS

Severe Service app for optimised control valve maintenance Emerson has released a Severe Service app, developed for process control engineers who need quick and easy control valve diagnosis and maintenance for difficult installations within process plants. Severe service control valves can fall victim to cavitation, erosion, high pressure, and other environmental challenges. The Severe Service app aims to help maximise the longevity of these critical assets. The app enables users to quickly perform initial sizing for Fisher globe control valves, as well as diagnosing potential valve problems before damage occurs. Once sizing and diagnosis have been completed by entering the valve and application specifics, the app will display a Cv value and potential issues that can arise, such as cavitation or noise. Users can share the results with internal maintenance teams or with a local Emerson sales office for efficient

maintenance management. Features include instant access to a Fisher control valve sizing tool, severe service control valve diagnosis information, a large technical library and a severe service industry application library to keep users up-to-speed on severe service topics with educational videos and reference collateral.

IO-Link added to inductive sensors Carlo Gavazzi has added IO-Link communication capabilities to its IBS04 & ICS05 ranges of inductive sensors. The IBS04 and ICS05 sensors offer a solution for industrial automation equipment in applications where space is limited and where non-contact detection of metal objects in general position-sensing and presence sensing is required. Each device can now be configured simply by setting the internal parameters via an IO-Link master. After connecting the sensor to an IO-Link master it is possible to configure additional advanced functions such as programmable sensing distance and hysteresis, switch point (single, two point or window mode), timer functions,

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February 2019

temperature alarms, divider function to read the speed of a sprocket (RPM counter), setting configurable outputs such as PNP/NPN and NO/NC Push Pull. All these parameters can be changed on-the fly. The in-built micro controller ensures stability with respect to environmental influences with highly repeatable measurements at temperatures of between -25 and +70Â°C.

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Human assistance camera improves manual assembly The Ricoh SC-10 camera inspection system, available from Stemmer Imaging, is designed to provide assembly instructions to operators and to verify that each step has been completed correctly. A set of work instructions are loaded into the camera and displayed on a monitor while the camera scans the work piece. The human operator follows the on-screen assembly instructions and after every action the system compares the result to the correct stored image before the next step can be taken. This reduces errors, helps operators learn new tasks and provides a digital audit trail of all operations. The camera automatically checks the assembly status and identifies incorrect or missing items by using either pattern matching, colour verification or identifying the presence of textures. Used in conjunction with a barcode scanner it can also record the part number and select the job instruction set, record the serial number and user ID. Each step completed is recorded in a CSV file including the time spent and an optional image of the inspection can be saved. The camera features in-built software which can be set up with a directly attached mouse and keyboard via USB. An HDMI monitor can be connected to display the assembly instructions and inspection state. No PC is required.

Control Engineering UK

INDUSTRY 4.0

THE ROAD TO INDUSTRY 4.0 MATURITY Paul Taylor talks about the Industry 4.0 Maturity Index which was developed to help companies introduce Industry 4.0 in manageable steps.

any organisations do not yet have a coherent plan for Industry 4.0 implementation, while others use Industry 4.0 only in selected areas. However to unlock all the opportunities offered by connected and smart production, efforts need to be extended to include the likes of logistics and customer service into the Industry 4.0 approach. To address these challenges the Industry 4.0 Maturity Index was developed by a consortium of research institutions working under the umbrella of acatech (Deutsche Akademie der Technikwissenschaften). The objective of this group of experts was to create a tool that enabled Industry 4.0 to be introduced in manageable steps and to provide a solid basis and certainty for investments and planning. The index is a systematic guide, supporting companies in the integration and continuous improvement of their IT and communication systems. To this end, it defines six successive stages: 1. Computerisation: While the use of IT and process automation has already become the standard, companies still use insular information systems at this stage. 2. Connectivity: Once the individual components are connected, companies have reached the maturity stage of connectivity and implemented digitalisation as defined in this guideline. However, they have not yet achieved full integration between information and operational technologies. 3. Visibility: At this stage, companies start to use sensors for real-time recording of conditions and processes. Control Engineering Europe

They produce a digital model of production, a ‘digital shadow’ that shows what is happening at any given point in time. 4. Transparency: Once companies use the digital shadow to identify and understand interactions, they have reached stage 4. To do so, they need to interpret the recorded data in the relevant contexts by applying engineering knowledge. Big data applications are deployed in parallel to business application systems – such as ERP or MES – to provide a common platform for data analysis. 5. Predictive capacity: To simulate scenarios and evaluate them in terms of their likelihood and consequences, the digital shadow is projected into the future. As a result, companies can anticipate future developments and make the necessary decisions. 6. Adaptability: At the highest stage of maturity, the IT systems will make these decisions independently. At this stage, Industry 4.0 has been realised in full. IT systems initiate the necessary alignment measures automatically and without delay. The extent to which IT systems will be allowed to act autonomously depends on two aspects: first, on the complexity of the decision, and second, on the costbenefit ratio of automated versus human actions.

A structured approach The Maturity Index has a modular structure and covers five functional areas – development, production, logistics, services, and marketing and sales. However, Industry 4.0 is more than the mere connection of cyberphysical systems (CPS), as a company’s

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corporate culture is equally important to its organisational structure. The index therefore defines four structural areas: • Resources: Includes a company’s workforce and their competencies, equipment, facilities, tools and products. • Information systems: Refers to sociotechnical systems in which people and technology provide and process data. • Organisational structure: Covers rules and structures which control a company’s internal and external relationships. • Corporate culture: Refers to a company’s value system, such as its workforce’s willingness to accept and actively shape change. Application of the Maturity Index covers three phases. The first phase is to analyse the current maturity stage to provide an overview of the current state of digitalisation. The second phase involves the definition of specific goals, including consideration of both the use of digital processes and corporate strategy. A gap analysis then identifies the capabilities and resources that are still needed to achieve these objectives. The final phase sees the experts develop a digital roadmap to build-up these capabilities, with actions being prioritised on the basis of a cost-benefit matrix. The connected world of Industry 4.0 adds a new and significant dimension of complexity. What makes the Maturity Index so useful is that single action delivers measurable benefits and the process is traceable at all times. ! Paul Taylor is head of industrial products (UK) at TÜV SÜD Product Service. February 2019

