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Control, Instrumentation and Automation in the Process and Manufacturing Industries June 2020

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CONTENTS Learning lessons and moving forward

Editor Suzanne Gill suzanne.gill@imlgroup.co.uk Sales Manager Adam Yates adam.yates@imlgroup.co.uk Group Publisher Iain McLean iain.mclean@imlgroup.co.uk Production Holly Reed holly.reed@imlgroup.co.uk Dan Jago Group Publisher David May Production Manager G and C Media Studio Design

As Europe starts to emerge from its varying degrees of lockdown, due to the ongoing Covid-19 pandemic, industry is having to quickly adapt to a ‘new normal’ and there has been much talk about this acting as an industry wake up call due to the fact that it offers a great opportunity to also refocus on sustainability and productivity goals. We have brought together variety of industry comments on this subject in this issue. We ask whether the Covid-19 pandemic will accelerate the speed of adoption of robotics and automation across the industrial sector (pg 10) and have gathered comments on how the greater adoption of digital technologies could help industry overcome the worst effects of a predicted global recession (pg 26 onwards). We would be keen to hear how you are adapting your plant or process and what technologies you have been found to be most helpful. Please do get in touch. Stay safe! Suzanne Gill Editor – Control Engineering Europe suzanne.gill@imlgroup.co.uk

INDUSTRY REPORT

IO MODULES & SYSTEMS

4 Smart sensors are key to revolutionising predictive maintenance in motor driven systems

18 Is IO-Link the key to making the automation environment smarter

EDITOR’S CHOICE

DRIVES & MOTORS

6 App-based flowmeter monitoring and performance optimisation; Temperature monitoring relays offer more functions in less space

22 Find out how a traditional mains-driven geared motor can be integrated into the IIoT

ROBOTICS

INDUSTRY COMMENT

10 Suzanne Gill asks whether the Covid-19 pandemic will accelerate the speed of adoption of robotics across the industrial sector 12 AI and robotics: exploring the challenges and the opportunities

ENERGY MANAGEMENT

23 MEPS will soon include ATEX motors

26 Jason Urso highlights five areas to improve remote operations and keep manufacturing sites running 27 Steve Sands talks about the lessons to be learned from the current pandemic 28 Adi Pendyala comments on the importance of AI adoption, right across the enterprise

14 The use of an energy management system has allowed a Coca-Cola plant to conduct detailed analyses of its resource and energy consumption

MACHINE SAFETY 16 Putting a focus on the importance of regular inspection and testing of electro-sensitive protective equipment Control Engineering Europe is a controlled circulation journal published eight times per year by IML Group plc under license from CFE Media LLC. Copyright in the contents of Control Engineering Europe is the property of the publisher. ISSN 1741-4237 IML Group plc Blair House, High Street, Tonbridge, Kent TN9 1BQ UK Tel: +44 (0) 1732 359990 Fax: +44 (0) 1732 770049

Control Engineering Europe

PG 8

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

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

June 2020

INDUSTRY REPORTS

Trends in manufacturing investment to enable Industry 4.0 Nokia has partnered with ABI Research to survey over 600 manufacturing decisionmakers to assess investment strategies related to 4G/LTE, 5G and Industry 4.0. The survey found that 74% of respondents are looking to upgrade their communications and control networks by the end of 2022 with more than 90% investigating the use of 4G and/or 5G in their operations. Over half of respondents believe that the latest generation of 4G/ LTE and 5G will be necessary to meet their transformational goals. The research also identified key business use cases that would drive investment in 4G or 5G. Respondents reflected the need to digitalise and improve existing infrastructure (63%), automation with robotics (51%) and achieve new levels of employee productivity (42%). Commenting on the findings, Manish Gulyani, vice president marketing at Nokia Enterprise, said: “We have reached

an inflection point in Industry 4.0 transformation as the fast, secure, low latency connectivity underpinning its implementation now becomes available. This research indicates the strong marketplace appetite for industrial-grade wireless networking to capture the transformational benefits of digitalisation and automation. We believe that demand, combined with easy-to-deploy private wireless solutions, will drive adoption.” The research examined near-term drivers influencing buying decisions for new industrial systems across IT (information technology) and OT (operations technology). IT drivers primarily focus on reducing downtime (53%), improving operations efficiency (42%), and enhancing security (36%). In comparison, OT drivers reflect a desire to replace aging infrastructure (43%), improve efficiency (40%) and increase capacity (38%).

Ryan Martin, principal analyst at ABI Research, said: “Research findings indicate a preference for deploying private fully-owned and operated wireless networks, with manufacturers favouring in-house management to allay security concerns. It is evident that respondents are not entirely committed to Wi-Fi/WLAN and will consider latest generations of wireless technologies. As a result, 2020 is a critical year for networking suppliers to educate the market regarding the merits of 4G/LTE and 5G. “Based on this research we also observe a pan-industry need to quantify not only the potential ROI of investing in private wireless, but also to clearly indicate the cost of inaction – vendors need to make the case for investing in Industry 4.0 today to gain a clear competitive advantage over those who choose to wait.”

Flowserve Corporation joins the FDT Group leadership team Flowserve has been a long-term member of FDT Group and a participant on its technical working groups. Recently, it has upgraded its membership to ‘Sponsor’ status and assumed roles on both the FDT Board of Directors and Executive Committee. FDT Group’s goal is to drive continued developments in open, standardised, universal network/ device integration and asset management, innovating the way automation architectures connect and communicate in process, hybrid and discrete manufacturing, including motion control applications. Sponsoring-level members have the opportunity to join the FDT leadership team, filling positions

June 2020

on both the Board of Directors and Executive Committee to lead the larger FDT mission. Welcoming Ken Beatty, director of product engineering for Flowserve as FDT’s newest board member, and Ed Silva, R&D engineering manager for Flowserve assuming the executive committee role, Glenn Schulz managing director at FDT Group, said:“Flowserve’s longevity in the industrial automation market space, industry expertise, and commitment to

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today’s ‘Connected World’ with FDT is invaluable to our leadership team with the imminent launch of the FDT 3.0 (FDT IIoT Server or FITS) standard.” Control Engineering Europe

INDUSTRY REPORTS

Smart sensors are key to revolutionising predictive maintenance in motor driven systems

Hungarian bioproducts company joins EEMUA

A new predictive maintenance focussed report from Interact Analysis (IA) highlights the potential for a new relationship between component manufacturers, OEM machine builders, and end users. It forecasts a boom in the sector, propelled by smart sensors which are able to monitor crucial parts of a motor-driven system that are not covered by legacy maintenance devices and methods. These sensors will allow delivery of viable cloud-based predictive maintenance service packages using a software as a service (SaaS) business model. The report shows that the market for predictive maintenance in 2019 was $117.5 million, largely made up from legacy predictive maintenance products such as portable monitoring devices. Many of these devices will maintain strong growth in the coming decade but will be used in tandem with new technologies such as smart sensors, the latter fuelling an expected boom in market value of predictive maintenance technology, up to almost $1 billion in 2024. Smart sensors, which typically monitor sound, temperature, and vibration, may not provide the depth of data offered by some legacy devices, but do have advantages. Whereas most legacy devices are attached to motors, IA predicts that only 53% of smart sensors will be attached to motors by 2024. The rest will be attached to other machine components which are also subject to the wear and tear of daily use. This means that the application of predictive maintenance will be far more widespread in the factories of the future. Commenting on the report findings, Blake Griffin, lead analyst on predictive maintenance at Interact Analysis, said: “Smart sensor technology coupled with IIoT capabilities give component manufacturers and OEM machine builders the scope to offer end users an anticipatory service package. For most providers of predictive maintenance, the logical business model will be software as a service. A side benefit of SaaS is that it ties all technologies together under a single solution – thereby eliminating concerns regarding data ownership. Additionally, advancements in embedded machine learning will improve the ability for predictive maintenance to be installed in new or non-standard applications.” Control Engineering Europe

June 2020

Hungarian bioproducts company, Pannonia Bio Zrt, is the latest company to join the Engineering Equipment and Materials Users Association (EEMUA) as a corporate member. Pannonia Bio operates a biorefinery which uses state-ofthe-art production processes. Mark Turley, group chairman and chief executive at Pannonia Bio, said: “As a company wholly committed to safety and operating a number of complex chemical and biological processes, Pannonia Bio decided to join EEMUA to fully avail of the knowledge base, training and safety standards of the association. Building on our commitment to the environment, we look forward to the latest developments on sustainability and renewable energy standards and EEMUA’s guidance on process safety, alarm management and operation of storage tanks.” Stefan Kukula, chief executive at EEMUA, said: “Pannonia Bio’s membership strengthens EEMUA’s representation in the biotechnology and renewables sector”. EEMUA Corporate Membership is open to companies from around the world that own and/or operate industrial facilities or that are significant purchasers or users of engineering equipment and materials.

EDITOR’S CHOICE

Transmitter for industrial measurements Vaisala has introduced the new industrial level Vaisala Indigo 520 transmitter. The durable, metal transmitter is compatible with the company’s range of Indigo compatible smart probes multi-parameter measurements – humidity, temperature, dew point, carbon dioxide, vaporised hydrogen peroxide, and moisture in oil measurements. It can accommodate up to two detachable measurement probes simultaneously, measuring the same or different parameters at the same time. The probes can be swapped quickly and easily whenever needed. The transmitter has an IP66- and NEMA 4-rated robust

metal enclosure, and a touchscreen display made of hardened glass. The Indigo 520 transmitter displays live measurements and transmits them to automation systems through analogue signals and relays, or digitally using Modbus TCP/IP protocol over Ethernet. The transmitters enable data visualisation, access to probe configuration, and more options for connectivity, supply voltage, and wiring. The product family consists of interchangeable smart probes, robust transmitters, and Vaisala Insight PC Software. Together they create a strong

HD TFT display as standard on VFDs Invertek Drives has updated its panelmounting Optidrive P2 IP20 variable frequency drives (VFD) to include a high definition TFT display as standard, which makes it easier for users to see operating information and parameters from any viewing angle. Safe Torque Off (STO) functionality is standard across the P2 range, providing easy integration into machine critical safety

circuits without the need for an Input Contactor. The IP20 includes Modbus and CAN on board as standard and the Optistick Smart (NFC and Bluetooth connectivity) rapid commissioning tool enables copying, backup and restoration of drive parameters to be undertaken quickly and efficiently – a useful feature when commissioning multiple drives.

Temperature monitoring relays offer more functions in less space Siemens Smart Infrastructure has transformed the temperature monitoring relays from its Sirius portfolio. The new series 3RS2 devices are available in analogue and digital versions and they use sensors to measure the temperature – of engine, bearing, and transmission oils, or cooling liquids – in industrial control cabinets. The relays are also able to monitor heating, air-conditioning, and ventilation systems, solar collectors, heat pumps, and hot water supply systems. The devices in the new Sirius 3RS2 series are approved for safety applications up to SIL 1/PL c, for use in industrial furnaces, as well as for monitoring burners and ATEX applications, among other things. With a width of 22.5mm, the Sirius 3RS26 digital devices are parameterised

June 2020

via an LCD display and can be connected to a sensor that evaluates whether the temperature is above or below a certain value or within a specific operating range. A SIL1-certified infrared communications interface makes it possible to wirelessly add two resistance sensors and one analogue input.

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chain of data to improve industrial processes in terms of ensuring energyefficiency, safety, and end-product quality.

