Control, Instrumentation and Automation in the Process and Manufacturing Industries April 2021
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Save money and installation time with seamless connectivity 5G starts to roll out Hyperautomation: what’s it all about? Taking steps to ensure secure OT environments
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The distributed one cable servo system: AMP8000
www.beckhoff.co.uk/amp8000 As a specialist for PC-based control technology and one cable automation, Beckhoff enables substantial control cabinet minimization with the distributed servo drive system AMP8000. With a servo drive directly integrated into the servomotor, AMP8000 allows the supply of several distributed servo drives with virtually unchanged power ratings* and installation sizes via the one cable solution EtherCAT P, which combines communication and power supply on one standard cable. Space requirements, installation effort, material costs and footprint are significantly reduced. sizes remain almost identical to the AM8000 servomotors no changes in existing machine designs required same high power ratings as before despite power integration* *Compared with a combination of servo drive and servomotor
CONTENTS Moving forward, staying safe
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 David May G and C Media
Group Publisher Production Manager Studio Design
In what would have been the issue that normally contains a preview of the annual Hannover Messe, I can only wonder when I will once again get to attend a live event. The pandemic continues to present us with a roller coaster ride of ups and downs. While in the UK we are promised that very soon we will all be able to meet up again, some parts of Europe are looking likely to enter another period of lockdown as infection rates increase. I hope that you are all staying safe, and that things will improve for us all in the very near future. In this issue, the focus has been put on cybersecurity, as we report on the steps that should be taken to ensure OT environments are secure from attack. We have been warned that risks are growing, as more attackers look to make money from easy to access systems. I was, therefore very surprised to hear that in the UK nearly 57% of manufacturers faced a cyberattack in 2020 – this is obviously an issue that still needs attention and it is vital that, as an industry, we stay one step ahead of would be attackers! Suzanne Gill Editor – Control Engineering Europe suzanne.gill@imlgroup.co.uk
INDUSTRY REPORT
INDUSTRIAL 5G
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20 5G starts to roll out
Industrial networking training programme created; Global ‘State of 5G’ survey published
21 Is 5G paving the way for Industry 4.0?
EDITOR’S CHOICE 6
MACHINE VISION
Flowmeters gain a real-time Ethernet solution; World’s first industrial 5G router and starter kit
24 Deep learning opens up new possibilities
CYBERSECURITY 10 What can engineers do to protect their processes and plants from cyberattack? Suzanne Gill asked for suggestions from a variety of industry specialists
LEVEL SENSING 28 We look at a new breed of IIoT sensors that are streamlining the task of remote stock monitoring
FINAL WORD
14 Securing OT systems against cyber-attack
30 Neil Sandhu discusses how the emergence of a new machine vision technology is driving the greater adoption of automated inspection technology
HYPERAUTOMATION 16 Gain insight into hyperautomation technologies and find out what benefits it might offer the industrial sector 17 Digitally transforming businesses with Robotic Process Automation
MOTION CONTROL 18 Simplified transport of sensitive workpieces
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April 2021
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INDUSTRY REPORTS
Do you have an appetite for automation knowledge? Following the UK Government setting down a roadmap out of lockdown, IML are delighted to be able to finally secure a date for the next Appetite for Engineering event, which is set to go ahead as a live event on 9th September, at the Manufacturing Technology Centre (MTC) in Coventry, in the UK.
This educational event brings together food industry experts and engineers, who are actively engaged in the food production sector, to talk about the latest innovations that are aiding lean and efficient food production. To register your interest in attending this live event, which is free of charge for those working in the food
manufacturing sector, go to: www.appetite4eng.co.uk
Amazon Web Services (AWS) joins OPC Foundation Amazon Web Services (AWS) has become the newest OPC Foundation member. Many manufacturers are adopting the AWS industrial data platform to take advantage of AI and machine learning capabilities needed to drive operational efficiencies in smart factories. One of the challenges manufacturers face today is extracting data from industrial assets such as PLCs, DCSs, SCADA systems and Data Historians at scale. Based on OPC Unified Architecture (UA) market acceptance and functionality, AWS adopted OPC UA to support the complex data connectivity challenges manufacturers
face implementing Industrial Internet of Things (IIoT) and Industry 4.0 initiatives. Specifically, AWS makes available OPC UA-enabled tools and a portfolio of services that extend cloud functionality into industrial operations. The tools enable manufacturers to readily ingest OPC UA-based data from industrial assets using AWS IoT Greengrass connectors into AWS IoT SiteWise or their IIoT applications on AWS. “By joining the OPC Foundation, AWS is excited to collaborate with industrial automation leaders as the manufacturing industry continues to transform, powered by data and
Global ‘State of 5G’ survey published Molex has published the results of a global survey of decision makers from telecom carriers exploring the state of 5G and the transformational opportunities it presents, along with its impact on deployment progress, current delivery challenges and emerging business prospects. Overall, carriers are optimistic: more than half of those surveyed expect to deliver substantial end-user benefits within two to five years while 47% reported that users are already seeing value or will within one year. “The 5G market is nearing an inflection point as carriers report steady progress despite continued challenges,” said Aldo Lopez, president, datacom solutions at Molex. “Fully realising 5G’s potential will transform multiple
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industries and markets. It is a long game that requires collaboration across an entire ecosystem of hardware, software and connectivity companies to innovate to these new mobile network standards, which in turn, will accelerate user adoption.” When asked to identify the most important technology or industry changes that will enable network operators to achieve their business goals, respondents cited reduced costs of 5G infrastructure and network equipment (41%); innovation in enabling technologies, including semiconductors and sensors (31%); availability of new types of devices that require connectivity (26%); as well as stable and consistent government regulations (22%).
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innovation,” said Sanat Joshi, director of global business development for manufacturing, Amazon Web Services, Inc. Stefan Hoppe, president and executive director of the OPC Foundation, said: “It is an honor to welcome AWS to the OPC Foundation. Cloud service providers like AWS are enabling Industrial IoT solutions today that are transforming how manufacturers, producers, and others use control automation. AWS’s adoption of OPC UA and its active participation in the community as an OPC Foundation member shows its commitment to open standards-based data connectivity.”