SCADA SYSTEMS

KEEPING PACE WITH THE DIGITAL TRANSFORMATION Suzanne Gill finds out more about the changing role of SCADA systems and asks what features are needed to ensure that this technology keeps pace with the demands of the digital factory of tomorrow.

oday’s SCADA does not really have very much in common with the SCADA systems of ten years ago. On top of the traditional SCADA functionality based on fixed brand PLC communication, a modern SCADA system is able to interact with many other software and hardware components. “Not only does it need to have a large library of built-in connectivity options for third-party drivers, it can also provide easy connectivity to databases and upperlevel systems like MES or ERP systems as well,” said Christian Nomine, solutions consulting and product marketing, Factory Automation EMEA at Mitsubishi Electric Europe B.V. It should also support web services, IIoT and cloud-based connectivity such as OPC UA or MQTT and IT connectivity like SNMP or ICMP to monitor IT assets. “Even in the field of machine learning and data analytics, SCADA still makes a lot of sense,” continued Nomine. “For example, using it as a simple way to

contextualise – by adding meaning to pure numbers like engineering units, comments, correct dimension, structures – and to visualise and understand logged machine data before it is put into a deep neural network to learn a predictive maintenance algorithm.” Nomine advises that, for maximum flexibility, a modern SCADA should be based on the latest programming environments and should support accepted programming language standards such as C#, VB.net or Java. These open programming interfaces will allow adaptation of the SCADA software to fit expectations. “Last but not least, a state-of-the-art SCADA system should be capable of running the operator interface in a platform-independent manner, whether than be on a Windows PC or on a smart device. “The role of a modern SCADA system has significantly expanded, providing features and functions which support the needs of digital transformation and changing business models for infrastructure and processes. However,

Figure1: Screenshot of FDT OPC UA Client showing the project tree exposing what devices are accessible.

February 2019

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one thing remains unchanged. SCADA systems will continue to focus on the real-time environment of industrial automation,” said Nomine.

Security considerations According to a Yokogawa spokesperson, less than 20% of SCADA systems and applications in operation today can be seamlessly upgraded to a new version, or can benefit from the latest OT/IT technology. This can make upgrades as expensive as a total system replacement. As a result, new investments in SCADA systems are often postponed beyond the point that legacy systems are able to keep pace with cyber intrusion risks. Every production plant operator should regularly evaluate their OT lifecycle and objectives to keep critical SCADA systems and applications continuously up to date. Potential security risks, reliability and efficiency of ageing SCADA systems should be regularly assessed. While the trend towards the IT domain converging with the OT domain brings new opportunities to optimise operations, it also presents challenges in protecting critical plant automation domain and associated operation tasks from a cyber-security point of view. Chad McGaw, hosted solutions marketing manager at Honeywell Process Solutions, also commented on the need to ensure that SCADA software includes robust security features. He said: “Today almost everything is exposed to the Internet – a flash drive, or computer with email connectivity – at some point.” All of these introduce the possibility of a cyber-attack. “To prevent this it is important that security is designed into solutions at all levels. For example, RTUs Control Engineering Europe

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PREDICTIVE MAINTENANCE?

Predictive Maintenance – Path to Industry 4.0 Success Detect changes and faults ahead of time, connect machines and sensors, enable cross communication and real time alerts to improve machine eﬃciency and reduce downtime quickly and easily with HARTING’s MICA (Modular Industry Computing Architecture).

Why create a Predictive Maintenance Solution with MICA? MICA provides you with the relevant data at the right time Improve machine eﬃciency Machine monitoring in real time Digitally retrofit existing machinery Digital dashboard on mobile, smart glasses or desktop Simple vertical integration (MES, ERP, cloud)

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People | Power | Partnership

SCADA SYSTEMS with ISA Secure Level 2 certification are designed to prevent hackers from making any changes to the OS, control logic, or data. RTUs serve as the edge device with connectivity to physical I/O, serial communications, and Ethernet, filters, and forward an encrypted VPN to the data center. Designing security at every level is a must if you want to trust the data you use to make decisions.”

Meeting expectations It is now possible to monitor and control hundreds of thousands of variables in thousands or even tens of thousands of devices spread across countries or continents – in near real time. The continuous evolution of mobile network bandwidth and speed is enabling further growth. What was once consumer infrastructure is being used more and more for industrial applications. To meet the expectations of the smart factory, SCADA systems must be able collect, store and analyse all types of factory data and present it in a concise and useful way. This requires the software to be constantly

updated to help improve performance, to add new functionalities for smart factory use and to add ever more advanced analytical capabilities, including predictive analytics calculations. Martyn Williams, managing director of COPA-DATA UK picked up on this point. He said: “Until recently, enterprise and OT operated in entirely different silos. Today, software is expected to execute a range of different tasks and processes, including those usually associated with IT, such as Enterprise Resource Planning (ERP). “Without regularly updating SCADA to meet these new requirements, platforms will quickly become outdated. These updates are not just for improving vertical integration, but also for improving existing capabilities.

Staying up-to-date Today’s SCADA software could, for example, provide meaningful future predictions which assess energy consumption in a factory in the event of a change in production volume.