Smart camera simplifies code reading and inspection

The compact MicroHAWK V/F400 and V/F300 series smart camera from Omron offers the ability to combine code reading and vision inspection in a single, compact device. Bundling multiple capabilities in one, the cameras can minimise the work required for commissioning and maintenance. Features such as the liquid lens autofocus option and a highresolution 5-megapixel colour camera ensure precision while enabling greater flexibility in production line layouts. The autofocus technology allows the camera to reliably inspect products that vary in size, shape, or desired inspection type, while its X-Mode algorithms can read any code on any surface, including curved, shiny or otherwise textured materials, minimising downtime and keeping production moving smoothly. Control Engineering Europe

EDITOR’S CHOICE

Cylindrical inductive safety sensors The SICK IME2S inductive proximity safety switch offers safe and easy non-contact position and safe area monitoring to help prevent accidents and unwanted collisions in production and logistics environments up to PL d (EN ISO 13849) safety requirements. SICK has redeveloped its cylindrical inductive safety sensor to deliver a more compact, wear-free device that can be integrated into machines without the need for a separate actuator. Using the inductive sensing principle to enable non-contact detection of metal objects, the IP67-rated IME2S offers high machine availability, even in dusty and high-moisture industrial environments. The new SICK IME2S replaces the SICK IN3000 sensor with an extended performance range of up to 15mm. It uses two self-monitoring OSSD outputs to ensure consistent reliable signalling to actuators and safe control systems, complying with Category 2, PL d, and SIL2. The SICK IME2S offer a field sensing range of between 4mm and 15mm without a blind-zone with a working temperature range of -25 to +70°C.

App-based flowmeter monitoring and performance optimisation

Bronkhorst High-Tech has developed a new ‘connect and go’ software tool, called Bronkhorst FlowSuite, which allows instruments to be easily monitored, configured and optimised via a single interface. Features of the software enable the display of multiple graphs, easy device configuration and real time logging of measured data in a comma separated file (CSV). The user interface is adaptive and multi-lingual (English, French, German, Chinese, Japanese and South Korean). Bronkhorst FlowSuite is available from the Microsoft store.

Air leaks in my pneumatic system are wasting energy, and affecting the performance of my machine. I need continuous monitoring that can identify them quickly.

YOU CAN DO THAT Emerson smart pneumatic solutions help to digitally transform your operations by providing actionable insights that improve machinery performance. By obtaining and analysing compressed air pressure and consumption data from your pneumatic systems, we provide you with an immediate way of detecting leaks. This helps to increase maintenance efficiency and reduce machinery downtime, energy waste and emissions. To find out how our easy-to-implement scalable solutions enable you to address your issues immediately, visit: Emerson.com/AVENTICS

COVER STORY

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OVERCOMING INDUSTRY’S INERTIA: NEW SCARA ROBOT AND CONTROLLER Trade fairs might be postponed, but the world of robotics is not at a standstill. TM Robotics, the official partner and distributor of Shibaura Machine industrial robots, has big plans for 2020.

rom Toshiba Machine’s corporate name change to Shibaura Machine in April, to the impending European launch of the company’s latest SCARA model and anticipated robot controller — things are in motion at TM Robotics. Toshiba Machine was initially founded as Shibaura Machine Tool Co. in 1938. Returning to its original name in April 2020, the transition has reflected its formal separation from the larger Toshiba Corporation. Despite the change, Shibaura Machine has achieved a seamless transition for customers or shareholders — and the same goes for TM Robotics and its network. “Even though the name is changing, our commitment remains the same,” explained Takahiro Mikami, president of Toshiba Machine. “Our goal as Shibaura Machine is to be a supplier of the highest quality machinery and systems, one that is well-positioned to grow and contribute to the global economy for decades to come.” Throughout this period of change, TM Robotics has continued to supply the company’s range of six-axis, SCARA and Cartesian robots to its network in EMEA, North and South America and Australia. Today, the company is preparing to introduce brand new products to its robot line-up.

New robot releases The THE600 robot is the latest addition to Shibaura Machine’s SCARA robot range and TM Robotics invites customers to contact them directly for full specifications, downloads and data on the new machine. Advancing from the specifications of the existing THE400 SCARA robot, the THE600 has been developed to meet growing demand for Control Engineering Europe

fast-cycle automation. The new model includes improvements in synchronised control and tracking precision. The THE600 is ideal for the assembly and inspection process of electronics equipment and automobile components. It boasts twice the speed and 60% higher payload capacity than competing SCARA models in the same price range, making it the price-toperformance leader. Another new launch for 2020 is the TS5000 robot controller, offering improvements in design and programmability against former Shibaura Machine controllers. The TS5000 is 33% smaller than existing versions, for minimal impact on the factory footprint. Weighing just 10kg with dimensions of 370mm width, 150mm height and 355mm depth, the compact design of the TS5000 allows for easy installation.

On the horizon Looking to the future, 2020 is set to hold more exciting releases for the Shibaura Machine and TM Robotics partnership. At IREX 2019, Japan’s largest robot exhibition, Shibaura Machine unveiled live demonstrations of two under-development collaborative robots – a humanoid and SCARA model. Shibaura Machine’s humanoid cobot was displayed in a live parts assembly demonstration at the aforementioned show. Boasting a 6kg maximum payload for each arm or 10kg when used in combination, the humanoid cobot is primed to meet growing demand for human-machine collaboration in parts assembly and inspection processes. The SCARA model, which is also collaborative, expands on Shibaura Machine’s established expertise in

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The THE600 has been developed to meet growing demand for fast-cycle automation.

manufacturing traditional SCARA robots. The SCARA cobot is set to be used in delicate electronics handling and packaging applications – a task usually limited to highly accurate industrial machines. Also featuring two arms, the SCARA robot will be suited to fast-paced handling applications. As collaborative robots, both models will be deployable alongside human workers, allowing manufacturers to benefit from a combination of automated and manual processes. Both models are currently under intense development by Shibaura Machine’s engineers in Japan. “2020 has already proven itself to be a year of immense change,” explained Nigel Smith, managing director of TM Robotics. “While some of the world and its industries are at an uncertain standstill, TM Robotics is continuing to deliver robotic solutions to our customers and throughout our distributor network. For now, or when industry begins to pick up speed again, we are here to help.” plus-circle More information on the new product releases can be found at www.tmrobotics.com. Alternatively, contact the European headquarters directly at info@tmrobotics.com or call +44 (0) 01707 290370. June 2020

ENERGY MANAGEMENT

COCA-COLA BOOSTS ITS ENERGY EFFICIENCY The use of an energy management system has allowed a Coca-Cola plant in Edelstal, Austria, to conduct detailed analyses of its resource and energy consumption with the goal of continuing to reduce its carbon footprint by reducing waste and water consumption and lowering emissions.

ne of the priorities of Coca Cola HBC Austria is to use resources responsibly and manufacture products in a way that is as environmentally friendly and carbon-efficient as possible, according to Theresa Fleischberger, environment nanager at Coca Cola HBC Austria. To reduce its consumption of resources like water and energy, CocaCoca HBS Austria has invested in new machines and systems at its Edestral site. This includes a new high-speed bottling line that is able to fill 45,000 glass bottles per hour – over 12 bottles per second. Not only is it one of the world’s fastest bottling lines, but it is also surprisingly energy-efficient. Thanks to the new lines and increased use of air to clean bottles before filling, the amount of water consumed by production has been significantly reduced. In addition, the company has already replaced the first high-pressure compressor for the blow moulding machines on the PET lines. According to Martin Surda, maintenance specialist at the plant, the new compressor consumes between 5% and 8% less electricity, depending on operating conditions and capacity utilisation. The plant is powered 100% from renewable electricity sources. “Although the savings have no additional impact on the carbon footprint, it is still important that we improve our energy efficiency on an ongoing basis,” said Fleischberger. This is partly motivated by cost – because the price of electricity and other fuels is constantly rising. At the

June 2020

same time, the plant consumes natural gas in addition to electricity, which means that savings in overall energy consumption also affect the carbon footprint.

Analysing consumption For some time Coca Cola HBC Austria has been tracking the success of its energy-saving measures in Edelstal with the aid of its own energy monitoring system – which recorded production and consumption data and made it possible to analyse and compare the energy consumption of individual lines. However, according to Surda, this solution has limitations. When the Coca-Cola plant in Edelstal began using the Simatic WinCC V7 system from Siemens to visualise production data it also

turned to Simatic Energy Manager Pro for energy management. “We were particularly impressed by the solution’s flexibility and scalability,” said Surda. Within two months, the task of energy management was transferred to the new system, which included the integration of numerous consumers that are captured by Sentron PAC energy measuring devices. Today, the consumption data is gathered by a Simatic ET 200SP system and is then transferred to Simatic Energy Manager Pro. In addition to the measuring devices for electrical energy, flowmeters for recording water consumption are also integrated in the system. Following initial training from Siemens, the team – headed by

Employees in Edelstal can now create their own dashboards in Simatic Energy Manager Pro, which lets them analyse and track KPIs in detail.

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Control Engineering Europe

ENERGY MANAGEMENT

Fleischberger and Surda – are now able to configure and operate the system independently. More than 100 data points for measuring energy consumption and 17 data points for water consumption are currently integrated in the system and are queried once per minute. The data acquired is linked to the production data from the ERP system, which enables a detailed analysis of energy consumption and energy efficiency for each individual product produced.

Quick reports “New analyses and dashboards can also be created at any time and with little effort,” said Surda. “We can generate new reports in no more than an hour. We used to have to hire external programmers to do this for us, with the result that changes sometimes took a week or even longer. Now we can do it all ourselves.” One additional benefit of Simatic Energy Manager Pro is that users can also view the data via a Web client – which is advantageous for Fleischberger, who works most of the week remotely. Control Engineering Europe

Increased awareness Even employees in production can now stay informed about current energy consumption. “This broadens the awareness of the issue. Each employee can contribute to boosting energy efficiency and see their success reflected in the numbers,” said Fleischberger. “Plus, the numbers we have access to are much more detailed. We can determine the exact consumption and costs for each individual line and each individual product. I consider this transparency to be an important benefit of the new system.” Altogether, these measures have allowed Coca Cola HBC Austria in Edelstal to reduce its CO2 emissions to 17.5g per litre of beverage produced in 2019 – which is 50% less than in 2010. There are also plans to use information from Simatic Energy Manager Pro to improve system maintenance and prevent energy losses. “Among other things, we want to identify when leaks or other problems start based on flow measurements and energy consumption in the compressed air supply,” said Surda. “This will allow

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us to service the systems promptly and in a way that saves money and resources.” Other plans include expansion of the existing energy management system, with six high-pressure compressors in the compressed-air network also being integrated into the system. These compressors generate air at a pressure of 36 bar which is used to form PET bottles from blanks. “This move will allow us to optimise the processes so that we consume less energy – for example, by reducing machine maintenance time and aligning the compressors more closely with our demand. Because these six units are responsible for about 20% of our energy consumption, the savings potential is tremendous,” said Surda. In conclusion, Fleischberger said: “With Simatic Energy Manager, we can define savings goals and prove the cost-effectiveness of efficiency measures in the areas of water and energy. The plan is to continue improving resource efficiency at the Coca-Cola plant in Edelstal with the help of the new energy management system. plus-circle June 2020

MACHINE SAFETY

DON’T NEGLECT ESPE INSPECTIONS Lee Ray highlights the importance of regular inspection and testing of electro-sensitive protective equipment.

ecause collaborative robots are designed to work alongside humans, they cannot be caged by a physical guarding mechanism. This means that electrosensitive protective equipment (ESPE), such as light guards and laser scanners, are now more prevalent. However, ESPE inspection and testing is often neglected as many machinery owners are unsure how often it should be assessed. The International Electrotechnical Commission’s EN 61496 series specifies requirements for the design, construction and testing of ESPE designed to detect persons as part of a safety-related system, employing active opto-electronic protective devices (AOPDs) for the sensing function. This is then used in conjunction with EN ISO 13855 to determine the correct installation location for the light guard, which should be verified after installation. The complete system for detection, actuation and stopping is not solely reliant on the electrical signals. There are normally wear components that are installed as part of that system to enable a shorter stopping time. Through the lifecycle of use, there is potential for these parts to wear and this could introduce a situation where access can be gained through a light guard, to a hazardous part of the machine, while it is still in run down. The Amended Use of Work Equipment Directive (AUWED) places requirements on machinery users to inspect and maintain the equipment and safety critical functions of the equipment. The testing frequency of the light guard cannot be determined by the component manufacturer for the stop time, as they are not responsible

June 2020

Because collaborative robots cannot be caged by a physical guarding mechanism it is vital to ensure that ESPE is not neglected.

for installing the system as a whole. It is the light guard integrators responsibility to select and configure the system correctly, and the user must conduct testing and maintenance to ensure this function does not deteriorate.