Collaboration to create easy-to-use AI-based imaging solutions Machine vision company, Teledyne e2v is collaborating with Yumain, an AI vision solution provider, to develop bioinspired vision solutions that can enable innovation in industrial applications. The recent emergence of AI for industry has demonstrated its benefits over traditional rule-based methods which have been proven to be unsuitable for applications with high variability. Yet to be harnessed to its full potential AI must be easily setup and trained, optimised by inexperienced users within minutes, must provide reliable results, be flexible in application, secure, and low power. By joining forces, Teledyne e2v and Yumain plan to address these challenges, to make AI technology more accessible. Control Engineering Europe
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Pyrometers. IR Cameras. Accessories. Software. We measure temperature non-contact from –50 °C to +3000 °C. Visit: www.optris.gobal
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The Westermo Academy includes a flexible online learning platform that allows courses to be selected and attended according to the learner’s needs, location and own timetable. All existing courses have been refreshed, to ensure they include the most relevant and up-to-date information and are provided in the most logical and easy to grasp format. Training can be delivered online or on-site/offsite, initially in English, but in local languages in the near future. Many of the courses give attendees hands-on experience to help improve familiarity with, and the efficient operation of, Westermo devices. The training courses are delivered by industrial data communications experts, who also have industry experience aligned with specific applications. Currently, there are four courses available, with an ‘introduction to IP’ and an ‘introduction to WeOS’ providing a gateway to the certified engineer courses focused on switching and routing. Additional courses will be made available that have introduction, fundamental, intermediate, advanced and expert levels of content.
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Westermo has launched a new global training programme aimed at supporting those responsible for operating and maintaining industrial data communications networks. Offering flexible online and in-person training, the Westermo Academy will provide certified courses to network engineers wherever they are located around the world, ensuring they have the expertise needed to maximise the performance and reliability of industrial networks. Industrial networking is constantly evolving to create more complex, resilient and secure networks, and with data networks often the backbone of mission-critical systems, it is essential for engineers to gain regular training updates. “Westermo has provided certified training courses since 2014, with hundreds of engineers attending a course on-site or at one of our training facilities,” explained Fredrik Oskarsson, product manager services at Westermo. “The launch of the Westermo Academy is a significant enhancement of our existing training services, ensuring that our certified courses are available around the world, but also increasing the flexibility and availability of training.”
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Industrial networking training services
Microscopic.
INDUSTRY REPORTS
To find out more about the Westermo Academy and the available training courses go to: www.westermo.com/ support/academy April 2021
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when temperature matters
EDITOR’S CHOICE
Flow meters gain a real-time Ethernet solution Bronkhorst is now able to offer POWERLINK as its 10th on-board fieldbus interface option on its digital flow and pressure meters and control offerings. Ethernet POWERLINK (EPL) is a patent-free, manufacturer-independent software-based communication system that delivers real-time performance. Because it is based on Ethernet communication, it can be applied with standard Ethernet cabling and is able to
support an unlimited number of nodes. With its multi-bus concept, Bronkhorst is able to offer an extensive choice of fieldbus interface options for digital metering and control devices which are applied across a wide range of industries including food & beverage and chemical, gas and fluid analysis equipment, glass and tool coating processes, testing fuel cells for the automotive industry and in machinery used to produce electronic chips, LED lights and solar cells.
World’s first industrial 5G router and starter kit? HMS Networks has released what it believes to be the first commercially available industrial 5G router optimised for industrial private networks. The Wireless Router 5G supports Ericsson Industry Connect 5G networks and allows users to get started with 5G in their own location. HMS also offers a ready-made starter kit for test and evaluation of typical industrial use cases. The Wireless Router 5G allows early adopters of 5G to try out the new technology. With 5G in a factory, users will benefit from a wireless network which is fit for industrial demands in terms of communication speeds and security – along with all the flexibility that comes with wireless. The system has been tested with the Ericsson Industry Connect 5G solution in standalone (SA) operation using band n78.
It enables users to create a robust cellular connection in an industrial production environment. Supporting 4G and 5G cellular technology, it is an ideal communication solution for automated guided vehicles, AGVs, and other industrial machines. The Starter kit includes the Wireless Router 5G and two industrial IO-Link sensors sending data across the 5G network. This allows users to try out 5G in their own facilities without having to set up applications from scratch. Data from the sensors can be accessed using the Modbus TCP and MQTT protocols as well as in JSON format. There is also a web-based demo ready to show the sensor data across the 5G network in a regular browser.
Magnetic gripper for safe and precise collaborative applications OnRobot has launched the MG10, an easy-to-use magnetic gripper for material handling, assembly and machine tending applications. Compatible with all major robot brands, through OnRobot’s One System Solution, the MG10 offers adjustable force and grip detection features that provide users with what are described as unprecedented levels of control. Standard magnetic grippers are only able to provide simple ON/OFF functionality. To adjust the force applied, users have to add rubber ‘feet’ to create space between the magnet and the part. This is an imprecise process that does not always guarantee perfect results, especially on applications that involve handling thin metal sheets and small metal parts where magnetic grippers often accidentally end up picking more
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than one sheet or part as the force cannot be adjusted. The MG10 comes with built-in grip and sensors for part detection. For applications that involve handling sheet metal – such as machine tending tasks that require robots to lift sheet metal from a stack, place it into a press brake/
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press bending machine, and remove it when the machine has completed its work – this functionality ensures smooth, consistent and safe operation. And if the robot loses power or has to make an e-stop while performing a task there is no risk of the part being handled being dropped. Control Engineering Europe
Servo drive package
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Complete servo drive package with seamless connectivity Dynamic movement and precise positioning, whether point-to-point or interpolating. That is why the servo drives CMMT-AS and servo motors EMMT-AS are fully integrated into the control concepts of third-party manufacturers or directly connected to the CPX-E from Festo. And with the initial commissioning wizard of the Festo Automation Suite, the drive system is easy to configure ready for operation in just five steps.
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COVER STORY
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SAVE MONEY AND INSTALLATION TIME WITH SEAMLESS CONNECTIVITY FROM FESTO! Connectivity in automation technology must be regarded as a whole – from the workpiece all the way to the cloud. With seamless connectivity, the mechanical, electrical and intelligent interfaces all need to be taken into account, for all components. Fredrik Stal from Festo SE & Co KG explains more.
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he objective of seamless connectivity is to make different interfaces as simple and easy to handle as possible, so using them is more reliable and faster. Machine builders and end users can then concentrate more effectively on their core tasks.