Consider the following to ensure your SCADA meets your future needs According to Yokogawa a state-of-the-art SCADA technology platform should include the following capabilities: • It should have the ability to easily bridge any gap between OT and IT domains to optimise production management • It should be possible to integrate IIoT and OT data streams into a single open SCADA platform that allows for the correlation of all data by the same means to enable real-time operational actions based on the most comprehensive information and analysis. • It should offer efficient and secure system management through support of virtualised and cloud-based architectures. • It should offer open information models and protocols that will simplify and enhance sub-system configuration, integration and diagnostics. • It should feature a higher level of application portability, modularisation and standardisation to protect investments. According to Yokogawa a state-of-the-art SCADA platform should provide fundamental elements for any industry application, including production management to ensure data and information consistency and security across the devised solution and it must be in compliance with strict regulatory and IT directives. This will ensure that there is no waste of costly resources and it will eliminate re-development efforts.

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Without regular updates, this valuable insight would not be available. “Analytical tools are not the only advantage of using SCADA software which is regularly updated, said Williams. “Updates are also important from a cyber security perspective. As industrial software becomes more sophisticated, the techniques used by hackers are also developing. Without consistently protecting systems from new threats, manufacturers may be putting their facilities at risk. Software with IEC 62443 compliance, for example, requires vendors to provide evidence that proves exactly how the software’s security is improving. As the standard requires recertification annually, manufacturers can ensure their software vendor is constantly under scrutiny from a respected thirdparty.”

Trend-driven changes According to Bernhard Staufer, business development SIMATIC SCADA at Siemens AG, digitalisation is being driven by two key trends – technology innovations and changes in user behaviour and expectations and it is these trends that are impacting what users expect from a SCADA system. “We now have to provide more than just supervision, control, and data acquisition on a workstation or terminal – users also want to be able to conveniently access information whenever and wherever they wish. SCADA systems will become the data backbone linking operational technology and information technology and will be a key component of digitalisation,” he said. This can already be seen in many areas, such as for tracking and tracing products and resources, or for optimising processes in various industries, from manufacturing to infrastructure. Data from SCADA systems can now support proactive maintenance – helping to detect impending failures, create dynamic maintenance plans complete with Control Engineering Europe

SCADA SYSTEMS parts lists, notify teams, and provide additional information on-site via mobile devices. “SCADA systems need to be flexible so that they can accommodate the requirements of different applications,” said Staufer. “It is also important to keep in mind that these systems are handling sensitive data. Plant owners want to be in control of their data at all times, and they want to be able to choose whether to perform a task on-premise or add features in the cloud. Therefore, SCADA systems must be open, supporting standards such as OPC UA or cloud protocols such as MQTT.” In the future, Staufer predicts that OT and IT will merge, giving users the freedom to choose between performing a task in their SCADA system, in the cloud, or using edge computing. “The question of what I want to do will become more important than the question of how and where to do it,” said Staufer.

The continual advancement of IT digitisation has become common practice for business processes according to Nathan Ghundoo, marketing manager, Software Industry Business at Schneider Electric. This, he says, can offer productivity gains and allows the return on investment to be measured. “Successful manufacturing businesses will now start to transfer this mentality into their OT as well as their IT,” explained Ghundoo. “It is important to identify the best ways to continually optimise a manufacturing processes. The first foundational step is having a robust SCADA system to connect all the machinery and equipment through a centralised hub. The hub sits at the core and acquires all the data from the site, including information like machine and process status and it gives operators the ability to control and monitor equipment. A good SCADA presents this information back via a

HMI allowing for a contextualised view into the organisation’s operations, empowering operators to make informed decisions quickly.”

Conclusion As systems evolve, the importance of collecting, storing and analysing this data is becoming more important. Historically, SCADA was used for operating and monitoring production in a plant. Today, however, SCADA systems are much more advanced, allowing operators to simulate the impact of their actions, not only against the yield of their product but against the financial impact on the business versus their production goals. “As SCADA technology continues to evolve, manufacturers will also need to educate their employees on how to operate SCADA systems efficiently through simulation, continuous improvement and by adopting best practices,” concluded Ghundoo !

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February 2019

PROCESS CONTROL

AUTOMATING A HANDCRAFTED PROCESS Denby Pottery’s clay manufacturing times have been halved and productivity has increased since the installation of a new control system.

lthough often perceived as a threat to traditional industries, in reality automation can empower artisans to have greater control over their skilled processes and it can help to ensure consistent product quality. When Denby Pottery, a producer of handcrafted tableware, looked at refurbishing its process control systems it set out to find a reliable and well-connected solution which would allow it to efficiently monitor, control and improve its clay production line. Clay is a raw material that can vary greatly from one batch to another. It therefore requires plant operators to have a good understanding of the clay’s physicochemical properties to accurately control the process parameters and obtain a consistent and high-quality output. Commenting on the application requirements, Steven Sands, technical

engineering project manager at Denby Pottery, said: “One of the key considerations is the dry weight of the material and its application in recipe calculations. Also, high accuracy and precision in controlling the concentration of solids in liquids are essential requirements in this process, so we have used some form of automation for a long time now.”

Maintaining quality To remain competitive and maintain the quality of the clay consistency, Denby Pottery decided to update its obsolete management system. Sands explained further: “The control system was prone to regular failure and running on an outdated platform that had no compatibility with current control elements. In addition, several replacement parts for the system needed to be custom made, as they were no longer available off the shelf. Therefore, the system was

Machines on the Denby Pottery production lines have been equipped with Mitsubishi Electric MELSEC NET H Remote I/O Nodes connected to a Qn Series dual redundant PLC system – linked, in turn, to three Mitsubishi Electric GOT2000 series HMIs (Images courtesy of Denby Pottery).