Inspection and test Inspection and tests must first be done when the ESPE and machine package is installed, and thereafter when modification or repairs have been made or the installation is relocated. In addition, EN IEC 62046 states that periodic inspection and testing should not be greater than 12 months unless local regulations state otherwise. This is to ensure that deterioration has not occurred in the stopping performance for the lifecycle of the machine. TÜV SÜD strongly recommends following guidance from local enforcing authorities. For example, in the UK the

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HSE has created HSG180 which defines the recommended maximum period between each periodic inspection and test as being six months for type 4 ESPE and 12 months for type 2 ESPE. However, this is still subjective as the guidance then says that the frequency of inspections ultimately depends upon on the equipment that the ESPE is fitted to and the risk as a whole. The good news for machinery end-users is that HSG180 requires the machine and the ESPE supplier to supply information relating to routine maintenance and inspection requirements. This should help the end-user to develop a robust inspection and set an initial test regime frequency. The guide also requires that the initial inspection and test is carried out by competent persons, such as an inhouse inspector, the installer or supplier, or an independent assessor. The results of any inspections must Control Engineering Europe

A supplement to Control Engineering Europe sponsored by the CC-Link Partner Association

CC-Link Partner Association eu.cc-link.org

Summer 2020

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OPEN the FUTURE of CONNECTED INDUSTRIES Learn about the comprehensive, industry standard, open development ecosystem available for CC-Link IE TSN

LEADING THE WAY IN OPEN INDUSTRIAL ETHERNET John Browett, General Manager, CLPA Europe, introduces this special CC-Link Partner Association sponsored supplement which focuses on the comprehensive industry support for CC-Link IE TSN product development.

he CC-Link Partner Association (CLPA) is one of the largest open network associations, with over 340 partner companies offering products compatible with the CC-Link family of open automation networks. With a total membership of almost 3,800 companies and 26 million devices installed globally, the CLPA has established itself as a key player in automation worldwide. We have led the way in open industrial Ethernet for many years. We were the first organisation to offer gigabit bandwidth for industrial Ethernet applications with CC-Link IE. In 2018, we continued our leadership by being the first to combine open gigabit industrial Ethernet with Time-Sensitive Networking (TSN). TSN is a set of IEEE standards that adds deterministic features to standard Ethernet by making changes to layer 2 of the 7 layer OSI model. By incorporating this technology, CC-Link IE TSN is now setting the standard for connectivity in the Industry 4.0 age.

Key benefits The key benefits of CC-Link IE TSN can be divided into three main areas: Performance, Connectivity and Intelligence: Performance: Gigabit bandwidth means the network architecture easily accommodates various types of traffic with no loss of productivity. This includes process related traffic such as control, safety and motion data. By adding TSN, it’s possible to incorporate other traffic such as TCP/IP communications from vision systems and so on. The possibility to also integrate other types

Summer 2020

of industrial Ethernet protocols exists. Connectivity: As with all types of CC-Link networks, CC-Link IE TSN is a fully open technology. Hence any company who wishes to make compatible products can do so after joining the CLPA. Moreover, full implementation flexibility is offered – master and slave devices can be developed with hardware platforms or software stacks, both with the option of 100Mbit or 1Gbit physical layers. Intelligence: A full range of diagnostic and configuration features are available and third-party diagnostic systems such as SNMP tools are supported. In this special feature, we will focus on the aspect of Connectivity, exploring the various options for companies wishing to incorporate CC-Link IE TSN technology into their products. This will allow them to take advantage of its benefits and offer market leading Industry 4.0 solutions. We showcase a variety of CLPA partners who offer industry standard development platforms and solutions for the network. For each partner, we examine the value CLPA membership provides to their organisation, the eu.cc-link.org

solutions they offer for CC-Link IE TSN and their key features and benefits. In summary, you will receive a comprehensive overview of how to get on board with CC-Link IE TSN and why you should consider including it in your development roadmap. We believe that CC-Link IE TSN represents the future of open industrial Ethernet. We and our partners would like the opportunity to discuss this with you further. Please get in touch! John Browett General Manager, CLPA Europe partners@eu.cc-link.org eu.cc-link.org partners@eu.cc-link.org

GIGABIT CHIP WITH PROTOCOL STACK FOR CC-LINK IE TSN With several million controllers having been installed, Hilscher’s netX platform technology has achieved worldwide success. It enables all proven fieldbus and real-time Ethernet systems to be realised in the smallest of spaces – and will soon also be available for automation providers keen to provide their products with CC-Link IE TSN connectivity.

he owner-managed Hilscher Gesellschaft für Systemautomation with headquarters in Hattersheim near Frankfurt was founded in 1986 and is regarded as one of the major international players when it comes to industrial communication solutions for modern factory automation. The company offers a full portfolio of hardware and software solutions for fieldbuses and Industrial Ethernet as well as services and customer-specific assembly production. Hilscher is a long-standing member of the CC-Link Partner Association (CLPA) and – with its communication chips, embedded modules, pc-cards, gateways and corresponding protocol stacks – supports all network communication technologies, from the CC-Link fieldbus to the industrial CC-Link IE Gigabit Ethernet variant which has already been realised on pc-cards as slaves. In addition, the compatible CC-Link IE Field Basic variant is ported to Hilscher’s 100-Mbit chips. Prototypes have already been created and the certification process is in progress.

Seeing a gigabit trend “With TSN in particular, we are seeing a strong trend towards gigabit technology and because of that, we are in the process of developing a new multiprotocol chip for gigabit bandwidth which naturally will also then support CC-Link IE TSN. We see gigabit TSN as having great market value,” said Sebastian Hilscher, son of the company’s founder and CEO at Hilscher. partners@eu.cc-link.org

The complete supplier is a prominent supporter of the CLPA, regularly exhibiting at trade shows and participating in press conferences. They realised the seamless exchange of data between the PROFINET network which is dominant in Europe and CCLink IE technology which is the leader in Asia with their coupler device – shortly after PROFIBUS & PROFINET International (PI) and the CLPA formulated and published their joint specification. “With the CLPA, we can stay up-to-date with the latest technology trends and we have also been involved in the development of CC-Link IE TSN since very early on. One of the huge benefits of being a member is that we get specifications very early so that we can align our product roadmap on it. The other is the marketing activities carried out together with the CLPA which increases awareness of our brand,” explained Hilscher. The launch of the new chip which will support gigabit bandwidth is planned for 2020. “That is when starter kits will be launched and samples available for customers to try out. Then we will collect customer feedback and go into mass production,” advised Hilscher. Hilscher, as a total solution partner, will deliver the chip as usual together with the matching software protocol stack. “Because we deliver both software and hardware we can perfectly match the components to eu.cc-link.org

With several million controllers having been installed, Hilscher’s netX platform technology has achieved worldwide success.

each other, that’s why our chips generate less power consumption and need only a small amount of space. Nonetheless, the chips provide the same level of performance as other CPUs because everything is totally matched and nothing on the chip is redundant,” continued Hilscher. The new generation of chips which supports gigabit TSN will be an extension of the netX chip family in the form of various derivatives, i.e. as a companion chip variant or as a single chip solution. The solution mainly focuses on factory automation and on the whole range of associated devices, from I/Os through PLCs and drives to incremental encoders and sensors. www.hilscher.com Summer 2020

ANYBUS SUPPORTS TIME-SENSITIVE NETWORKING THROUGH CC-LINK IE TSN The Anybus concept from HMS Industrial Networks is a leading-edge portfolio of connectivity products including hardware and software. Interacting with a variety of industrial networks, it reduces development efforts for device manufacturers to a minimum – and will soon also be available for the implementation of CC-Link IE TSN.

ounded in 1988 and with a head office in Halmstad and a global sales network, Swedish company HMS Industrial Networks is one of the leaders in technology when it comes to connectivity between automation devices and industrial communication networks. The Anybus product family is regarded as the de facto standard and enables the exchange of data from field devices, machines and systems via all current fieldbus and Industrial Ethernet networks. HMS is a long-standing member of the CC-Link Partner Association (CLPA) after the company experienced unexpectedly high demand from Japan at the end of the 1990s: “However, progress in industrial communication technology always came from Europe and partly from the USA, and at the time, the device manufacturers in Asia needed new networks for their products,”, explained Christian Bergdahl, Product Marketing Manager at HMS. “So conversely, we then also included the Asian de facto standard CC-Link in our network portfolio.” Bergdahl praises the consistent marketing activities carried out by the CLPA and the active support from its partner that ensures HMS has good market visibility: “As an independent network organisation, the CLPA really opens doors for us. We also benefit from its outstanding market observations – it always has its finger on the pulse in terms of its technologies. This helps us to make an early start.” Consequently, HMS has added CC-Link IE TSN to its latest modular

Summer 2020

embedded family Anybus CompactCom. As a result, the new technology from the CLPA is the 13th network supported by multinetwork connectivity but the first to be based on TSN. This will be particularly beneficial for the HMS customers – of whom there are more HMS has added CC-Link IE TSN to its latest modular embedded than 1,000 – who are family Anybus CompactCom. already using the modular embedded product family users. As with the two earlier CLPA and have therefore implemented the technologies CC-Link and CC-Link IE, host interface for communicating with HMS is also developing the interface the Anybus modules: “They will be module for CC-Link IE TSN first. “Then able to access the new network very when we have the basic technology, it quickly and easily because they have will be introduced into our gateways already done the preliminary work and edge gateways,” continued needed through the interface method. Bergdahl. We supply the TSN-based embedded HMS presented its concept for the CCproduct in the desired form factor Link IE TSN CompactCom module as part and customers can get their devices to of the development solutions display on market very quickly,” stressed Bergdahl. the CLPA stand at SPS 2019. The market HMS is indeed expecting the Asian launch is scheduled for mid-2020. The market in particular to develop rapidly logical next step is to integrate the but the quick CC-Link IE TSN solution new CompactCom technology in HMS should also be of interest to its customer gateways. base in Europe and the USA, not least Factory automation in the for placing end products on the markets manufacturing industry remains the in Asia. “It will work both ways,” said principal market for Anybus. Millions Bergdahl. “Especially during the second of robots, drives and HMIs worldwide step when our gateway solution for CCare connected in this way. Fields of Link IE TSN is also available.” application such as the process industry, Anybus gateways link various building automation and infrastructure industrial communication standards. are becoming increasingly important. They make network integration and expansion quicker and easier for end www.hms-networks.com eu.cc-link.org

partners@eu.cc-link.org

DEVELOPMENT SUPPORT FOR CC-LINK IE TSN AND CC-LINK IE SAFETY MESCO offers CC-Link IE TSN and CC-Link IE Safety development services for automation component manufacturers. Through modular concepts and the use of MESCO design packages, TSN-based, safetyrelated and non-safety-related industrial communication solutions are implemented with minimum effort and risk.

ESCO Engineering, based in Lörrach, was founded in 1990 and is dedicated to developing hardware and software for factory and process automation. Other fields of development that the technology provider focuses on include ‘Industrial Communication’, ‘Functional Safety’ and ‘Explosion Protection’. Engineering consultancy services throughout a product’s life cycle complete the portfolio.