Meeting machine builders’ wishes For mechanical and control systems, an almost overwhelming number of products, components and solutions are available from thousands of manufacturers – all with their own interfaces, hardware solutions, programming languages, software systems, communication protocols, etc. A typical question is: how can a mechanical axis, a servo motor and a servo drive be easily combined so that they complement each other perfectly? And how can this electromechanical drive package be integrated quickly and easily into the controller? When Festo developed their automation platform, priority was placed on seamless connectivity from the outset. The mechanical system, the drive system with motor and controllers as well as the software modules were designed as one unit – this applies to the mechanical interfaces as well as to the electrical and intelligent interfaces. This is no simple task with millions of combinations of axis, motor and drive. Compatibility with the many controller manufacturers was also key. For example, the latest generation of servo drives and servo motors from
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Festo, together with the intuitive commissioning software Festo Automation Suite, makes integration easier and speeds it up significantly. These components can be integrated virtually seamlessly into all commonly available, Ethernet-based external controllers (Figure 1) and users will not notice that the hardware manufacturers are different. The same can be said for remote IO connectivity. It is critical that a seamless communication chain is established from the simple sensor or IO link device all the way to the PLC and beyond to the cloud. In Automation whilst this is now quite normal, what is often missed are the pneumatic elements. With the new Remote IO system from Festo, the CPX-AP-I this connectivity extends directly to the Valve Terminals bringing with it all the diagnostic advantages.
the complexity of the automation task enables faster, more reliable build times, reduced work-in- progress and lower costs. plus-circle For further reading on connectivity and to download a whitepaper on the subject visit: https://connectivity.festo.com/gb/en/
Conclusion Festo Seamless Connectivity from the workpiece to the cloud offers a solution to many of the challenges faced by today’s machine builders. Reducing
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Figure 1: Servo drives with controller CMMTAS and motor EMMT-AS integrated directly in Ethernet-based control solutions. Control Engineering Europe
CYBERSECURITY
TAKING STEPS TO ENSURE SECURE OT ENVIRONMENTS What can engineers do to protect their processes and plants from cyberattack? Suzanne Gill asked for suggestions from a variety of industry specialists.
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he convergence of information technology (IT) and operational technology (OT), the wider connectivity of OT with external networks, and the growing number of Industrial IoT (IIoT) devices, is helping to boost the efficiency of industrial processes. It is widely acknowledged, however, that this convergence trend also comes with cybersecurity dangers. Kirill Naboyshchikov, business development manager, Kaspersky Industrial CyberSecurity at Kaspersky, pointed out that, according to recent statistics nearly 57% UK manufacturers faced a cyberattack in 2020. Last year Kaspersky ICS CERT identified a previously unknown multi-module C++ toolset used in highly targeted industrial espionage attacks dating back to 2018. “Incidents on industrial organisations organically attract attention from the cybersecurity community as they are sophisticated and focused on sectors that are of critical value. Official organisations and initiatives such as ENISA or European Commission’s Cybersecurity Strategy highlight the importance of having a dedicated approach to addressing cybersecurity risks – targetted attacks, espionage campaigns or sabotage,” said Naboyshchikov. “As a result, cybersecurity has become a critical factor for the whole enterprise – right up to board level. “Enterprises need to keep their industrial processes stable, prevent intrusions and stay compliant to policies and requirements. Relevant cybersecurity practices should allow them to control OT environments, adopt new engineering best practices and digitalisation projects, but must
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also protect old equipment and systems that may still be in use.” These practices mean considering security aspects at the very beginning of any project. It is also important to have access to the most relevant threat intelligence, vulnerability assessment and mitigation, updating incident response programs to cover specific ICS actions and using dedicated cybersecurity solutions. Kaspersky recommends implementing the following technical measures: • Regularly update operating systems, application software and security solutions on systems that are part of the enterprise’s industrial network. • Restrict network traffic on ports and protocols used on edge routers and inside the organisation’s OT networks. • Audit access control for ICS components in the enterprise’s industrial network and at its boundaries. • Provide dedicated regular training and support for employees as well as partners and suppliers with access to your OT/ICS network. • Deploy dedicated endpoint protection solution on ICS servers, workstations and HMIs to secure OT and industrial infrastructure from random cyberattacks; and network traffic monitoring, analysis and detection solutions for better protection from targeted attacks.
concluding that the increased adoption of remote technologies during the global pandemic would have increased the risk exposure for industry. However, this has not been the case for well architected, well managed operations.” When it comes to cybersecurity, and the effort needed to operate effectively in the pandemic environment, it is very easy for engineers to push concerns aside to focus on the daily challenges of running and maintaining a plant. It can be viewed as a problem for another day or seen as a low-likelihood risk. Conversely, plant managers may feel paralysed at the perceived scale, complexity and financial requirements assumed to be needed in order to
A changing landscape “Due to the pandemic, we find ourselves within a cybersecurity landscape where nothing’s changed, yet everything’s changed,” said Robert Putman, global manager for cybersecurity systems at ABB Process Automation. “You could be forgiven for
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Control Engineering Europe
CYBERSECURITY successfully tackle cyber security concerns. According to Puttman there is some good news and some bad news for engineers concerned about protecting their processes and plants from cyberattacks. “The bad news is that cyber security needs to make its way higher up the to-do list. There have been a number of high-profile cyber breaches over the past 12 months, and exposure to risk has the potential for far more significant real-world consequences beyond a data or information leak. The good news is that it is possible to effectively and substantially improve cybersecurity by establishing basic security controls, at scale, across a plant’s systems.” Putman advises the introduction of strategies to reduce the attack surface area for would-be adversaries – essentially closing as many doors as possible on two fronts. “We invest a lot to make systems simpler for colleagues to use – but we must also make them harder for would-be attackers to
penetrate. Firstly, engineers need to take steps to make systems unappealing – introducing software and solutions that obfuscate and frustrate the efforts of a potential human attacker; so that they are thwarted to the point of giving up, or are forced to move on to a different target. “Secondly, it is critical to ensure systems are also inaccessible to the exploits that ransomware/malware depend upon. The application of basic security controls at scale can mitigate the unintended infection of malware and its propensity to move horizontally, causing further damage.” This can be achieved without huge financial outlay, says Putman. He highlights five key steps that plant engineers should take at the earliest opportunity: • Establish a plant-wide anti-virus (AV) regime – this may include combination of signature-based AV and Application White Listing. Signature based AV is the traditional McAfee and Symantec where security researchers develop criteria used by the anti-virus applications to identify the presence of malicious software. • Deliver a watertight back-up and recovery to quickly restore a compromised host from a known good image. • Ensure all software update patches are downloaded, validated, and installed consistently and at appropriate intervals to mitigate disruption of operations. • System hardening and configuration. From individual hosts to network segmentation, assure your architecture is what it should be to minimise exposure. • Maintain a reference architecture, audit adherence to the design, and make updates to the design as new best practices and/or threats require.