February 2019

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proving increasingly costly and timeconsuming to maintain.” This was affecting plant productivity and jeopardised the manufacturing processes that lie beyond the clay production lines. Steve Hazell, engineering manager at Denby Pottery, takes up the story: “Some time ago we experienced a major breakdown of the control system. Before solving the issues, the plant experienced an outage of four days.” In addition to addressing issues with the previous control system, Denby Pottery wanted to embrace the principles of modern smart manufacturing to gain greater control over its production materials, processes and machines. In particular, it wanted to measure clay quality attributes ‘on the fly’ to fine-tune the manufacturing process in real-time and improve the quality consistency of the clay. The solution to address all these challenges was provided by Mitsubishi Electric and its technical distribution partner, BPX. The initial installation of a fibre optic network opened a wide range of opportunities for Denby Pottery to monitor and control their manufacturing materials, processes, machines and full production lines. Improved machine communications enabled greater control over the clay manufacturing processes, easy interaction between the processes and identification of any equipment malfunction. The machines on the production lines were equipped with Mitsubishi Electric MELSEC NET H Remote I/O Nodes connected to a Qn series dual redundant PLC system – linked, in Control Engineering Europe

PROCESS CONTROL turn, to three Mitsubishi Electric GOT2000 series HMIs, which were installed to monitor different areas of the factory and report to a central Mitsubishi Electric Manufacturing Execution System (MES) interface within the engineering department. By using the MES interface module and the Virtual Network Computing (VNC) Viewer functionalities of the GOT2000 HMIs, the operators are now able to remotely control and monitor the production line and obtain data on the Overall Equipment Effectiveness (OEE). Another useful VNC server function allows the plant operators to view and operate the GOT screens remotely and securely from any connected mobile device or PC.

Simplified maintenance The resulting decentralised control system simplifies maintenance and operation of the plant with the facility

to securely programme from remote locations by the HMIs interfaced to the Qn series controllers. While the replacement of the legacy control system addressed the reliability issues of the plant, a dual redundant PLC system was selected to increase the system robustness by providing a highly reliable solution. The standby system – with its own CPU, fully synchronised to the controlling CPU during operation – can mirror the controlling CPU and instigate a seamless bypass in the event of failure of the main CPU. This minimises any risk of plant downtime. Tyler Hatton, automation manager at Denby Pottery, said: “The versatility of the system has allowed us to expand into OEE machine monitoring on various pieces of equipment and machinery. This is helping us highlight problems and improve efficiency throughout the factory.”

When control worlds converge Distributed Control Systems (DCS) and PLCs are increasingly converging. PLC systems have acquired more extensive visualisation systems, similar to those traditionally used by process engineers to manage complex processing workflows. For today’s PLC-based systems, even I/O points in the high five digits do not pose a challenge. In addition, software engineering environments now feature a broad range of libraries and plenty of function blocks so that even highly complex closed-loop control structures can be designed quickly and reliably. Traditionally simple machines have evolved into more complex production lines within tightly networked plants, and operators have become more interested in using distributed peripherals that can be linked to fast fieldbus systems and deliver the bandwidth needed to accommodate the resulting flood of data. As a result, systems that can offer distributed intelligence are now prevailing, according to Beckhoff Above all it is the vision of the Internet of Things (IoT) which has resulted in PLC-based systems taking on characteristics of DCSs, especially in terms of integration capabilities. This, in turn, has increased support for mature protocols that offer cross-system data exchange, for example based on OPCUA, but also for communication between the supervisory control level and the cloud through protocols such as MQTT and AMQP. With its PC-based control solutions Beckhoff believes it can offer the ideal automation toolbox to implement all the requirements of both the machine builder and the process engineer in a complete and integrated solution. Through the addition of specific innovations for process technology applications, process engineers now have access to the same automation system that has long been proven in machine design and factory automation. Control Engineering Europe

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A dual redundant PLC system was selected to increase the system robustness.

Since installation of the new system the previously encountered maintenance issues have ceased. Sands explains: “The system is now completely reliable, even during a power cut. In the case of a machine failure, the visual features of the HMIs alert plant operators and enable them to quickly detect the cause and solve it. This, coupled with Mitsubishi Electric’s round-the-clock support and responsiveness, made it possible to slash downtime as well as quickly identify, investigate and plan maintenance tasks.” The solutions have provided Denby Pottery with its wished for ‘Smart Factory’ monitoring capabilities and has correspondingly increased flexibility of the production line. Additional benefits include improved accuracy of the calculations on clay properties and increased quality of the clay and its consistency. More impressively, the clay manufacturing time has been halved, increasing time-efficiency and productivity. Hazell concludes: “Thanks to the flexible control system we have now and due to the positive experience with our suppliers, we are now looking to expand the network and will be implementing additional functionality such as barcode readers for product serialisation and traceability in the future.” ! February 2019

EXHIBITION REVIEW

SHOWING EVIDENCE OF A SHIFT TOWARDS SOFTWARE Suzanne Gill reports on some of the highlights of the SPS/IPC/Drives 2018 event, which was held in Nuremberg last November.

he 2018 SPS/IPC/Drives exhibition saw around 65,700 visitors visiting 1,630 exhibitors from across the globe, situated across 17 halls, to find out more about the current trends and cutting-edge industrial automation technologies. The software and IT in manufacturing area of the event has continued to grow, now filling Hall 5 and half of Hall 6. The ‘Automation meets IT ‘ and ‘wireless in automation’ shared booths were also noticeably well attended areas of the event. To mark the event’s 30th anniversary in 2019 it was announced that the exhibition will be changing its name to SPS, with the abbreviation now standing for Smart Production Solutions. The name change reflects the growing trend in automation equipment towards software-based function blocks that are distributed across a variety of hardware components, and to reflect the fact

that cloud and big-data technologies, artificial intelligence (AI), machine learning, digital twins, and other IT functions are being integrated into automation technology. One of the most well attended press events seen by the Control Engineering Europe team at the event was held by OPC Foundation to announce its TSN initiative. The audience heard more about how OPC UA will be including Time-Sensitive Networking (TSN) down to field level – a move which has prompted the rapid engagement of many leading automation suppliers, many of whom were present at the press conference. Contributions to the initiative now include suppliers such as ABB, BECKHOFF, Bosch-Rexroth, B&R, Cisco, Hilscher, Hirschmann, Huawei, Intel, Kalycito, KUKA, Mitsubishi Electric, Molex, Omron, Phoenix Contact, Pilz, Rockwell Automation, Schneider Electric, Siemens, TTTech, Wago, and Yokogawa. The audience heard that significant

Once again Siemens occupied the largest booth at the event.