MESCO carries out development for a wide range of industrial communication protocols and is a member of numerous network organisations. MESCO recently joined the CC-Link Partner Association (CLPA), adding CC-Link IE TSN and CC-Link IE Safety to the Industrial Communication and Functional Safety service areas respectively. “This is a highly interesting development for our customers because through modular concepts, MESCO provides a smart way to get started with safety-related

and non-safety-related TSN-based industrial communication. It also offers a way to expand in the Asian market,” said Peter Bernhardt, Head of Sales & Marketing at MESCO Engineering. The development concept with design packages facilitates the product development process for CC-Link IE TSN- and CC-Link IE Safety-compliant slave devices and provides a quick and easy way of getting started with these pioneering technologies. “CC-Link IE TSN enables the seamless linking of higher-level IT systems to operational systems in production (OT) and opens up potential for numerous new manufacturing applications. Compared to conventional Industrial Ethernet, the new protocol offers improved communication functions such as time synchronisation, real-time frames for real-time communication and frame pre-emption for prioritised data packages,” explained Bernhardt. “Support for 100 Mbit/sec is also very important.”

Safety-related developments Particularly in the case of safety-related developments, enormous savings on development and certification efforts can be made through the use of design packages. By this, MESCO is referring to circuit boards and software components which have been tried and tested as reference designs in product development and certification. MESCO develops customised solutions based on the requirements of its customers on this basis. “We see it as our task to make life easier for developers,” continued Bernhardt, summing up the company’s mission statement and referring to its full offering including professional hardware and software development services and the use of tried and tested design packages as well as consultancy services from concept to certification.

MESCO Engineering based in Lörrach was founded in 1990 and is dedicated to developing hardware and software for factory and process automation.

partners@eu.cc-link.org

eu.cc-link.org

www.mesco-engineering.com Summer 2020

DEVELOPMENT SOLUTIONS FOR CC-LINK IE TSN-COMPATIBLE MASTER/SLAVE DEVICES Mitsubishi Electric sees Time-Sensitive Networking as the future and is focusing its development activities on the new industrial communication network CC-Link IE TSN. Besides a fully compatible product portfolio, the automation specialist has announced development solutions for device makers.

ounded in 1921 and with its headquarters in Tokyo, today the Mitsubishi Electric Corporation is one of the leading international electronics and electrical equipment manufacturers and has sales offices all over the world. The Factory Automation Division offers a full portfolio of automation products including CNC control systems, laser and eroding machines, PLCs, frequency inverters and servos as well as industrial robots and software. The open fieldbus network CC-Link was developed by the Mitsubishi Electric Corporation in 1997 and made an open technology in 2000 so that independent manufacturers could incorporate CC-Link compatibility into their products. Since then, the management and further development of the network technology have been taken care of by the CC-Link Partner Association (CLPA). According to Piotr Siwek, Deputy Product Marketing Director EMEA at Mitsubishi Electric Europe, one of the major benefits of being a member of the CLPA itself is the contact with experts from other fields of automation such as sensor technology, for example, which has enabled the company to develop further partnerships for the purpose of developing joint customer and market solutions. “CC-Link IE TSN is one of the most advanced communication networks for the industrial sector,” said Siwek. “Having such an efficient network is very important for us as a full serviceprovider as it enables all the different components to communicate with each

Summer 2020

other effectively that servo drives and it also supports can be directly efficient edge controlled in the computing.” same network, Mitsubishi Electric along with the will help other other automation CLPA partners to components: develop CC-Link “We can IE TSN-compatible integrate motion products. “Remote controllers without stations (slave compromising functionality) are on performance Mitsubishi Electric sees time-sensitive already supported – networking as the future and is focusing its and synchronise customers can select development activities on the new industrial axes in real time. communication network CC-Link IE TSN. The their development Automating main benefits of CC-Link IE TSN fall into three categories: performance, connectivity and technology as a machine or intelligence. both the ASIC production line development kit and enables the protocol stack are already available. customer to use a single network to The latter reduces development effort carry out a full range of tasks. That to a minimum without compromising reduces costs and naturally also saves on functionality while the ASIC version time,” he said. enables the TSN technology to be used Siwek sees the versatile to its full potential,” continued Siwek. communication network having The company presented its own universal benefits: “Ultimately, CC-Link IE TSN-compatible products, everyone in the EMEA region will also including PLCs, decentralised I/Os, benefit from the Ethernet-based simple operator terminals and frequency cabling and low engineering costs – the inverters, on the CLPA’s stand at SPS automotive and consumables industry 2019, and Siwek confirmed that but also the food and beverage industry development kits would be available in and the mechanical engineering sector 2020 for the master station too, again in as a whole, for example. Existing the form of ASICs and a software stack. Ethernet-based networks can be Mitsubishi Electric also has the new integrated via TSN which protects ground-breaking servo technology investments made.” Mitsubishi Electric Melservo-J5 in the pipeline and this aims to add CC-Link IE TSN capabilities was also demonstrated on the CLPA to its whole product portfolio, including stand at SPS 2019. Siwek sees the all robot models, by the end of 2020. main benefit of CC-Link IE TSN in this field of application as being the fact eu3a.mitsubishielectric.com eu.cc-link.org

partners@eu.cc-link.org

SOFTWARE STACK AND SOM FOR THE DEVELOPMENT OF CC-LINK IE TSN PRODUCTS An engineering company that specialises in industrial real-time data communication, has developed two alternatives for CC-Link IE TSN products: a software stack (master/slave) reduces in-house development time and costs for the component manufacturer while an embedded System on Module (SoM) can directly expand existing platforms.

ounded in 1990, port industrial automation GmbH, based in Halle/Saale, is committed to industrial real-time communication in all sectors. More than 500 product and system developers worldwide use microcontroller unit (MCU) middleware, libraries, cores, protocol stacks, drivers, tools and development services from port to successfully place their products on the market. Since the beginning of CANopen, the company has primarily relied on multi-protocol solutions, working in collaboration with market drivers from the European and US automation industries. Today, port focuses on the Industrial Ethernet protocols in their many forms and that is why, in June 2018, it joined the CC-Link Partner Association (CLPA) in order to support its latest Industrial Ethernet technology CC-Link IE TSN which combines gigabit bandwidth and Time-Sensitive Networking (TSN). “port mainly serves industrial markets such as factory automation, logistics automation, sensor technology and the process industry and our real-time communication solutions cover the whole communication chain. CCLink IE TSN provides an interesting technology platform which enables data from sensor to interface ‘IT’ to be displayed safely and represents an important addition to our portfolio,” explained Dietmar R. Franke, CEO/CFO

partners@eu.cc-link.org

of port industrial automation. “We will continue to develop the company by focussing on TSN as we will fully support the whole topic of ‘Time-Sensitive Networking’ with a variety of products.”

The product range The product range for CC-Link IE TSN currently includes a software stack that contains the tools required to configure, manage and install the new open specification. A decisive advantage of the stack solution is its hardware independence. The stack is ported to the relevant hardware platform in a consistent format and already contains the TSN features that are supported according to IEEE standards. In addition, there are appropriate configuration and management tools. Moreover, port has developed a hardware product for CC-Link IE TSN in the form of an embedded System on Module (SoM) which can be used as an add-on or expansion board for existing systems. “In other words, customers who are currently using a platform that offers a Serial Peripheral Interface (SPI) can also add CC-Link IE TSN to their platform via this interface,” said Franke. While the licensing of port’s CC-Link IE TSN stack is aimed at customers who will then be able to optimise their development effort for larger quantities, the company also wants the embedded module to offer a CC-Link IE TSN option for companies which produce very small quantities. eu.cc-link.org

port has developed a hardware product for CCLink IE TSN in the form of an embedded System on Module (SoM) which can be used as an addon or expansion board for existing systems.

Franke sees opportunities for the SoM alternative for mechanical engineering in particular: “This fully integrated SoM alternative is particularly suitable for manufacturers who make more specific products such as certain gateways or I/Os with small annual production runs because all the customer has to take care of is the integration of the hardware. However we also offer that as a service for the CC-Link IE TSN system,” he said. www.port.de Summer 2020

RENESAS UPGRADES INDUSTRIAL NETWORK TO THE NEXT STAGE Industrial networks are part of the technologies used in factory automation. As a chip manufacturer, Renesas sees CC-Link IE TSN as a key factor in the industry’s progress because the network enables temporal precision, ensuring secure transmission within a given period of time, and mixed implementation with other communication protocols.

enesas has developed a CC-Link IE TSN-compatible System-on-Chip (SoC) as well as software and a development environment. By using this solution, customers can start evaluating CC-Link IE TSN communication after a set-up time of just one hour. The SoC supports CC-Link IE TSN networks with a minimum of external components, simplifying system design and saving engineering costs. The SoC for Industrial Ethernet communication enables multi-protocol capabilities for Industry 4.0 through Renesas’ key technology R-IN Engine. The SoC contains dedicated hardware for CC-Link IE TSN with integrated Gigabit physical layer (PHY) and said R-IN Engine consisting of a Cortex-M core, real-time operating system components (HW-RTOS) and an Ethernet accelerator. Because the synchronisation accuracy between devices with the Renesas SoC in the same network can be less than 1 μs, the company also sees great potential for the internal networking of large-scale technical systems such as machine tools and production plants in the semiconductor and automotive industries, for example. Renesas is an internationally active Japanese semiconductor group headquartered in Tokyo with numerous subsidiaries in Europe, including Renesas Electronics Europe in Düsseldorf. Renesas offers reliable, innovative semiconductor solutions in embedded systems. Billions of devices

Summer 2020

Through CLPA’s activities, Renesas has been able to increase its LSI’s presence among other CLPA members and connect with new customers. Photo Credit: iStock

networked via these systems help to improve productivity at work and quality of life in general. Renesas already offers SoCs with CC-Link communication protocols and as a member of the CC-Link Partner Association (CLPA), the company can provide optimal technical support for its customers. The effective support of the CLPA network organisation in its PR work also increases visibility for Renesas and its customers. eu.cc-link.org

“Through CLPA’s activities, we have been able to increase our LSI’s presence among other CLPA members and connect with new customers,” said Toshihide Tsuboi, VP of the Industrial Automation Division at Renesas. “We have been supporting CC-Link and CC-Link IE Field for seven years through our SoC R-IN32 series.” www.renesas.eu partners@eu.cc-link.org

SOFTWARE DEVELOPMENT KIT FOR CC-LINK IE TSN REDUCES DEVELOPMENT EFFORT The fieldbus stack from engineering services provider SILA for Modbus is currently actively used by a broad user base. However in view of growing industrial communication requirements, this older protocol which does not yet have realtime capability is becoming unsustainable. By developing a new solution for the development of CC-Link TSN-enabled components, SILA wants to pave the way forward for its customers.

ounded in 2014 and based in St. Pölten in Lower Austria, SILA Embedded Solutions sees itself as a development services provider for the European market and specialises in customer-specific software and electronic development. Its services mainly focus on the fields of industry, lighting and railway technology as well as measurement and control technology. A subsidiary in Innsbruck focuses predominantly on software development and industrial networks in particular. SILA has been a full member of the CC-Link Partner Association (CLPA) since September 2019 because the company considers these open standards to be of growing importance in industry. “A lot of customers are afraid of committing to a supplier as they think it will take away their freedom to purchase from whoever they like. On the contrary, an open standard means healthy competition, numerous manufacturers and a wide variety of products. Customers can be sure that their investments will be looked after and that products are mutually compatible,” said Christian Walter, Director Electronic and Software Development, and one of the two founders of SILA, explaining the decision to join.