Standard practice Stefan Woronka, director industrial security services at Siemens, says that with ISA 99/IEC 62443, the ISA and its members have created a well-accepted and broadly used standard that Control Engineering Europe
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vendors, operators and integrators can use and adapt to their environment. “For operators that would like to start the endeavour, Siemens recommends conducting an IEC 62443 Assessment to determine the gaps of two important aspects: How well are the processes (the IT Security Management System) established? And what are the gaps between the standard and the industrial automation and control systems as configured and operated that require attention?” Based on the results of the IEC 62443 assessment operators can determine the necessary measures to improve their cybersecurity. Next to technical measures – such as the application of a defense-in-depth concept with a zones and conduits model – the setup of an IT Security Management System (ISMS) needs to be considered. “The ISMS will define responsibilities and additional organisational measures – such as policies and procedures. Also, it will help raise awareness among employees, engineers and operational staff,” said Woronka. “This measure must be considered as a regular activity in the same way as safety training.” The technical measures of a defensein-depth concept range from the implementation of zoning firewalls to the use of endpoint protection solutions such as whitelisting and antivirus. As a prerequisite the operator should seek guidance from the vendor of its industrial automation and control system, in case the measures the operator seeks to implement require approval or might cause any compatibility issues with the automation hardware and software. “With this, the first steps towards a functioning security architecture are taken,” explained Woronka. “But it is not the time to rest, as the attacker never sleeps! Operators need to consider continuous measures for implementation. The most basic one and at the same time a complex one is the setup of a proper management for vulnerabilities.” > p12 April 2021
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CYBERSECURITY This requires four major steps: • The identification of all relevant assets including firmware and software patch level. • The identification of existing vulnerabilities of these assets. • The plan to mitigate these. • And, finally the patching itself. “One additional measure to consider is the implementation of a monitoring solution, that will baseline and monitor the industrial automation and control system for anomalies and changes,” concludes Woronka.
Be aware The first step to protect processes and plants is to be aware of the consequences of cyber attacks, according to Massimiliano Latini, ICS cybersecurity & special projects director at H-ON Consulting. While the IT world is already aware of security issues, OT security has opened up a world that was previously hidden and unknown. “OT networks are much more accessible than traditional IT systems and consequently much more attractive to cybercrimes, where hackers can easily breach those most vulnerable parts of industrial automation control systems,” said Latini. He believes that the most dangerous effects of a cyber attack are related to business continuity, due to the possible shutdown of the plant assaulted, and also to safety and environment issues, in other words, injury or accidents involving people and hazardous environmental emissions. “Above all other things, engineers can protect their processes by tidying up their data infrastructure,” said Latini. He advises that the first measure companies should implement – in compliance with IEC 62443, which is the most important reference for Industrial Cyber Security – is organising the network into zones with a clear separation between IT and OT, and where the segmentation
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of the OT network is rigorously managed in case of remote access as well. “The use of firewalls designed specifically to manage issues related to industrial infrastructures is strongly recommended,” he continued. “The selection of high-quality tools is also crucial to counter attack the hackers. This obviously depends on the type of infrastructure and the problems that need to be managed. The most effort must be employed in investigating what are the most adequate firewalls and Layer 3 switches for segmenting the network in accordance with the IEC 62443. And finally, a software for monitoring the network can be also very useful for idetinfying what vulnerabilities are affecting a system.”
Know your system Edward Kessler, technical executive at EEMUA, believes that the most important consideration, when looking at securing process and plant cybersecurity, is to know what you have and what it is connected to – in terms of both networking and control – and to educate yourself on industry best-practice. It is important to have a good idea of the roadmap for developing a cybersecurity strategy, and while there is a huge body of information available – in the form of standards which are still being developed – in many cases
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there is too much information for a busy engineer to take on. “There are a number of places that easily digestible best-practice information can be found,” said Kessler. “You could look at EEMUA guidance and in the UK there is also HSE guidance. This will help engineers to better understand their equipment, what each element is dependent on, what the dataflows are and what the basic network map is.” Kessler points out that many organisations will already have a fixed asset register, but this is not likely to contain the information that is most useful from a cybersecurity perspective. “It is important to examine in detail what the connections are. Just saying it is an Ethernet or RS232 connection, for example, may not be what is significant when it comes to cybersecurity. You also need to look at dataflows and what is dependent upon what – for example, you might think that you are just sending control information to a device. But you may have a logging function on it which is dependent on GPS, so you need to know where this comes from too. All of these elements need to be brought into the mix because they may be significant from a cyber security point of view.” Kessler concludes by warning that the cybersecurity risk in the OT environment is growing because the only real interest of many attackers is to make money, so attacks are likely to be be random – but opportunistic – targeted at the most easy to access systems. Those organisations that practise good cyber security hygiene will stand a better chance of deterring attackers. It is important to stay one step ahead of the attackers, so cybersecurity needs to be a continuous process and when it comes to cyber security prevention is definitely better than cure! plus-circle Control Engineering Europe
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CYBERSECURITY
SECURING OT SYSTEMS AGAINST CYBER-ATTACK As the worlds of information technology (IT) and operational technology (OT) continue to merge the demand for security measures to protect OT networks is growing. David Bean looks at some fundamental aspects that need to be considered.
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s the technologies to bridge the divide between the worlds of IT and OT within a plant have become more established, the digitalisation of businesses has accelerated. The goal of this digital transformation is to provide a foundation to boost productivity, optimise asset availability and maximise plant utilisation. However, with greater levels of integration comes an increased need to consider and improve cyber security. Figures from the Centre for Economics and Business Research (Cebr) and gov.uk estimate the cost to UK businesses of cyber breaches is in excess of £18bn. From a general manufacturing perspective cyber-attack brings the risk of lost production, theft of intellectual property and the negative impact on brand confidence as well as potential environmental damage if safety systems are affected. It is therefore not surprising to find that, according to a Make UK report, the threat of cyber-attacks is stopping some 35% of manufacturers from investing in digitalisation. Further, from the perspective of safety critical infrastructure, asset owners also have to consider the potential cost of being found to be non-compliant with the Network and Information Systems (NIS) Directive. In the UK, the maximum penalty for a breach of the NIS Directive is £17m, enough to give even the biggest businesses pause to think.