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progress has already been made on the set-up of the initiative, with work groups being incorporated into the OPC Foundation organisational structure. A steering committee has also been formed to manage the technical and marketing working groups. Initial work will focus on the core functionality of field device communication, developing a next generation architecture and general model for devices which can be adopted as easily as possible by automation suppliers. This architecture and general model will be expanded with devicetype specific functionality by specialist working groups. Extended OPC UA standardisation documents will be published including test scenarios and certification procedures to ensure that the wider community can build compliant devices. OPC UA will be able to share a multi-vendor converged network infrastructure with other applications including the existing and updated Industrial Ethernet solutions. To achieve this goal, the TSN Profile for Industrial Automation standardised by the IEC/ IEEE 60802 committee will be used and all working groups will closely align with this for TSN related specification sections. Also well attended was the CC-Link Partner Association (CLPA) press event, where it announced completion of the CC-Link IE TSN specification – a next generation network based on the current CC-Link IE. CC-Link IE TSN was developed to meet future market demands by including TSN technology, which are additional standards related to IEEE Ethernet, to integrate Operational Technology (OT) Control Engineering Europe

EXHIBITION REVIEW

and IT while further strengthening performance and functionality. Also, with the diversification of development methods, it has enabled flexible implementation for various types of equipment and also achieves mixed usage of information communications by utilising Internet Protocol (IP) and control communication technology. It is expected that these additions to the technology will improve efficiency and reduce time for the construction of smart factories utilising the IIoT.

Flexible and versatile motion functions One of the most interesting product launches at the 2018 event came from Beckhoff in the shape of its XPlanar system which comprises a series of floating plates that are able to move freely over a surface of tiles (sized 240 x 240mm). These can be set out in any format, to suit individual materials handling or assembly applications. The use of integrated permanent magnets allows the plates to move freely in two-dimensional motion and there is no direct contact with the tile surfaces which avoids friction. We were told that the system can work horizontally, vertically or even upside down. Collision-free and synchronised movement of several movers, with automatic path optimisation, is provided by TwinCAT automation software. We are greatly looking forward to reporting on use cases for this latest Beckhoff innovation. Siemens used the event to present a range of sector-specific solutions and future technologies from the largest booth at the exhibition. The central focus of the booth was on products, solutions and services from its Digital Enterprise portfolio which are designed to enable the merger between the physical and digital worlds. The continuing adoption of Artificial Intelligence (AI) was much in evidence across the event including the Siemens booth, with the announcement of AI capabilities being integrated into its Simatic S7-1500 controller and Control Engineering Europe

The XPlanar system from Beckhoff comprises a series of floating plates that are able to move freely over a surface of tiles.

its ET 200MP I/O system. The neural processing unit is said to enable efficient processing of neural networks which helps optimise visual quality checks. Siemens also announced the expansion of its Simatic industrial PCs to include the Simatic IPC127E which can be used as a gateway to enable data management directly in the production environment. Whether it is based on Windows or Linux, the IPC is said to make it possible to network existing systems with machinery of different manufacturers and different technological versions. The newly developed Simatic IPC127E makes it possible to reliably record, collect, process and transfer data directly in the production environment and can also be flexibly used as an IoT gateway between the cloud or the corporate IT level and production. Thanks to pre-configured versions, the right product is available to users in a very short time. Siemens also showcased a range of new features for the ever developing MindSphere – its cloud-based IoT operating system – these range from visualisation through data analysis to edge computing functions.

Holistic solutions The Mitsubishi Electric booth aimed to

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demonstrate how the company is able to support customers in the integration of smart manufacturing projects. It presented products and technologies for industrial automation across three production areas – engineering, manufacturing and maintenance. For engineering it showed how its life cycle management tool MAPS can offer time savings in project development and integration. Using object-oriented functions, it is able to integrate and visualise devices and external equipment more easily. The latest offering – MAPS 4 – enables fast provisioning, including connection to the cloud as well as adaptability and scalability for future requirements. In manufacturing it showed how production can be intelligently automated at various levels through the use of control and drive technology, operating devices, software and circuit breakers as well as robotics. For maintenance the company demonstrated its ‘GOT Drive’ function which is available on servo drives and frequency inverters to enable commissioning, adjustment and maintenance directly via the graphical user interface of a GOT2000 series HMI. The drive can record load data from the machine and issue an early warning signal when a defined threshold value is reached without the need for an > p26 February 2019

EXHIBITION REVIEW external sensor. Ready-built templates for visualisation are included to make commissioning faster and more convenient. With the GOT Mobile version, it is possible for activated production data to be queried from any location and alarm messages can be received via mobile phone, tablet or PC.