in trade events and comprehensive marketing measures that the mediumsized company would not be able to realise on its own. “For us, the CLPA is a very good platform for reaching a larger customer segment and also for increasing awareness of CC-Link IE TSN technology in Europe,” continued Walter. “In the field of measurement and control technology in particular, there is a need for things to run synchronously with each other, thus providing real-time capability. In this regard, we see TSN-enabled devices providing major benefits – and particularly CC-Link IE TSN, an open standard, for which a wide range of applications will be available.” SILA is currently developing a software development kit. This software stack enables manufacturers of automation devices, in fields such as sensor technology or drive technology, for example, to make their products CCLink IE TSN-compatible and also to focus on their own core task. The integration of the stack reduces development effort and thus the time-to-market for a device

manufacturer. SILA offers not only the software solution but also help with the integration of the stack. Walter sums up the main benefits of the CC-Link IE TSN solution from SILA: “The SILA stack was designed to be easily portable so that it can be easily adapted to the customer’s hardware and architecture. It is already available as a demo stack for Linux and the STM32 platform and is therefore available to a large part of the market for evaluation. In addition, the software was written with a C-based programming interface and is supplied as source code in order to guarantee independence and investment security for the device manufacturer.” The market launch is scheduled for Q2/2020, however visitors to SPS 2019 were given the opportunity to find out more about the solution. At the trade fair, visitors were able to get a close look at the CC-Link IE TSN development stack in its current state of development via an executable demo application. www.embedded-solutions.at

Benefits of cooperation Besides support for the future-oriented CC-Link IE TSN industry network, SILA sees its cooperation with the CLPA bringing benefits such as participation partners@eu.cc-link.org

SILA Embedded Solutions specialises in the design and development of complex and sophisticated electronics and software products.

eu.cc-link.org

Summer 2020

KEY PLAYERS IN INDUSTRIAL COMMUNICATION SUPPORT CC-LINK IE TECHNOLOGIES Analog Devices (ADI), a leading global high-performance analog technology company, has a rich history of solving its customers’ toughest challenges and designing breakthrough industrial communication solutions – from the early days of 4 to 20mA and serial fieldbuses to today’s Ethernet-enabled protocols for the factory of the future.

hrough this evolution, CC-Link has played a vital role solving customers’ most complex automation challenges. The next generation CC-Link will advance automation even further by providing a strong foundation for Industry 4.0 applications and enabling the open flow of information from the sensor to the cloud. ADI supports CC-Link with its robust roadmap of products and is actively investing in new developments for

CC-Link supported Ethernet solutions. “We look forward to many years of success partnering with the CC-Link community to enable seamless and secure Ethernet connectivity,” said Brendan O’Dowd, General Manager Industrial Automation, when asked about membership and collaboration within the CLPA. The multi-protocol communication processors from the Sitara series of another leading US semi-conductor manufacturer Texas Instruments (TI) support the CC-Link IE Field Basic

The FIDO 5200 chip from Analog Devices is a real-time Ethernet multi-protocol switch (REM) which supports various industrial Ethernet protocols with the help of embedded firmware.

Summer 2020

protocol of the CC-Link Partner Association (CLPA) and provide industry-compatible solutions. CC-Link IE Field networks bring the benefits of Gigabit data bandwidth and 100-Mbit compatibility to Industrial Ethernet at the field level – ie, high speed and performance combined with a wide variety of instrument control and management data. TI offers a CC-Link IE Field Basic master and slave system design package (reference design) for Sitara processors. The network is supported by

The ADIN300 Ethernet switch from Analog Devices is a single-port Gigabit Ethernet transceiver with low power consumption designed for industrial Ethernet applications.

eu.cc-link.org

partners@eu.cc-link.org

a Software Development Kit (SDK) for the Linux and RTOS processors AMIC110, AM335x, AM437x and AM57x. This enables CC-Link IE Field Basic-compliant implementation on various platforms which are also individually certifiable. TI’s Industrial Development Kits (IDKs) and Industrial Communications Engines (ICEs) for CC-Link IE Field Basic are independent test, development and evaluation modules used by hardware and software developers for industrial control and communication applications.

TI offers a CC-Link IE Field Basic master and slave system design package (reference design) for Sitara processors.

www.analog.com www.ti.com

CLPA establishes global strategic advisor role CC-Link Partner Association (CLPA) has recently created a global strategic advisor role and has recruited Thomas J. Burke to fill this position of critical importance to its future development. Thomas J. Burke is the past president and executive director of the OPC Foundation. Thomas was the founding leader of the OPC Foundation, which is focused on delivering the best specifications, technology, process and certification necessary to achieve multi-vendor multi-platform secure reliable information integration across disparate devices and applications from the factory floor to the enterprise. In his new role Burke is primarily responsible for: 1. Increasing awareness and adoption of CC-Link IE TSN in the global marketplace; 2. Advising CLPA leadership on industry trends, standards and market strategy; 3. Sustaining and increasing the number of CLPA partners from North America; 4. Facilitating collaboration with suppliers and end-users to maintain CLPA’s industry leading position; 5. Collaboration with other industry

partners@eu.cc-link.org

standards organisations, focusing on harmonisation across industrystandard organisations. CC-Link IE TSN combines the gigabit bandwidth of CC-Link IE with TimeSensitive Networking (TSN) to meet future automation market demands, such as Industry 4.0. This provides flexible integration of Operational Technology (OT) and IT while further strengthening performance and functionality. A comprehensive portfolio of device development options is also ensuring that any vendor can easily add this technology to their product line-up. The aim is to improve efficiency and reduce time to market for Smart Factories utilising the IIoT and the products they manufacture. As of April 2020 – a year and a half after the announcement of the CC-Link IE TSN specifications – more than 100 partner products have been released or are under development. By leveraging his unique assets and experiences from the OPC Foundation, Burke will be the perfect fit to achieve the aim of CLPA global strategic advisor. He will work synergistically with the other CLPA branches to help companies across a wide range of

eu.cc-link.org

different industries such as automotive, semiconductor, machine tools and food & beverage understand how the CLPA’s industry leading technologies clearly provide a way to increase their competitive advantage.

Summer 2020

OPEN the FUTURE of CONNECTED INDUSTRIES

CC-Link IE TSN: Time-Sensitive Networking joins open gigabit Ethernet to deliver the world’s most advanced automation network technology for Industry 4.0. • Performance: Combines gigabit bandwidth with TSN to deliver the highest productivity network solution for Industry 4.0. • Connectivity: Open technology provides freedom of choice for end users, OEMs and device vendors. • Intelligence: A wealth of intelligent features reduce time to market and downtime while increasing productivity. Contact us now to see how CC-Link IE TSN can meet your needs. partners@eu.cc-link.org | eu.cc-link.org

MACHINE SAFETY also be recorded. The HSG180 guide helps the inspector to ensure that the inspection and test process achieves a good general standard of performance. For example, it should not be possible for the dangerous parts of the machine to be set in operation while any part of a person is in such a position as to actuate the AOPD. We have seen multiple instances where the need for light guard testing has not been realised. While functional safety checks are recognised as good practice, they are no substitute for the required periodic testing. The stop time test, performed as part of the periodic test, would detect any deteriorating system parts which no longer offer the required protection. This is something that usually cannot be seen, like in fixed guarding, and therefore can only be proven by testing. plus-circle Lee Ray is operations manager for Industrial Products (UK) at TÜV SÜD.

Modular operating mode and access permission system A Pilz modular operating mode selection and access permission system offers flexibility when implementing safety and security on equipment and processes. The PITmode fusion consists of a reader unit with RFID technology and an integrated web server, and a safe evaluation unit (SEU). Its modular design enables the system to be integrated individually into the design of existing control consoles. Existing pushbuttons can be used, enabling better operation for the user. PITmode devices are used on plant and machinery in which users switch between different control sequences and operating modes. Authorised users have a coded RFID transponder key that provides the necessary access rights for performing the tasks required of them. Up to five safe operating modes can be defined – such as automatic mode, manual intervention under restricted conditions, or service mode. The key is inserted into the control console, the SEU detects the specified operating mode, and the PITreader ensures functionally safe switching. Accidents, misuse and manipulation are therefore prevented. Users benefit from higher availability of their machines. The system can also be used to implement a range of functions beyond access permission and operation mode selection. It may be a simple enable that replaces a key switch at the control console, or access permission for machine subfunctions. Further, a complex hierarchical permission matrix with various groups and permissions can be created in the free user area. These functions are bundled on the RFID key, replacing additional mechanical keys or access cards, which makes management of access privileges an easier task.

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I/O MODULES & SYSTEMS

IO-LINK: MAKING THE AUTOMATION ENVIRONMENT SMARTER Industrial environments are generating more data than ever. Whether for production volume, downtime or serial numbers, this information can offer insight into processes and productivity, as Svenja Litz and Kate Zimmerman explains.

any plants already rely on this data for tracking purposes but it can offer much more – it can help improve operations, expand go-to-market strategies, streamline maintenance, boost uptime and increase yield. But, to see these benefits it is first necessary to find a way to collect, analyse and display the data in an appropriate format. Using plug-and-play smart sensors, powered by IO-Link, can help achieve this, allowing engineers to take full advantage of data generated by the plant.

IO-Link history Within the last decade, the industry has experienced a few big changes. To be used in things like robots or attached to hard-to-reach equipment, sensors needed to become smaller as mechanical components started to shrink. This made it difficult to integrate fieldbus interfaces into sensors due to size limitations. Manufacturing and automation equipment became more complicated which created the need to gather and control data beyond basic ‘on/off’ or ‘high/low’ capabilities. Further, it was becoming more difficult to keep up with the various types of cables used for digital and analogue sensors. Each required a different installation configuration and needed to be stocked in case of performance problems. These factors resulted in the creation of IO-Link technology. As a standardised interface, it works in even the smallest of devices. IO-Link devices can be easily integrated via an IO-Link master to different fieldbus environments or automation systems. For easy installation a single cable is run from an IO-Link device (such

June 2020

as a sensor or actuator) to an IO-Link master, which controls communication with devices and links to networks like EtherNet IP or Profinet to share information with the control system. Data is then transmitted from the IO-Link master via a high-level fieldbus communications protocol to a PLC or computer.

level is ‘high’ or ‘low’, for example, smart sensors utilising IO-Link can provide current temperature readings.

What is IO-Link?

• Data storage: IO-Link masters have the capability to store up to 2 KB of the parameters that impact how a sensor or actuator functions. When a device connects to the IO-Link master, the correct parameters are automatically uploaded. This makes things like sensor replacement quick and easy, with no need for manual intervention once the device is installed. • Remote configuration and monitoring: Device and sensor parameters can be changed

IO-Link is a simple point-to-point communications protocol used to link sensors and actuators to the fieldbus or industrial Ethernet. It was created to make sensors smart. Without it, simple sensors can communicate one parameter: on/off, no object/object present, high/low, etc. With IO-Link, even small sensors can communicate much more data – and can translate data into actual values. Instead of telling you whether a temperature

www.controlengeurope.com

The value of IO-Link In addition to facilitating fast, costeffective communication among devices to reduce downtime, IO-Link offers other benefits:

Control Engineering Europe

I/O MODULES & SYSTEMS remotely as needed, saving time in the manufacturing process to accommodate things such as product changeovers (shifting from small bottles to large bottles on a production line, for example). This also makes it easier to reconfigure devices in hard-to-reach locations. Sensor outputs and status alerts can be monitored remotely in real time to help quickly identify and resolve problems before they cause downtime. • Diagnostic capabilities: Smart sensors equipped with IO-Link can communicate about their own status via the IO-Link master to the PLC. Before processes come to a halt, it enables users to know immediately if a sensor needs to be replaced, requires maintenance or is experiencing an error. This gives

the ability to optimise machine maintenance schedules and diagnose problems with a specific sensor without shutting down the entire line or a piece of equipment

Technology limitations While IO-Link has the capability to streamline manufacturing processes and save valuable time, it does have some limitations: • The cable that runs between the IO-Link device and IO-Link master has a 20m distance limit. • IO-Link devices can transmit up to 32 bytes per cycle, which means that it cannot transmit megabytes of data, for example. • IO-Link is designed for integrated automation applications; if you manage simple, standalone

applications, you may not see a great benefit. Belden has worked to overcome these limitations. With the addition of IO-Link hubs to its LioN-Power IO-Link System, for example sensor and actuator connectivity can be improved. LioN-Power IO-Link hubs connect up to 16 standard digital I/O signals on one end and transmit them to the controller via IO-Link. When combined with LioN-Power IO-Link masters, up to 136 digital I/O signals can be cost-effectively transmitted up to 20m from the IO-Link masters. plus-circle. Svenja Litz is product manager at Belden Deutschland GmbH and Kate Zimmerman is marketing communications manager – Industrial Markets at Belden Inc.