Implementing standards Despite this, the risk of not investing in digital transformation is enormous. From an OT perspective, there are now established standards that provide all of
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the stakeholders in a deployed industrial automation system – the asset owners, the system designers/integrators and the individual product vendors – with the tools and guidelines that they need to secure an installation against cyber-attack. Chief among these is IEC 62443, which provides a systematic and practical approach to cyber security for plant OT systems, covering every aspect from initial risk assessment right through to operations. It defines the differing security roles of the key stakeholders, specifying the unique requirements for each security level within the control ecosystem. IEC 62443 reinforces the accepted ‘defence in depth’ strategy, defining methodologies for implementing OT cyber security measures and outlining procedures as well as policies that can form the methods, for firstly hindering an attack and secondly recovering from an attack. It is notable that IEC 62443 places the onus on the automation equipment supplier to embed protective features within their products to contribute to system design considerations and lifecycle management, as well as respond to any vulnerabilities that may be discovered.
Defence in depth This is something Mitsubishi Electric takes very seriously. Its products have long offered a number of security features that support the development of a robust cyber security strategy. The ‘defence in depth’ approach that it adopts when advising systems integrators and asset owners on the
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methodologies that should be used to implement secure networks and control systems are closely aligned with IEC 62443. In addition, Mitsubishi Electric has established a Product Security Incident Response Team (PSIRT) as defined in IEC 62443. A risk audit service is also available to help asset owners understand the risks in terms of criticality and consequence of a potential cyber breach. This includes a written report on the status of the networked industrial control systems and offers recommendations for any remediation that is required to meet the standards set out in IEC 62443. Most recently, Mitsubishi Electric has built a collaboration with Radiflow, whose intrusion detection and analytical tools for generating risk reports and remediation measures meet the requirements of IEC 62443.
Evolving cyber threat Implementing robust cyber security solutions is a vital element of a successful digital transformation strategy and ensures that companies can boost productivity and enhance their competitiveness. plus-circle David Bean is solutions manager at Mitsubishi Electric. Control Engineering Europe
HYPERAUTOMATION
HYPERAUTOMATION: WHAT’S IT ALL ABOUT? Guy Kirkwood offers some insight into hyperautomation technologies and explains how it might offer benefits for the industrial sector.
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yperautomation is the application and combination of advanced technologies to deliver end-to-end automation and digital transformation within an organisation. It allows businesses to automate every process and task that is automatable. This is no small task: for example, according to McKinsey, in the US alone, there are 2.6 trillion hours of work per year that is automatable. The starting point is robotic process automation (RPA), which mimics human behaviours to automate process-led and repetitive tasks. Hyperautomation expands RPA’s capabilities with the addition of artificial intelligence (AI), machine learning (ML), process mining and other advanced tools. By bringing these tools and technologies together, hyperautomation can be used to enhance the productivity of workers and automate virtually any repetitive task that they carry out – including the more complex and longrunning ones that previously required exception processing and human intervention. In the years to come, hyperautomation will continue to combine new tools and technologies, improve the working lives of an increasing number of employees, and accelerate automation of the next generation of business processes. It’s going to reshape what we understand to be ‘work’ as we know it. There can be no doubt that the age of hyperautomation has arrived. In fact, Gartner has named it a top strategic technology trend of 2021. Its upwards trend has only just begun. Hyperautomation technologies can be employed to maintain control over their back-office and operational processes. However, it goes much further than this. It can also support the core functions
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of an industrial process. For example, one of Schneider Electric’s industrial sites creates electrical switchboards for residential, commercial and industrial premises. When its manufacturing specifications are received, they are printed, along with the labels required to identify electrical circuits and circuit breakers. Preparing these documents for staff responsible for installing electrical switchboards at client premises is tedious. Schneider created an automated solution to open and print the documents, allowing staff to focus on other more rewarding work. If this type of automation was scaled across the enterprise to support many more functions, with the addition of AI, it could be characterised as hyperautomation. As with any change, there will be challenges to the adoption of hyperautomation. Perhaps the most obvious one is ensuring employees are on-board to ensure there is no resistance to change. Without employee buy-in, hyperautomation projects may struggle to meet their full potential because hyperautomation means that digitisation will no longer be controlled by specialised IT departments, but rather a co-production between IT experts and non-technical users. By its nature, if an organisation plans to automate everything that can be automated, it means all staff need to be able to use it. And for that, you need acceptance.
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Another challenge is ensuring truly holistic approach. It can be easy to fall into the trap of deploying robots in isolation, focusing on one specific task rather than an entire process or workflow. Such tactical use of RPA creates siloes and limits overall benefits.
Upskilling Getting employee buy-in is all about education. Investing in a technology is one thing but experience tells us, that without skilled resources, technology does not thrive. Thankfully, gaining access to automation skills is open to everyone. To fully realise hyperautomation and avoid creating tactical, siloed automation, businesses need an automation first mindset, which encourages users to imagine a future where software robots are always part of the solution and part of an integrated workforce of humans and automation. Businesses also, therefore, need a complete end-to-end software solution that can bring that thinking to life. plus-circle Guy Kirkwood is chief evangelist at UiPath. Control Engineering Europe
HYPERAUTOMATION
DIGITALLY TRANSFORMING BUSINESSES WITH RPA Dr Paul Rivers highlights how Robotic Process Automation (RPA) is an area of technology that will help to drive business transformation forward, but only if implemented correctly.
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ll industries have had to reconsider their infrastructure, processes and workforces as a result of the Covid-19 pandemic. With additional pressures to meet increased customer demand while restricted by social distancing measures, many organisations are turning to technology for a solution. According to recent research, almost half of existing jobs could be automated within the next generation due to technology integration and the acceleration of automation.
Key to productivity RPA is an IT solution which brings humans and software together in order to find ways to streamline mundane processes, in turn, making it easier for humans to complete tasks with more precision. This collaboration helps the human by eliminating as much repetition as possible while also improving speed and efficiency. RPA is not a new concept – but its application has evolved over time, from the ability to automate processes to handling business and computing decisions, which has coincided with advancements in other technologies, such as Artificial Intelligence (AI) and Machine Learning (ML). According to Gartner, the worldwide RPA market is expected to reach nearly $2 billion by the end of 2021, providing a digital solution to help businesses contribute to meeting their strategic objectives and stay competitive, driving business transformation.