App store Phoenix Contact used the event to highlight its PLCnext Store – a software store that provides software applications (apps) that can be used to add technical functions to its PLCnext controller. Depending on the app, the user does not need any deep knowledge of programming to create the application directly using the software solutions. The open nature of the store allows third-party providers, in addition to Phoenix Contact, to sell the apps that they have developed. Having such easy access these apps can help reduce programming work and so accelerate application development. The company also highlighted its IP20 and IP67 portfolio of IO-Link masters, IO-Link devices, cabling, and software. Direct connection to the Proficloud via the controller or a Cloud IoT Gateway enables convenient remote evaluation and diagnostics of data. Moxa showcased its expertise

February 2019

in TSN technology, demonstrating how standard Ethernet with TSN technology can enable the exchange of all data in automation architectures in parallel or vertically in real-time and with deterministic low latency. It demonstrated use cases in a unified, standard Ethernet infrastructure with guaranteed quality of service and deterministic low-latency environments including in-machine-to-supervisory real-time communication, machineto-machine real-time communication, and in-machine latency-guaranteed communication based on standardEthernet. Moxa also participated on the stands of various technology and standard groups interoperability demonstrations, including Edge Computing Consortium (ECC), Industrial Internet Consortium (IIC), Labs Network Industry 4.0 (LNI 4.0) and Ethernet POWERLINK Standardization Group (EPSG). All the demonstrations showcased the interoperability of Moxa’s TSN switches with those of other vendor devices in one standard Ethernet-based network infrastructure that can build the future of industrial automation and open up the possibilities brought by the IIoT and Industry 4.0. Moxa has been participating in three of the world’s most significant TSN

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interoperability testbeds built by ECC, IIC and LNI 4.0 respectively. Through these activities in the testbeds, it can rigorously test TSN interoperability and ensure that the developing implementation is stable and reliable before going to market. Moxa also introduced its IIoT Edge Gateway that pre-installs Microsoft Azure IoT Edge to provide Microsoft Azure customers with an easy-to-use solution to extend their IT infrastructure and enables OT data connectivity within industrial applications. To enable further OT/IT convergence, the industrial-grade edge gateway has been optimised for IIoT applications in the factory automation, intelligent transport system (ITS), energy, and oil and gas sectors. Moxa’s IIoT Edge Gateway also integrates the company’s industrial protocol expertise, offers long-term Linux support, and facilitates optimised device management for large-scale deployments.

Stranded data retrieval Often in industrial environments, potentially useful data is not recovered into IT or OT systems because the cost of recovering the information outweighs its value. Here, wireless sensor networks can offer a low-cost of data recovery by eliminating the need to lay cables, allowing previously stranded data points to be made accessible to the enterprise. Advantech showcased a range of local and wide area wireless sensing solutions built on a variety of wireless technologies. Besides enhancements to its existing Wzzard local area mesh system, it demonstrated the recently launched WISE4471 NB-IoT sensing node, which has already completed validation on Vodafones NBIoT network in Ireland, and is being validated in other European countries as the Control Engineering Europe

EXHIBITION REVIEW

networks roll out. The company also used the event to showcase its I/O interface solutions for wired and wireless data recovery, using a variety of transmission media and protocols. The Wi-Fi connected WISE series is said to offer a flexible selection of remote I/O configurations creating digital data that can be shared via Modbus, MQTT or REST. Overall Equipment Efficiency (OEE) is becoming an increasingly important KPI in todayâ&#x20AC;&#x2122;s production environments, Advantech believes it is able to offer a one-stop solution, integrating all the different steps from raw data collection through to creating meaningful KPI data. An interesting interface solution was shown on the Harting stand. The Han-Modular Flexbox is able to greatly reduce the construction and connection of energy chains through the provision of a modular multiconnector solution, which has been co-engineered with energy chain provider, igus. The Han-Modular Flexbox makes it possible to sub-divide energy chains into easily replaceable segments. The housing concept replaces the traditional solution of multiple individual connections for each section of an energy chain. Instead the Han-Modular Flexbox offers a single plug-in and disconnection point as a compact overall solution. Fastening elements can be used to join the housings together in different variations. As a result, the height and width of the interface can be flexibly designed offering space saving benefits. Softing Industrial introduced its new uaGate 840D gateway which gives access to Siemens SINUMERIK 840D sl machine tool data, via OPC UA, and enables this data to be reused. The controller is used in a large number of machine tools. Traditionally, only solutions for accessing the data of the integrated SIMATIC S7 controller were available. The new gateway is said to extend the integration possibilities for the CNC controller and, for the first time, also enables access to the NC and drive Control Engineering Europe

data via the OPC UA communication technology. This allows important spindle and axis data to be read out and further processed. This data can then be used for analysis tasks. Visitors to the Emerson booth were able to see how its Plantweb digital ecosystem can be implemented without adding system complexity, leading to improved production performance and availability and ensuring product quality, as well as machinery and worker safety. The use of standardised communication protocols provides greater access to process and device performance data which can provide actionable insights, enabling smarter decisions to be made. Emerson also demonstrated how its ASCO and AVENTICS fluid control and pneumatics technology uses diagnostics, sensing and monitoring capabilities to improve system uptime and performance, enhance safety and optimise energy usage. Connectivity, via a range of communications including Ethernet and IO-Link, provides remote access to device health information, enabling faults to be quickly identified and maintenance scheduling to be improved. The latest Rosemount and Micro Motion measurement technology, including analytical, level, temperature, pressure and flow devices, were also on display.

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TTTech used the event to showcase its real-time machine data kit which has been designed to solve the challenge of accessing real-time data from industrial machines without altering existing I/O infrastructure or adding gateway devices. The TTTech solution is designed to be used by machine builders to add value to brownfield installations without causing disruption or making changes. It allows them to better predict machine maintenance needs and develop software patches and updates using the real-time data acquired. End users also benefit â&#x20AC;&#x201C; gaining a deeper understanding of real-time processes and gaining access to the latest software features and functions quickly and securely.