Modular I/O solution for mixed IP20 and IP67 applications In addition to centralised automation technology, there is also an increasing need for decentralised, intelligent control systems to bring greater flexibility to production environments. Weidmuller has responded to this need with u-mation, a modular hardware portfolio which can be flexibly combined and extended and which applies equally to a traditional panel application as well as a decentralised controller. Part of this portfolio includes u-remote, a remote I/O concept consisting of a range of modules that allow users to connect signal systems in the panel, in mixed IP20 and IP67 applications or directly in the field. Benefits are said to include speeding up of the installation process. Where systems grow to a size where the count of signals is too great for the cabinet, the UR67 provides an I/O and fieldbus solution for the collection of local signals. It encapsulates signals with IP67 protection at the very point where sensors and actuators are located. It supports common fieldbus systems, while incorporating multiprotocol variants for those wishing to standardise on an I/O block. UR67 is said to offer a solution where production environments require a high number of sensors and

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actuators in the field need to be connected to a central control system. The UR20 multi-protocol distributed remote I/O allows users to keep their remote I/O station as compact as possible. The header module also provides individual current paths for inputs and outputs, resulting in fewer additional power feed modules for larger systems to keep systems compact while providing flexibility for expansion.

UR20 is a multi-protocol distributed remote I/O.

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June 2020

PRODUCT DESIGN

A SOLUTION FOR COMMUNICATIONS IN PROCESS AUTOMATION Thomas Brand explains how a measurement controller was designed so that it is well prepared for Industry 4.0.

he shift toward digitisation, driven by Industry 4.0 and the Industrial Internet of Things (IIoT), can be seen in industrial automation technology. The production floor is changing and individual production sites are being networked to allow them to communicate with one another and between different company divisions or even across company boundaries. The effectiveness of overall production can be significantly increased through condition monitoring and optimisation of mechanical installations and technical systems. However, this requires constant communication between all participants in the enterprise, whether human or machine, to exchange countless volumes of data and a wide variety of parameters. Where connectivity was once handled relatively simply – the analog sensor signals from the various systems were transmitted to a central controller and digitised there – in the era of Industry 4.0, digitisation is shifting toward the sensor. The implementation of smart, intelligent sensors that can be integrated anywhere in a complex network allows them to pass on the digital form of the recorded physical quantities over the network. As shown in Figure 1, apart from the actual

measurement parameter sensing, this intelligent sensor unites a major part of the signal conditioning and processing in one housing. Furthermore, the smart sensors are often already equipped with a bus interface. Through the digitisation of the measured parameters, significantly more data can be transmitted and at a faster speed. Another advantage lies in the more robust signal transmission. Through the digital signal transmission, signal changes and interference can be lessened or even completely prevented. In addition, in the ideal case, the busenabled sensors can be connected to the network via plug and play, meaning they are automatically detected by the control unit. If one sensor fails, the others continue to function.

Network solutions However, all of this requires an omnipresent, reliable, and real-timecapable network extending from the individual sensors and actuators to the machines and finally to the complete systems. Ethernet – especially Industrial Ethernet – has emerged as a key set of communication standards. Compared with previous field buses, Industrial Ethernet provides decisive advantages such as efficient and synchronous transmission of larger data volumes

on a shared transmission medium. In addition, Industrial Ethernet offers the possibility to create the entire communication on a uniform basis, which complements the classical Ethernet with real-time extensions for determinism. It was for this type of application that Analog Devices (ADI) launched a real-time Ethernet multiprotocol (REM) switch chip family, the fido5000, to the market last year. The family features two TSN-enabled Ethernet ports to realise, for example, line, ring, star, and redundant star network topologies. In addition, any host processor can be connected with the switch chip through its configurable memory bus interface. The flexibility of the fido5000 REM switch allows developers to future-proof their designs despite constantly evolving standards because it supports every current Industrial Ethernet protocol. These advantages were realised by the JUMO Group which develops and manufactures products and system solutions for measurement, control, and analysis of physical and chemical quantities for a wide variety of industries. All of the industries served by Jumo require a variety of process data to be communicated over large networks – an ideal application for the fido5000 and the reason why it is used in one of the

Figure 1: Transformation from a simple analog sensor to a smart sensor. A smart analog sensor includes the complete signal chain and the processing unit.

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PRODUCT DESIGN latest JUMO designs, the DICON touch. The DICON touch is a 2-channel process and program controller that can be visualised via a TFT color graphics screen and can be operated intuitively by touch. Besides providing the RS422/RS-485 MODBUS RTU, Ethernet, and PROFIBUS DP interfaces that were previously available, the latest DICON touch also makes it possible to connect and communicate with a PROFINET controller. This is enabled by its integrated fido5000 2-port switch, which allows simple network topologies to be established. The network application has integrated features that include evaluation of registration data, setup configuration, and web server functionality for online visualisation, which are available along with the PROFINET real-time data exchange. Conformity to the PROFINET standard and compatibility with applications from various manufacturers are guaranteed through certification. With JUMO, ADI moved beyond being a supplier of individual components and into the role of being a true design partner. “With Analog Devices, we gained a competent partner that has supported us extremely professionally in developing the PROFINET interface for our multichannel process and program controller JUMO DICON touch,” said Klaus Otto, product manager at JUMO GmbH. In the development of the DICON touch, ADI has a solution for the requirement of designing all devices based on the Ethernet protocol PROFINET. The challenge was to develop a device that was as universal as possible to offer customers a large number of possibilities. The DICON touch was to be developed as a modular, powerful concept: with a simple plug-in card and an integrated PHY for standard Ethernet or, alternatively, with an extended plug-in card with PROFINET functionality. “In the development, we placed special focus on an individual PROFINET solution that was not yet available on the market with such a functional range,” said Otto. Control Engineering Europe

The DICON touch 2-channel process and program controller is the first JUMO product to have a PROFINET interface.

In addition to the fido5000 REM switch chip, the integrated RapID platform was used. It demonstrates a complete solution based on the fido5000 as an embedded design. It combines the fido5000 switch chip, a communication processor, JTAG interface, and PHYs, as well as different memories like Flash, SDRAM, and EEPROM, all on one board. The next generation of this RapID platform will include a more powerful and powersaving ARM Cortex-M4 processor as a communication processor, on which additional processes can be implemented, depending on the requirements. For the development of the DICON touch, the properties of the existing RapID platform – including the availability of common precertified Industrial Ethernet protocols – were very much in JUMO’s interests. The possibility to download all relevant information on the RapID platform, including circuit diagrams and layout data, considerably reduced development time. Another interesting feature of the RapID platform, which is also on the DICON touch, is the dynamic, integrated web server that can be used to read or change network parameters as well as input and output data in a very simple way. Also, it is possible to configure the PHY via RMII and I²C interfaces. In addition, the PROFINET module can be

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updated on startup because the firmware is mirrored on the DICON touch. Thus, the RapID platform’s flexible configuration for the DICON touch also enables firmware updates and network access. There were also no limits placed on creativity in the development of the DICON touch. For example, the standard blinking LEDs, an important feature of PROFINET, were not implemented on the electronics. Instead, the complete LCD display of the DICON touch will blink. Cybersecurity also played a key role in the development of the DICON touch. Cybersecurity for industrial controllers cannot be addressed with a one-sizefits-all solution. Instead, a far-reaching approach must be taken based on the risk assessment for the system. As part of its security strategy, ADI concentrates on making all of its Ethernet components as secure as possible. Current Industrial Ethernet and TSN solutions are thereby one focus of the company’s security developments. The fido5000-based RapID platform was supplemented with security features that offer key management, secure boot, secure updates, and secure memory access to protect against cyberattacks. plus-circle. Thomas Brand is a field applications engineer at Analog Devices. June 2020

DRIVES & MOTORS

BRINGING OLD TECHNOLOGY INTO THE DIGITAL ERA Control Engineering Europe finds out how a traditional mains-driven geared motor can be integrated into the IIoT without the need for a frequency inverter.

nvented in 1889, today the squirrel cage asynchronous motor is still one of the most frequently used electric motor designs for standard industrial applications. Integrating geared motors into the Industrial Internet of Things (IIoT), would allow operators to benefit from greater precision, energy efficiency and reduced maintenance costs. But, how can such traditional, passive technology be brought into the digital world? Bauer believes it has found a solution with TorqueControl4.0, an electronic controller which is able to convert a passive asynchronous geared motor into a smart drive, communicating data via IO-Link. Simon Scharpf, research and development engineer at Bauer explains more about the history of Torque Control4.0: “A customer asked us to investigate an alternative to mechanical overload clutches. The company was looking for a solution that would be more efficient for torque monitoring and control of conveyor systems. It

wanted to improve performance during operation and reduce reaction time in the event of torque overload. We quickly identified that an electronic solution was the best way to achieve this and it would also offer the added advantage of communicating real world data to the cloud via IO-Link.” Mechanical torque limiters protect the drivetrain by designing in failure when a specific torque load is reached. This is an effective, if simple, means of protection for applications such as conveyors where a foreign object could obstruct the drivetrain and generate unexpected loads. Most modern mechanical torque limiters will also feature a sensor which can alert the operator should an overload occur. However, in this event, the mechanical clutch needs to be partly disassembled and then reengaged, which prolongs any downtime encountered by the operator. The mechanical system is also self-contained and only allows for binary control – whether it is engaged or disengaged.

TorqueControl 4.0 is suited to operations involving material handling, intralogistics or processes that need to start under load.

June 2020

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TorqueControl4.0 is an intelligent, electronic control that allows all mainsdriven Bauer geared motors to be integrated into an Industry 4.0 network cost-effectively without the need for a frequency inverter. This makes it possible for the operator to set a flexible – yet precise – overload torque and constantly monitor performance. In the event of an overload being detected, the central controller can communicate the information to the production line and put all equipment on hold while the overload situation is resolved. Once the issue has been addressed it is a simple process to restart the system over the network. The ability for TorqueControl4.0 to connect with the Industry 4.0 network via IO-Link allows environmental data from a standard geared motor to be monitored and reacted to in real-time, and because it is integrated into the motor’s terminal box, the motor will retain its standard IP rating. “TorqueControl4.0 allows monitoring of the operational status, hours running, temperature and load cycle,” continued Scharpf. “It can also effect independent shutdown of the torque while providing status data such as current, voltage or power. Parameters can be set to shut down the drive within milliseconds in the event of an overload, preventing any damage to the drivetrain. At the same time, operators can limit the starting current in the same way as a conventional soft start. By allowing continuous load-point monitoring, TorqueControl4.0 will be able to adjust the voltage to run the drive efficiently while under partial load. We estimate this increases motor efficiency by up to 25% in some cases.” plus-circle Control Engineering Europe

DRIVES & MOTORS

MEPS SET TO INCLUDE ATEX MOTORS Marek Lukaszczyk explains the changing energy efficiency regulations for hazardous area motors.