Successful deployment As with any new technologies, it is first necessary to have some clearly defined Control Engineering Europe
processes in place. In order to successfully deploy RPA, organisations first need to consider the business value or pain points that they want to gain or solve. Once the business case of implementing automation technologies has been fully evaluated, it is then possible to gradually deploy solutions. The automation solution needs to fit and work alongside existing processes, while ensuring it is flexible and scalable to meet any changes and growth internally. The human workforce needs to be part of the deployment and it is important that they understand the technology, and its benefits – minimising the need for them to conduct repetitive tasks and focus their time and attention on more complex needs. When technology can completely eradicate these arduous tasks individuals are likely to respond well to the change, but they do need to be educated, trained and confident in the solution. They need to understand how the technology works and how they work together, as well as the benefits that collaboration will bring.
of data is generated daily, collecting information about performance, accuracy and repeatability, but the value of this information can often be lost if it is left to humans to process. The insights provided by the collaboration between RPA and Big Data can be used to recognise any risks within business processes and help companies resolve and streamline these points within their operations. Covid-19 has acted as a catalyst by accelerating the uptake in automation, especially within the manufacturing and logistics industry. With less staff able to be present within the same environment due to the need for social distancing, organisations faced significant challenges. This is where RPA can play a vital role in helping keep up with the pace of change and to drive efficiency across the business. Such technology is critical to business response and continuity by amplifying automated support systems in order to strengthen a resilient human and machine workforce.
Conclusion
Big data
More and more businesses are now inquiring about automation and wanting to find out about existing technologies that can help make processes more efficient, by ensuring that technologies such as RPA fit into existing business operations and deploying it successfully, RPA can enable businesses to benefit from improved efficiencies and productivity, in turn, driving business transformation now and into the future. plus-circle
The concept of ‘Big Data’ is driving automation, and particularly RPA, acting as a data-driven process. Vast amounts
Dr Paul Rivers is managing director at Guidance Automation.
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MOTION CONTROL
SIMPLIFIED TRANSPORT OF SENSITIVE WORKPIECES A key innovation of a new plasma systems treatment unit, created by Plasmatreat, is the inclusion of a planar motor system which transports workpieces with greater precision and flexibility.
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lasmatreat GmbH, is a German manufacturer of plasma systems for surface treatment and production processes. Its plasma treatment unit is designed to surfacetreat a variety of material samples in a two-stage process. During the first stage, the substrate is moved under a nozzle for cleaning and activation. During the second stage, a separate nozzle applies a functional coating and when designing the system, this where the company focused its innovation efforts. Jochen Stichling, head of design at Plasmatreat, explains: “We wanted a fast, fully programmable, wear-free system to transport the workpieces.” The best solution found to achieve this goal was the XPlanar motor system from Beckhoff. The XPlanar system consists of planar tiles that can be arranged in any pattern, combined with contactless movers that float over them and can be positioned exceptionally fast, flexibly and precisely. The movers operate jerk-free and are capable of traveling at speeds of up to 2m/sec. They can also accelerate at 1g and can be positioned with a repeatability of 50 µm – silently, and without wear or abrasion. The system supports movement within the x-y space and also provides additional functions which allow movers to be positioned with up to six degrees of freedom when necessary. In the Plasmatreat machine the XPlanar consists of six 240 x 240mm planar tiles and a single planar mover which has eliminated the need for complex six-axis robots and linear motors. For Plasmatreat, one big advantage of the XPlanar technology is that the
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plasma jets used to treat surfaces no longer need to be moved and, as a result, can be installed in fixed mountings. The jets are complex, both mechanically and electrically, and the ability to move the workpieces, rather than the plasma jets themselves, reduces wear to the feed lines. The company identified other additional benefits as a result of the increased flexibility offered by XPlanar. Stichling said: “We can attach a variety of material samples to the mover for treatment using just simple adapters. We can easily add processing stations alongside the plasma jets – markers for good parts, for example, or optical sensing heads to conduct full part inspections – and carry workpieces to them flexibly as needed. XPlanar’s rapid acceleration also lets us move material samples at high speeds; with thin samples this helps minimise treatment time with the fixed jet.”
Functional benefits According to Stichling, the functional benefits offered by XPlanar are proving valuable in a range of applications: “Conventional setups use a six-axis robot or linear motors to move a plasma jet around a stationary workpiece. From a cost perspective, XPlanar comes in somewhere between linear-axis and robotic systems. With flat parts that don’t require much vertical travel on the z-axis, where robotic systems are usually ideal, XPlanar offers a good alternative to gantry-type systems. Its lack of
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wear, easy cleaning, and clean-room compatibility also offer benefits.” Stichling believes that XPlanar has the potential to optimise plasma surface treatment in two key areas – direct integration of in-line testing for full inspections during the treatment process, and custom-programmable mover travel routes for end customers. Another advantage identified by Plasmatreat was that it took less than two months to integrate the XPlanar system into its machine. Beckhoff was quick to supply the required 3D data and the electrical connection information that enabled the company to incorporate the XPlanar starter kit into its machine design. According to Stichling, XPlanar has proved to be both robust and reliable. “Another advantage is that the entire plasma treatment cell has now been fully automated using PC-based control, making it a system solution from a single source,” he concluded. plus-circle Control Engineering Europe
New releases: Secure your OT networks and prevent cyber attacks Procentec’s Virtual Product Launch | April 8
The importance of IT-security has been acknowledged by experts for years but securing Industrial Control Systems seems to have been overlooked. Now that attacks on these Operational Technology (OT) environments are becoming more frequent, companies are becoming aware of the vulnerabilities and are looking for ways to bridge the gap between OT and IT. Procentec, the global leader in diagnostic and monitoring solutions, will be presenting new cybersecurity tools during its Virtual Product Launch on Thursday, April 8. Be sure to register for this one-day event full of new releases, expert-advice, livestreams, entertainment and more. https://releases.procentec.com/ • info@procentec.com
INDUSTRIAL 5G
5G STARTS TO ROLL OUT
Control Engineering Europe spoke to Sander Rotmensen, director industrial wireless communication at Siemens Digital Industries about 5G technology. Q: Where do you see 5G applications offering the greatest benefits in the industrial sector? We are just at the beginning of the 5G roll-out. At this moment most use cases focus on remote connectivity with high bandwidth. However, in the future, 5G will enable more challenging use cases such as plantwide autonomous logistics and robots becoming cobots. Another interesting use case is for the production of products that require the inclusion of large software packages – with 5G these can be wirelessly equipped during the manufacturing process and not afterwards in a separate step as it is often done today. Industrial 5G will allow users to run multiple different applications over the same infrastructure. All in all it should be expected that, in the future, Industrial 5G will change the way we make decisions, manufacture products, and maintain factories.