This year This year, SPS 2019 will take place at Nuremberg Messe from 26 to 28 November. With its new name the event will continue to offer a showcase for cutting-edge automation technology and complex solutions. Over the years it has become a must-visit event for many involved in the manufacturing industry, as it offers a great networking event, bringing together key players from various sectors and providing insight into the latest trends and innovations. ! February 2019

HAZARDOUS AREAS

SAFE OPERATION OF FLAMEPROOF MOTORS IN EXPLOSIVE ATMOSPHERES Maintenance and inspection of flameproof motors is critical to ensure safe operation. Pedro Maia offers advice on keeping them in good working order.

lameproof motors are widely used across many industries that feature explosive atmospheres. Standards such as IEC 6007917 specify the correct design and definition of components that should be utilised. This standard also offers good advice about maintenance plans in order to maintain certification. Flameproof motors require routine inspection and careful maintenance, otherwise there can be serious ramifications. The correct functional operation of hazardous area equipment requires regular inspections which should be performed by skilled personnel and, if necessary, subsequent maintenance and repair works. IEC 60079-17 specifies the need for up-to-date documentation and qualified staff, and defines inspection tables for Ex-marked equipment. For example, daily checks are recommended for noise levels of the complete motor, as well as noise and vibration levels of the bearings. Weekly tasks include bearing lubrication and checking the coupling alignment, while annual checks include the re-fastening of bolts, measuring the insulation resistance of the stator and rotor, and cleaning the inside of the terminal box. Cleanliness is a big issue. Motors

should be free from dust, dirt and oil, which can be removed using soft brushes, clean cotton rags or jets of compressed air. However, the cleaning operation cannot be performed if a potentially explosive atmosphere is present at the time.

Lubrication It is well documented that bearings are one of the most common causes of failure in electrical motors. As a consequence, correct lubrication is important to maximise bearing life and to ensure low-noise and lowtemperature operation. The lubrication of bearings must be made respecting the quantities and intervals stated on the motor nameplate and documentation; using too much grease can cause overheating and leakage into the motor’s windings. It is also important to apply a grease which is compatible with that supplied by the motor manufacturer. Using an incompatible grease may mean that it offers different viscosity and performance, potentially reducing bearing life. Ensure repair procedures deliver maintain compliance: Carefully implemented repair procedures can have a big impact on motor operation

Position indicator for ATEX areas The GEMÜ 1205 electrical position indicator, which is housed in a flameproof enclosure, is based on tried-and-tested engineering for use in demanding ambient conditions. The GEMÜ 1205 electrical position indicator has continuously adjustable microswitches for recording end

February 2019

positions, with which the closed and/or open position can be reliably recorded with a valve stroke of 2–70mm. It has been designed for demanding applications in Category 2, Zone 1 and/or Zone 21 ATEX areas as well as for robust use at low temperatures down to -20°C.

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and machine uptime. Again IEC 6007919 gives guidance on the practical methods of repairing equipment and defines procedures to maintain compliance in line with product certification. IEC 60079-19 states that repair facilities shall operate a Quality Management System (QMS) and appoint a responsible person with authority and technical knowledge of explosion protection standards. In addition, repair facilities need to be informed regarding equipment certificates, special conditions of use, and all necessary information from the equipment manufacturer. This includes information relative to previous repairs or modifications. The documentation dossier. may include drawings, technical specifications, operating conditions and dismantling and assembly instructions, for example. Records of inspections and of any jobs performed on a flameproof motor need to be retained by the repair facility. Ensure flameproof joint repairs respect manufacturer’s documentation: Common faults include damaged or corroded flameproof joints which may be repaired by means of material addition and machining following the methods approved in IEC 6007919. However, the resultant joint gap must respect the manufacturer’s documentation. If this documentation is not available, guidance can be found in IEC 60079-19. In accordance with the same standard, repaired or overhauled equipment must be marked with a relevant symbol, applicable standards, the name of the repairer and the date of repair. The symbol will either be the letter ‘R’ in a square box, which Control Engineering Europe

HAZARDOUS AREAS

indicates repair in accordance with certificate documentation and the manufacturer’s specification, or the letter ‘R’ in an inverted triangle, which indicates repair in accordance with type-of-protection standards but not certificate documentation. In cases of systems that after repair do not comply with certificate documentation or type-of-protection standards, the original manufacturer’s label should be removed or altered to give clear indication that the equipment is not compliant. If a supplementary certificate cannot be obtained, the equipment is not in a suitable condition for use in an explosive atmosphere. Should any repair procedures require spare parts, these should be obtained directly from the manufacturer wherever possible. In the case of bolt replacement, they must be of the same type, diameter and with at least the same tensile strength as specified by the motor manufacturer. The correct maintenance of flameproof motors is crucial to assure the safety of personnel and plant in hazardous areas. Respecting the recommendations, manufacturer documentation and industry standards can make the difference between a

In hazardous areas cleanliness is a big issue so motors should be free from dust, dirt and oil.

unit that offers an operating life devoid of problems, and the occurrence of heavy vibration and noise that leads to damage and failure. Following carefully prepared maintenance plans with periodic inspection and monitoring will help to predict potential faults and permit end users to take actions that minimise the risks and allow for preventive repairs. These repairs must be registered and documented to permit the tracing

of modifications to the certified equipment, preferably respecting manufacturer documentation. Finally, the correct marking of the repair procedures is mandatory and permits inspection teams to access the conformity of installed equipment, granting that the safety of the hazardous area is maintained. ! Pedro Maia is coordinator of research, development and certification at WEG.

Hazardous area inspection software Boulting has launched A BS EN 60079:17-compliant cloudbased inspection software that enables plant engineers to inspect control equipment in hazardous areas. The company has worked in collaboration with an ATEX certifying body to design and implement a secure, paperless, cloud-based system for maintenance procedures in hazardous areas. The result is an App that provides visibility of hazardous area inspections and incorporates RFID tags that make it easy to recall information for each device. The system integrates the documents required to form an Explosive Protection Document (EPD) for an unlimited number of items, including all area classification documents, risk assessments, equipment certificates and details of all equipment requiring inspection, frequency of inspection and associated drawings. By going paperless and installing the software on a Control Engineering Europe

tablet, engineers are able to navigate vital documents with ease. In addition, the software can help identify trends in any faults that may be common to a specific manufacturer or model.