here are over eight billion electric motors in use across Europe, consuming approximately 63% of the electricity generated. In a bid to cut energy consumption from electric motors, Minimum Energy Performance Standard (MEPS) was introduced in 2009 by EU Commission Regulation EC 640/2009 which required motors of 0.75-375 kW to reach international standards set by the International Electrotechnical Commission (IEC) for single-speed threephase motors. IE1 describes standard efficiency, IE2 is high efficiency and IE3 is used for motors with premium levels of efficiency. Updates to the legislation in 2016 specified that electric motors require an energy efficiency class of at least IE3, or IE2 class if the motor is used with a variable speed drive (VSD). The regulation, bolstered by improved design and materials for electric motors, brought about huge improvements to the energy consumption related to motor use. More recently, the European Commission’s (EC) ecodesign committee has approved a new, stricter version of the ecodesign requirements, which take effect from July 1, 2021. Previously, the scope of the regulations only covered 3-phase motors ranging from 0.75 kW to 375 kW, leaving motors outside this power range excluded. From 2021, this will no longer be the case. The new regulation will require all new 2-, 4-, 6- and 8-pole motors in the power range of 0.751000kW to meet IE3 efficiency class. The previous legislation allowed for an IE2 motor to be used provided it was controlled by a VSD, but this will no Control Engineering Europe

longer be valid. Sizes from 0.12-0.75 kW will need to meet IE2 class. Special purpose motors, such as explosion-proof or flame-proof motors, were exempt from the previous regulation, out of precaution for the higher-risk environments they were used in. From July 2021, new ATEX motors entering the supply chain must be rated IE3 or higher with increased safety motors Ex eb being the exception. These motors will need to be at least IE2 efficiency level by 2023. In energy-intensive industries, such as chemical, pharmaceutical or oil and gas, thousands of motors often operate 24 hours a day. Even a slight improvement in efficiency, extrapolated over the sheer volume of motors and hours of operation, will benefit the businesses’ bottom line. Energy costs for electric motors can account for up to 97% of total life cycle

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costs, depending on the application. Investment in energy-efficiency drives and motors – even if not through choice – will usually provide a very short return on investment. The legislative changes will impact many industries, but sectors with high energy usage or employing hazardous area motors may see the most transformation. The new regulation, which will impose new minimum efficiency requirements for ATEX motors, could lead to very significant energy savings in the chemical sector. The food industry will also be impacted, as there are many applications using hazardous area motors where there are high levels of combustible materials such as flour or dust residues. Marek Lukaszczyk is european and middle east marketing manager at WEG plus-circle. June 2020

PLCs & PACs

OPEN-SOURCE BENEFITS FOR INDUSTRIAL CONTROLLERS Bill Dehner explains how new controller options make it possible to add open-source features to industrial-grade automation.

ndustrial microcontrollers are bringing open-source benefits to industrial applications even though many industrial automation technologies seem to be a frumpy distant relative of the glitzy consumergrade hardware and software so common in our everyday lives. Industrial controller technologies are closing the gap with consumer cousins, which is creating some significant and unexpected benefits for end users. Industrial automation technologies, including controllers, are often portrayed as developing at a slower pace when compared with consumer technologies, and rightfully so. The lag is explained because consumer technologies only will be adopted into more conservative and rugged industrial applications after proven and accepted in the mass market. Because industrial applications need to reliably operate potentially dangerous equipment for years, it is more important for automation products to be carefully crafted and packaged. This means other controller features, such as ease of use and good connectivity, are often secondary considerations. Over the past 15 years or so, a ‘maker’ culture has gained momentum in the consumer world. This community brings a passion and creativity to using PCs and microcontrollers to operate all sorts of do-it-yourself projects. Most of these developers make these homebrew projects ‘open source’ for anyone to use, but the technologies usually aren’t ready for the factory floor. Industrialised microcontrollers now combine open source benefits with proven industrial platforms to give

June 2020

end users more automation options.

Open-source processing Open-source projects are relevant for industrial applications in many ways. For example, the common Linux open-source operating system has played an increasing role in the past few years as it is embedded within Industrial Internet of Things (IIoT) implementations and as a platform for running control and visualisation software. Open-source programmers make code snippets and programs available to all users, generally at no cost. Many would consider this open nature as increasing risk to those implementing it. However, greater openness makes code available for anyone to inspect, and the large community of developers can provide a quick response when issues are identified. From an open hardware standpoint, the two leading microcontrollers are Raspberry Pi and Arduino. The former is more like a miniaturized single-board PC, while the latter is more barebones. For Arduinos, stackable accessory boards called shields add Ethernet, Wi-Fi, GPS, and other extended functionality, making these systems well suited for prototyping and hobbies. Microcontrollers like the Arduino were created for students learning to program in C++ and are designed to be usable by those with any level of

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Arduinos and similar microcontrollers are a staple of the maker community, enabling many hobby-focused computing and automation projects. All images courtesy AutomationDirect.

programming experience. An effectively free and extensive software library, many low-cost hardware options, and an end-user design focus have made this open-source concept a favorite of the maker community. Microcontrollers’ popularity has made the industrial automation industry take notice because many of the features desired by hobbyists also are needed for industrial projects. Some end users have even incorporated consumergrade microcontrollers into industrial applications, but there is some risk involved related to the differences between commercial and industrial specifications.

Open-source programming benefits End users choosing open source for their automation project will certainly benefit from the mashup of contemporary programming options with proven Control Engineering Europe

PLCs & PACs microcontroller at home to remotely control lights and other devices also could extend the same concepts to automate lighting and environmental controls at a commercial or industrial facility.

Industrial environments New products, such as AutomationDirect’s ProductivityOpen, offer a way to combine open-source microcontroller functionality within an industrial-grade form factor with I/O designs.

industrial practicalities. Users can mixand-match many ways to get just what they need. Sometimes, it makes sense to continue using a programmable logic controller (PLC)-based system, while adding an industrialised open controller networked nearby to perform specialised tasks or calculations. In some cases, users can develop all the control logic and general-purpose calculations in the open controller, and then automate associated equipment with input/ output (I/O) devices. Another consideration involves design and maintenance personnel skill sets. While existing industrial users have been trained on PLCs through their careers, the next generation of users are more likely to be comfortable with contemporary technologies and programming languages used in maker hardware. This platform can bridge open controllers with PLCs and I/O, industrial manufacturers can apply their current skillsets while growing their technical staff with new employees who would prefer to work on modern open-source platforms.

solution for operating machinery, while incorporating more advanced algorithms and data handling than they would with a PLC. Open source also can be a great fit for various semi-industrial applications like environmental controls or laboratory equipment monitoring. More consumeroriented applications such as automated smoker grills, home automation and agricultural projects also become viable with industrialized open-source platforms. A gardening hobbyist might configure a microcontroller to operate a backyard vegetable hothouse and irrigation. At work, they could use these same concepts to automate much larger-scale agricultural systems and equipment. Someone using a

The proliferation of consumer-grade microcontrollers might be a tempting automation choice, especially for machine manufacturers, due to the low hardware cost. However, any controller unable to withstand an industrial environment will drain support budgets because up to 20% of operating expenses are typically maintenance-related. Now that PLC and programmable automation controllers (PACs) technologies have evolved to include industrialised opensource hardware options, end users can incorporate modern automation systems they want using the robust platforms they need. plus-circle Bill Dehner is technical marketing engineer at Automation Direct. This article originally appeared on www.controleng.com

Open-source controller applications As industrial open source gains momentum, users will continue to find new applications. A basic way to use an open controller, even for those who are new to C++, is to configure it as an inexpensive data logger. Original equipment manufacturers (OEMs) can use open controllers as an all-in-one Control Engineering Europe

Unlike consumer-grade controllers, industrialised controllers are tested in extreme conditions to ensure reliability in the field.

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June 2020

REMOTE OPERATIONS

IMPROVING REMOTE OPERATIONS Jason Urso highlights five areas to improve remote operations – a subject of growing importance today to keep manufacturing sites running.

ndustrial organisations are striving to keep workers and communities safe and healthy and contending with the effects of the Covid-19 pandemic to the economy, to supply chains and operations. As the pandemic spreads, plant owners/ operators seek ways to change how they work. This includes refineries, chemical plants and manufacturing facilities. With the loss of human assets from the pandemic and retiring of experienced workforce, it has become clear the on-site operating model must change quickly. Benefit from digitisation: Digital effectiveness is key to staying ahead in today’s manufacturing environment. An emphasis on digital asset and process management will enable plant operating companies to achieve new levels of efficiency, productivity and safety. Tools include the latest technologies in sensors, connectivity, data capture, visualisation and advanced analytics. Activities such as remote monitoring and operations, condition-based and predictive maintenance and real-time operator intelligence can help. Transition to remote plant operations is made easier with secure digital tools. Remote monitoring and operations software can be cybersecure without increasing plant risk. Evaluate remote operations: To help industrial organisations meet their business objectives, automation suppliers have developed innovative remote operations solutions, which provide the expertise, skills and technology capabilities customers need to operate in a difficult business climate. Remote operations help with running complex manufacturing plants and this relies on a modern automation infrastructure. Using

June 2020

data from process or assets, plant personnel can manage daily production, maintenance and safety and improve multiple sites. They can operate the plant, track production targets, monitor asset health, and create scenarios to determine the effect of operational changes prior to implementation. Remote capabilities support installed automation systems, networks and devices, and migrations. Use safety, digital, monitoring: Remote operations and support strategies can lower worker risk compliance with social distancing guidelines may require reducing the number of onsite employees. This will help protect workers who are onsite and keep operations running. It is important to support them with advanced safety equipment and use tools such as digital video systems for the facility’s security as well as monitoring access control systems, so it is clear who is on site. Physical equipment and devices can be remotely monitored with a secure app, giving plant operators visibility of critical processes on a mobile device. Use services for remote operations: Technical service and support can be performed remotely, including remote consultation and maintenance and video collaboration and troubleshooting. With a wearable device, workers can help the remote team identify issues and troubleshoot in real time. During a production problem, team members can access systems and collaborate to solve the matter remotely. This helps plant personnel perform essential tasks with the knowledge and insights required to do the job correctly and maintain operational uptime. Update controls and cybersecurity: Modernisation can be achieved

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Wireless process transmitters can help remote operations, as shown at the Honeywell Users Group Americas, June 2019. Image courtesy: Mark T. Hoske, CFE Media and Technology

through plant automation and cybersecure software updates. Experience has shown remotelyoperated migration methods for upgrading control systems offers lower risk, flawless execution and lower costs. A remote controls modernisation can minimise risk, time and effort in field and improve a migration experience. This approach can reduce cycle time by up to 80%, lower operational cost by as much as 20% and improves migration productivity by at least 60%, with the latest cybersecurity and process control improvements. Virtual training using augmented reality (AR) technology can enhance skillsets with an ‘on-call’ operator where needed. plus-circle Jason Urso is chief technology officer for Honeywell Process Solutions. This article originally appeared on www.controleng.com Control Engineering Europe

COMMENT

LEARNING LESSONS AND TAKING BACK CONTROL While we are still embroiled in the battle to contain and defeat Covid-19, nobody truly knows the eventual outcomes – but we can begin to assess the impacts and respond positively to change, says Steve Sands.

he impact of the Covid-19 pandemic has varied enormously, with some companies massively increasing production, some re-purposing their plants to new demands or opportunities; while others are having to prioritise for survival and damage limitation, furloughing or even laying off staff as production is halted. With a global recession predicted, it is vital that we assess the learnings and take back control. There is no way back! The pandemic has transformed the nature of work. The challenge for new homeworkers hasn’t been how to work effectively, but how to ensure they maintain a quality home life. The reduction in travel has increased productive working hours and all this could have an irreversible effect on our car and aerospace industries: but our environment and wellbeing are benefitting already.