Q: What are your predicted timeframes for seeing the technology being used in real-life applications? Industry will start to benefit from the higher bandwidths that 5G has to offer in remote connectivity applications this year. Industrial 5G routers – such as the SCALANCE MUM856-1 – will be available very soon. These products are based on Release 15 of the 5G standard.
However, with the recent launch of Release 16 of 5G, the first requirements for 5G on the shopfloor have been integrated into the standard. However, it will take some time before products based on this standard hit the market. Based on ARC research industrial products for the shopfloor based on Release 16 are not to be expected before the end of 2022. plus-circle
Private 5G network focuses on industrial applications This year, the Deutsche Messe exhibition site in Hanover, Germany will become 5G-ready. The organisation has started to set up one of the largest 5G zones in Europe, spanning 30 halls and buildings as well as the entire open-air ground. Siemens is playing a big role in this project, setting up a private 5G campus network with a focus on industrial use in one of the exhibition halls in Hanover. The network can be used by exhibitors during trade shows and, outside of trade show times, can be used by companies for tests and field trials. “In the exhibition hall, innovative solutions for industrial networks will be presented using this 5G network infrastructure. The Siemens infrastructure will remain in the exhibition hall permanently and will be handed over to Deutsche Messe for commercial use. This will enable other customers to use the technology as a test environment for their products,” explained Dr Jochen
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Köckler, chairman of the Board at Deutsche Messe AG. “New network technologies have always been an important driver for innovation. The same is true for 5G. Through the use of private 5G networks, for example at production sites, companies can make full use of the advantages of this technology. This paves the way for future-oriented applications – such as mobile robots in manufacturing, autonomous vehicles in logistics or augmented reality applications for service engineers,” said Cedrik Neike, member of the Board of Siemens AG and CEO Digital Industries. Siemens has already taken steps towards a private industrial 5G network in its Automotive Test Center in Nuremberg and is currently creating its own private 5G infrastructures in its plants in Amberg and Karlsruhe. The company is able to rely exclusively on its own independently developed products and solutions for these projects.
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Control Engineering Europe
INDUSTRIAL 5G
5G: PAVING THE WAY FOR INDUSTRY 4.0? Friedrich Haussmann discusses the benefits and barriers to the adoption of 5G in industrial applications.
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ndustry has experienced many shifts over the last century – from the rise of mass production to the automation present today – industrial players continue striving to take advantage of technologies that can help increase productivity and efficiency. Today, we are in the midst of another major transition – Industry 4.0 – which sees greater automation, data gathering, and intelligence providing the power to expand autonomous technologies, reduce downtime, improve safety, and support industrial companies to reach their business objectives. In this environment, the timing for the adoption of 5G couldn’t be better. Many opportunities lie ahead while many questions remain about how a rollout of the technology will unfold.
The possibilities There are many industrial 5G testing environments within manufacturing facilities across Europe. Companies are considering issues such as the equipment they will need, the skillsets required to maintain the system, and the processes that will need to be implemented to deploy various tasks. It is expected that by mid-2021, many large industrial corporations will have completed their testing of the first generation of 5G and will then be ready to consider engineering deployments on a larger scale. There are three primary areas where 5G testing is taking place: 1. Mobile, autonomous robotics: Many manufacturing facilities use robotic machinery or other autonomous, mobile equipment in their production process. Reliable network Control Engineering Europe
connectivity is critical to monitor location and stop the equipment if someone or something crosses its path. 2. Critical data reporting for quality control: Precision is key in manufacturing. One missed turn of a screw, or a missing ingredient could cause product failure. Machines today are connected to the plant floor network and are continuously monitored to ensure that processes are followed – every time, all the time. 3. Non-critical data storage: Every aspect of machine performance is monitored in an automated environment. Collecting and analysing data allows for predictive maintenance, anticipating when a malfunction may occur and scheduling maintenance to avoid downtime. Data analysis can also help improve productivity by optimising processes and performing tasks in the most efficient manner. In larger companies, more data is available to analyse, which translates to more opportunities for improvement.
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Questions remain 5G is a big step forward in industrial network connectivity. The primary question that remains revolves around global standardisation of how 5G will be licensed. To date, each country has its own regulations. For global manufacturers, some level of standardisation must be in place for a large-scale 5G rollout. Additionally, manufacturers seek comprehensive solutions for deploying and managing the technology, including product selection, network expertise and on-call support. They rely on partners who are able to draw from their experience with industrial customers to deliver solutions from implementation through support. Within the next one to three years, live rollouts will begin on plant floors around the world with large organisations leading the way and small organisations following. 5G will allow for an advanced level of automation, productivity, quality, and more. plus-circle Friedrich Haussmann is product manager wireless at Belden. April 2021
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FOOD INDUSTRY FOCUS
DO YOU HAVE AN APPETITE FOR AUTOMATION KNOWLEDGE? The Appetite for Engineering event is designed to highlight the benefits of automation and digitalisation technology in food production applications.
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ow that the UK Government has set down a clear roadmap out of lockdown, the team is delighted to be able to have finally secured a date for the next Appetite for Engineering event. It will take place, as a live event, on 9th September, at the Manufacturing Technology Centre (MTC) in Coventry. Every year the Appetite for Engineering event provides a forum for senior engineering food and beverage professionals to network and learn about the latest engineering and automation technologies and issues that can have a positive effect on business and which helps companies remain competitive in an ever-more challenging business environment.
out – how and where technology and automation is being adopted, and what benefits it is offering. The global pandemic required the food industry to make some very rapid changes to production lines and we believe that this has acted as a wake-up call for many, in relation to the flexibility and efficiency of their production processes. This will be one of the leading topics of conversation at the event and it is believed that this year the Appetite for Engineering event will have additional importance for the food and beverage sector – offering a very timely opportunity for the industry to finally come together again to discuss challenges and explore solutions.