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February 2019

PRODUCT FORUM •

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CHEMICALLY RESISTANT FILTER HOUSINGS FOR API MANUFACTURING Amazon Filters is a leading supplier of robust, corrosion resistant filter housings for Active Pharmaceutical Ingredient (API) manufacturing processes. Highly corrosive chemicals such as concentrated acids are often used in API manufacturing which places great demands on both filter media and filter housings. Where highly corrosive chemicals are being processed, specialised filter housings such as those manufactured with an internal coating or made from exotic nickel alloys may be considered. However, neither of these options is ideal. Coatings are prone to mechanical damage and nickel alloys have limited resistance to corrosion by certain acids and some other chemicals. www.amazonfilters.com/products/filter-housings/corrosion-resistant-housings/ +44-(0)1276-670600 sales@amazonfilters.co.uk.

SENSATA TECHNOLOGIES INTRODUCES MULTI-TURN ABSOLUTE ENCODERS FOR SMART INDUSTRIAL APPLICATIONS Sensata Technologies (NYSE:ST), an industrial technology company and a leading provider of sensors, today introduced the availability of MHM5 and MHK5 Absolute Multi-Turn encoders with either Ethernet/IP or ProfiNet interfaces for Factory 4.0 applications. To provide additional design flexibility, these encoders are available in either shafted (MHM5) or blind shaft (MHK5) configurations. These model MH encoders provide up to 16 bits per turn and 14 bits of turns counting. The compact packaging allows these encoders to be easily integrated into existing designs while a wide operating temperature range (-40 to +85C) and an IP65 rating makes them suitable for most any industrial application. To learn more about these new encoders, review the specification sheets or check out application notes, visit www2.sensata.com/mh-encoders.

ROBUST, CHEMICALLY RESISTANT FLOWMETER Oval Gear (OG2) flowmeters from Titan Enterprises provide an ideal solution for applications that require a highly accurate and chemically resistant flow measurement device. There is a choice of construction materials for the OG2 flowmeter, including totally non-metallic wetted components, like ceramic, a choice of elastomer, and PEEK for metering aggressive chemicals. OG2 flowmeters are compact and have a rugged design, which allows them to operate reliably even at higher pressure, providing steady performance with minimal maintenance. Furthermore, OG2 flowmeters are able to operate at temperatures up to 150°C and are fully IP67/NEMA 4 compliant. Each OG2 flowmeter comes with a pressure test certificate that verifies the device’s ability to handle pressures up to 700 bars (for OG2-700 model). With a standard flow range from 0.03 to 4.0l/min on 30cSt oil, OG2 flowmeters are able to regularly achieve outstanding repeatability (0.1%) and accuracy (0.75%). Applications that have benefited from OG2 flowmeters include monitoring hydraulic fluids in earth movers and wind turbines, chemical pump testing, measuring sulphite spraying in a vineyard and for medical dosing. For further information on the OG2 flowmeter range please visit www.flowmeters.co.uk/og2-positive-displacement-pd-oval-gear-flow-meters-swept-volume-flowmeters/

or contact Titan Enterprises on+44-1935-812790 / sales@flowmeters.co.uk.

To maximise exposure, contact Lisa Hales on: Tel: 01732 359990 Email: lisa.hales@imlgroup.co.uk

February 2019

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Control Engineering Europe

FINAL WORD

Hybrid OT for IIoT and control projects It is critical to understand differing operational technology (OT) and information technology (IT) priorities to achieve collaboration and controls integration argues John Fryer, senior director, industry solutions at Stratus Technologies.

ith the rise of the Industrial Internet of Things (IIoT) and edge computing, the phrase IT/OT convergence has become commonplace. This is because the use of information technology (IT) at the operational level is becoming more common and is blurring the line that has traditionally separated IT and operational technology (OT). To integrate these two different areas for successful IIoT initiatives and control projects, a new species of technologists with a unique combination of skills is emerging – the ‘hybrid OT’ professional.

IT and OT priorities At the core, IT and OT have similar concerns and different ways of prioritising them. Priorities for IT include: 1. Security: The first priority is security (and cybersecurity). They want to constantly monitor and scan machines to make sure everything is secure, which can sometimes interrupt processes. 2. Data integrity: Next is data integrity and making sure only those who need data can access it. 3. Downtime: is also something they want to avoid, but if IT systems like email are down, while irritating, they will not bring operations or production to a halt. Priorities for OT: For OT, the first and last priorities are swapped. 1. Downtime is enemy number one Control Engineering Europe

for operations. Downtime can cost a large amount of money and potentially create dangerous situations for employees or impact company reputation. Maintaining data integrity and data accessibility for those who need it. While security ranks high on OT’s list of concerns, it comes in third compared to avoiding downtime and maintaining data integrity and data access.

It is critical to understand the differing priorities to achieve collaboration and integration between these teams. Without this, IIoT and control projects will fail.

Hybrid OT benefits Organisations able to take elements of what OT requires and blend them with the skills of IT are the ones that will see the most success. These hybrid OT professionals understand the priorities that drive technology decisions at the network edge on the production floor as well as how edge data can drive strategic

business decisions in the C-suite. Having the skills to make these connections is what makes hybrid OT professionals so valuable. As edge computing is being performed at more remote locations, IT skills become less available. Hybrid OT professionals who may have some of the necessary IT knowledge can address potential challenges they aren’t always equipped to handle. By leveraging solutions and systems that are self-protecting, selfdiagnosing, always available, and easily maintained, they may avoid IT support. Hybrid OT professionals are entering the workforce with education and training in electrical engineering or computer science, and in some cases even digital science and analytics, making them well equipped to handle the needs of modern industrial organisations. As the industrial edge continues to become more digitized, connected, and intelligent, the hybrid OT professional will be a critical part of most companies’ IIoT and control project successes. ! This article originally appeared on www.controleng.com

Helping with hybrid operational technology implementations, Stratus’ ztC Edge is a zero-touch, fully virtualised and self-protecting computing platform, designed for industrial edge environments. Image courtesy of Stratus Technologies.

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February 2019

Calibration

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