Digital adoption? Massive and unpredicted consumer demand spikes have challenged production and logistic capabilities, particularly those based on rigid pre-planning. The next phase of the pandemic will call for increases in automated testing, sample preparation and laboratory analysis and then, when clinical trials are successfully concluded, there will be increased demand for vaccine and drug production. These may be extreme examples, but they highlight the increasing need for production agility across manufacturing; the ability to cope with rapid changes in demand through a fast reacting supply chain. These aren’t the only characteristics that align to Industry 4.0. The rate of digital adoption as a result Control Engineering Europe

of the pandemic is being massively accelerated. The UK Government’s Ventilator Challenge showed what can be achieved in an incredibly short space of time. In a matter of days, it required designers to meet strict regulatory requirements in a complex, high dependency, medical device. What did it take to compress the development process from years to days? • A common sense of purpose created engagement and a determination to succeed. While commercial organisations are not going to create the same imperative as an impending health disaster, leaders can consider the parallels in creating effective cross-team collaboration. • An effective project management office, bringing together all stakeholders, including suppliers, to determine the best way forward. The value of this was especially important in the early stages, where they could have the greatest positive impact. • Breaking down silos, creating flexibility and collaboration within teams of specialists working to a common agenda. This allowed experts with many years’ experience, knowledge and skills to ‘roll up their sleeves’ and be directly engaged in the process. It resulted in a ‘dream team’ approach and delivered the results needed. • The adoption of virtual meeting and project management tools like MS Teams enabled the storage and realtime sharing of critical data as well as the ability to conduct meetings throughout the project duration. Teams working in shifts could continue to drive developments 24/7.

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The rate of digital adoption is being massively accelerated by the current pandemic.

As the ventilators moved from design projects to production, the ability of companies to re-tool and re-purpose their facilities came to the fore. Manual assembly is highly flexible, but it cannot achieve the efficiency of automation. The valiant efforts of individuals and organisations making medical masks has helped to plug critical shortfalls; but highly automated, local plants would be a far more effective long-term solution to deliver the required quantities at the right price, quality and speed. To conclude, automation provides resilience to disruption. Bringing processes and control closer to market needs further protects production. This won’t just be ‘pandemic proof’ production: it will increase output agility and protect organisations from single source of supply bottlenecks. It will put us back in control. plus-circle Steve Sands is product and marketing manager at Festo UK & Ireland. June 2020

ARTIFICIAL INTELLIGENCE

AI: HELPING BUSINESSES ACT WITH INTELLIGENCE Adi Pendyala comments on the importance of AI adoption, right across the enterprise.

hile the term artificial intelligence (AI) is wellrecognised, it can mean different things in different situations – and as such, it can be tricky to define. While most people think of AI as a technology in its own right, in reality it is more of a general term used to refer to a number of different technologies that enable systems to act intelligently. When it comes to business applications, AI can support intelligent functionality by helping the system sense, understand, perform and learn. By using machine learning or deep learning to train a system, the system can assess how to act in each situation by analysing data, rather than relying on prescriptive, hard-coded actions. The resulting agility and responsiveness mean that quality, accuracy and overall performance can be improved – and this is what makes the system truly intelligent. In the current climate and with uncertain times ahead, several enterprises are looking at how they can adapt and accelerate their digital transformation strategy. With remote collaboration, operational agility and autonomous production becoming evermore critical to business continuity – the importance of AI is on top-of-mind of many executives today.

Machine learning What sets AI apart from other automation technologies is its ability to learn and adapt. In an industrial environment AI systems can have a significant impact on business performance by reducing manual labour: quickly identifying patterns in

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large amounts of data and analysing and extracting features from both structured and unstructured datasets. Most importantly, it can learn from these tasks and improve over time. Machine learning can be executed in a number of ways – supervised learning, unsupervised learning and reinforcement learning. Supervised learning uses pre-organised training data and feedback from humans to learn the relationship of given inputs to a given output. This method is useful if the input data and predicted behaviour type is already classified, but the algorithm needs to be applied to multiple different datasets. Unsupervised learning does not require any pre-defined labels in the data – no output variables need to be pre-identified, and the algorithm can analyse input data to find patterns and make classifications. And reinforcement learning allows the system to learn to perform a task by trial and error.

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In essence, this method is based on rewards and punishments, with the overall aim of maximising rewards and minimising punishments in the feedback received for its actions. This approach is particularly useful when there is not a lot of training data to use, it’s difficult to identify the desired outcome and this is the only real way to interact with and learn from the data.

Why, what and how? In an increasingly digital world some organisations are looking to AI to revolutionise more than just their technology: they want it to redefine business processes as a whole. From pioneering innovation to everyday customer service, AI is transforming the business landscape, and defining this paradigm shift is the key to understanding enterprise AI. The ‘Constellation of AI,’ a paradigm introduced in the book Human + Machine: Reimagining Work in the Age Control Engineering Europe

ARTIFICIAL INTELLIGENCE

of AI by Paul R. Daugherty and H. James Wilson, is one such framework that exists to try and explain the application of AI on an enterprise level.

applications can be simplified and fully assessed to allow enterprises to build an all-inclusive AI program, analyse and define the business value for

In the current climate and with uncertain times ahead, several enterprises are looking at how they can adapt and accelerate their digital transformation strategy Using this framework, enterprise AI can be viewed across three levels. The first level identifies the ‘why’ and the ‘what’ – the business applications that use data to provide greater value to its stakeholders. The second level identifies the suite of AI capabilities that can be leveraged to power the business application. And the third level looks at the ‘how’ – which machine learning methods can deliver the pre-identified AI capability. Using this framework, the complexities of AI-based business

each AI initiative, and determine the basic requirements that would drive a successful AI program and justify investment.

The future While there is clear business value in adopting enterprise AI, asset-intensive, process-based industries are significantly behind other sectors when it comes to implementation. This is largely due to the need for new skills and a lack of quality data.

When managing real pressure is your job… MIPC® helps engineers stay on-site and on top of the latest industry developments and good practice in primary containment of hazardous substances.

Adi Pendyala is a senior director at Aspen Technology.

MIPC® shortlisted for the Best E-learning/ Online Education Initiative memcom membership excellence awards 2020

Using a blend of live, online classes, one-to-one sessions with expert tutors, and e-learning, enhanced by a mentor’s support and guidance, EEMUA’s Mechanical Integrity Practitioner Certificate course delivers in-depth training to engineers where they work – to give professionals the flexibility to learn on-site or on-call. Induction for the next EEMUA MIPC® training course begins in July 2020. For more information please contact EEMUA online-learning@eemua.org +44 (0)20 7488 0801 www.eemua.org

According to Gartner, 56% of enterprise leaders feel they need updated skills to accomplish AI-enabled tasks, and 34% say that poor data quality is a key concern. 42% of Gartner respondents also said they don’t fully understand the benefits of AI or the implied return on investment (ROI) due to the challenge of quantifying the benefits of AI. However, by 2024 ROI will be measured by quantifying AI investments and linking them to specific KPIs – giving the future of enterprise AI a clear direction of travel in terms of measurement and real-world statistics. And by establishing a common understanding of AI’s enterprise value and setting out clear guidance for business application, organisations can capitalise on the simple Constellation of AI framework to implement successful AI projects, now and in the future. plus-circle

SIMULATION

MAXIMISING OPERATIONAL EFFICIENCY AND PRODUCTIVITY Tim Bednall explains why running discrete event simulation (DES) on existing processes can help identify and unlock additional production capacity.

utomation has proven to be a valuable asset in addressing many of the issues that face manufacturers today. However, many manufacturers still remain under pressure to improve productivity and output levels even further. Investing in additional machinery or automation to meet these demands is one option. However, there are instances where subtle changes to an existing process can help yield additional production capacity. The challenge is identifying which areas of the process holds potential for improvement. Most automated manufacturing systems are designed to meet detailed technical specifications and production efficiency targets. Once installed, they are then fine-tuned to meet these criteria, and the prime objective then is to maintain these production and up-time levels. However, today there is pressure to increase production levels. The dilemma is two-fold, it is likely that the customer will want to see the increased capacity quickly, and the manufacturer may not have the time or the capital expenditure available to invest in additional equipment. Discrete event simulation can be used to analyse the existing process step-by-step and identify bottlenecks or areas where the current process can be improved. Discrete event simulation models break down the process into a series of different events or smaller operational blocks, which can then be triggered as required. The process is effectively analysed at the lowest levels including the distances that parts travel, where they move to, the speed at which they travel and, of course, process times. In one example, a manufacturer was

June 2020

Following a discrete event simulation the capacity of this system was increased from 30 units per hour to 50, with just some subtle changes to event timings.

tasked to increase production from the current level of 30 units per hour to a throughput of 50 units per hour. An initial overview performed in-house by the customer suggested that a specific part transfer operation was restricting the output from the line. However, when we ran a discrete event simulation it was determined that subtle changes in timings in various areas of the line would allow the system to achieve the 50 units per hour target. In addition to this, the transfer operation initially thought to be the bottleneck by the customer, proved to actually have additional capacity following the simulation. In another example, the customer was considering linking two consecutive process steps, carried out in separate systems, with a view to having dual systems, each of which performed both processes as a means of increasing throughput. We performed a discrete event simulation based upon the current configuration, operational sequences and timings of the existing equipment and then followed that with another simulation taking into account the proposed changes. The outcome of this simulation proved categorically that there would be no benefit from the

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proposed changes. However, further evaluation of the application through the simulation model identified that, even with restricted floorspace, it would be possible to integrate additional equipment which would achieve the increase in output desired. Running discrete event simulation on processes or machines makes it possible to predict output and performance over an extended period, such as a year, in just minutes, by running the simulation at enhanced speeds. It is also possible to build in additional factors including mean-time-between-failure and meantime-to-repair to provide a holistic view of the process over time. Manufacturers will continue to seek ways to enhance productivity and output levels from their existing automation systems. Discrete event simulations are very often used as a relatively quick and cost-effective contribution to a continuous improvement process, which can identify and unlock efficiency savings, quality improvements and additional production capacity. plus-circle Tim Bednall is sales & marketing manager at Wood Automated Systems UK. Control Engineering Europe

PRODUCT FORUM •

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Alarm systems management

Complex industrial systems require complex control systems – but carefully thought out alarms systems EEMUA is the acknowledged leader in the field, with EEMUA 191, ‘Alarm systems - a guide to design, management and procurement’, being regarded as the benchmark in alarm systems management. The EEMUA Alarm Systems e-learning module provides an introduction to EEMUA 191 and is positioned at the awareness level. It offers simple and practical guidance to managers, designers, supervisors and operators on how to recognise and deal with typical human-factor problems involving alarm systems. Its scope covers many sectors, including the energy, process and utilities industries.

The e-learning is recommended for both discipline and project-focused engineers from a variety of backgrounds who want to gain an introduction to the fundamental principles for design, management and procurement of alarm systems. The course is also relevant to engineers and managers from operating companies as well as specialist contractors and equipment suppliers. Visit the EEMUA website for further details. www.eemua.org

TO BE FEATURED IN THE CEE PRODUCT FORUM Contact Adam Yates on +44 (0)7900 936909 or email Adam.Yates@imlgroup.co.uk Creating a successful control environment Know what you want, plan what you’ll get, check that you’ve got it! The EEMUA Control Rooms e-learning module provides guidance to engineers and the wider teams involved in the design of control rooms, control desks and consoles. It will help during newbuild and modification projects, as well as evaluating existing set ups where people operate industrial processes and activities on facilities such as chemical plants, power stations and oil refineries. The e-learning will benefit anyone with an interest in process plant control rooms and control desks using Human Machine Interfaces. It is especially relevant to control engineers, control room console (and HMI) designers and vendors, control room operators, engineering consultants, engineering contractors,

Control Engineering Europe

engineering managers, facilities managers, graduate engineers, plant operations managers, process safety managers, SCADA engineers and systems support managers. The e-learning is positioned at the awareness/introductory level and is an optional precursor to working through EEMUA 201, ‘Control rooms: A guide to their specification, design, commissioning and operation’. Visit the EEMUA website for further details. www.eemua.org

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June 2020

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OPC UA for Field Level Communication – A Theory of Operations Version 1 // June 2020

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➞ Modeling: W Updates on OPC UA for Devices extensions W Collaborations: Overview W Harmonization working group – status & strategy W Announcement: New group “UA for Cloud Library”

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