Applying technology
While an entire smart food factory is probably still some way off, genuine improvements in efficiency and quality are achievable right now. For example, it is already possible to upgrade legacy plants and equipment to gain valuable operating or performance data, measure energy consumption, or ensure unexpected production downtime is
The conference programme and its associated exhibition are designed to showcase how the food and beverage industry can apply technology to help increase productivity and efficiency and to ensure product safety. Delegates can hear – directly from engineers working in the food industry day in, day
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Genuine improvements
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minimised. You don’t have to have a brand-new plant to adopt technology that will help make your business more profitable. Advances in intelligent connectivity and automation technologies continue apace and the Industrial Internet of Things (IIoT) and smart machines and factories are starting to become reality for many. The food and drink industry now has a real opportunity to make major productivity step changes. For engineering leaders looking to remain competitive in the UK’s ever-more challenging supply chain, understanding how to maximise the opportunity to grow and develop businesses and organisations through better plant, productivity, process and people is crucial. You are invited to join the team on 9th September at the MTC in Coventry – to join in the discussion and learn more about how you could reap the benefits of automation technology. plus-circle For more information about the event and to register your interest in attending go to: www.appetite4eng.co.uk Control Engineering Europe
MACHINE VISION
Sponsored article
A 3D VISION SYSTEM FOR ALL CASES Janina Guptill discusses a new 3D vision system that is said to make inspecting parts in 3D as easy as using a 2D smart camera.
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hen it comes to inspecting parts, users can choose from several established technologies. If the decision is made in favour of machine vision, the question arises: Do you need an inspection in 2D or 3D and how much effort is required to implement the respective solution? Depending on the application, a proven 2D system is then often the first choice, even if the (theoretical) advantages of 3D image processing may be obvious. Why? Until now, there was no 3D vision system that met the requirements of most inspection applications in terms of ease of use and cost. Three-dimensional vision inspection was too expensive and complicated for most companies, and there were also few vision tools that worked with true 3D images. An additional PC had to be installed to solve the application, resulting in significantly more space and programming requirements. Further, 2D inspection with a smart camera works very robustly and with great ease of use. So, in many cases, there was no real need to make the transition to a 3D inspection system. This situation is now changing with the introduction of the Cognex In-Sight 3D-L4000 vision system. This smart camera enables engineers to solve a range of inline inspection, guidance and measurement applications on automated production lines quickly, accurately and cost-effectively. It offers an easy-to-use suite of true 3D vision tools. In addition, the patented speckle-free blue laser optics are an industry first, enabling the capture of high-quality 3D images. Control Engineering Europe
Making the difference Typically, 3D imaging systems struggle with speckle – light effects that occur when laser light is scattered from the surface of the part back to the imaging system. Speckle changes the appearance of the part and reduces image accuracy. The system can only estimate where the laser is located. To date, no 3D system has been able to eliminate speckle. However, the laser used in the In-Sight 3D-L4000 is a significant technical advance in laser-based imaging – and a reason for the excellent results delivered. It eliminates speckle by using a special laser in the blue light range. As a result, the imager sees a clear laser line, resulting in higher accuracy 3D images. In addition, the laser provides its own illumination for both 3D and 2D images - the system does not require any external light. In most traditional laser-based 3D vision systems, the laser head captures an image that is sent to a PC for processing and the dependence on PC programming makes 3D inspections cost-effective only for very complex applications. The In-Sight 3D-L4000, however, has processing power built in allowing the vision tools to perform true 3D point cloud inspections without
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the need for an external controller or thirdparty PC-based software. In the past, 3D visual inspection was difficult to understand and use. Most existing systems transform 3D data into 2D images. In doing so, the height of a point is represented as a gray value. So to understand the height information, one uses a false color representation of the rasterized 3D image in the 2D image. In this representation it is very difficult to see and successfully process the nuances of the 3D part. A common method is to convert a section of the rasterized 2D image into a 1D height profile. However, with the new technology used in the 3D-L4000, the image is a pure point cloud; what you see and evaluate is a true 3D image, not a reduction to a 1D height profile. And since 3D inspection is new to most users, the 3D tools are designed so that everyone can fully understand and use the new three-dimensional tools. In other words, you are essentially doing the same thing, but unlike before, you are working on an image that looks exactly like the part itself. plus-circle Janina Guptill is senior marketing communications specialist, Cognex Germany Inc. April 2021
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MACHINE VISION
DEEP LEARNING OPENS UP NEW POSSIBILITIES Control Engineering Europe looks at some of the latest machine vision technology advances.
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arsten Traupe, head of product management at IDS Imaging Development Systems, believes that for industrial automation, both embedded vision and AI-based image processing solutions are amongst the most influential developments today. “The combination of low price, integrated computing power and compact design makes embedded vision devices the most logical solution for many applications. The performance of embedded vision systems improves continuously, despite their compact form factor and it is now possible to realise applications that were unthinkable just a few years ago.” Traupe says that, on the manufacturer side, the focus is currently also on the integration of interface standards to simplify commissioning and control to help drive customer acceptance. “It must not be forgotten that the central purpose of these systems is to replace a host PC. If we consider the best case, modern embedded vision systems are flexibly usable and freely programmable. They can execute neural networks ‘on-board’, hardwareaccelerated, and can be seamlessly integrated into processes and plants through standardised interfaces, for example through industrial protocols such as OPC UA. “The greatest added value in these solutions for real-world applications comes from the combination of embedded vision, classic image processing routines and deep learning.” The complete AI solution IDS NXT ocean, for example, features vision apps which can be used to flexibly control which task the
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Image courtesy Cognex.
embedded vision system solves – from barcode reading to object detection. Image processing takes place directly on the camera and can then be transmitted as a result, for example to a machine control system. Coordinated workflows and all the necessary tools are provided to allow stakeholders to develop their own applications and bring it into the field without complications. “With the IDS-hosted cloud-based AI training system, for example, users can train a neural network with their own images without any prior deep learning knowledge and without having to install any hardware or software,” said Traupe. “This is remarkable, because although automation is a defining topic in the market, only a few all-inone packages for embedded vision with deep learning are available so far. In many cases, this is still project work, with customers building the
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systems themselves step by step. We have made it our task to remove these hurdles so that companies without dedicated AI specialists can also benefit from the current state of the art.”
New possibilities Commenting on how deep learning is opening up new possibilities for previously impossible inspection applications, John Dunlop, founder and chief technology officer at Bytronic Vision Automation, said: “If you want to better understand a subject as complex as deep learning, simply hold your mobile phone. In that action, you are doing the two things that machines have never been able to master. Through learned experience, you know what is or isn’t a phone, and you can tell by touch whether the is damaged and where the edges are. “In deep learning terms, these two processes – known as surface inspection Control Engineering Europe
MACHINE VISION
and categorisation – have always been beyond the capabilities of a typical automated factory. ‘Reading things’ and ‘sorting things’ are tasks that have always been left to human operators.” Recently, however, deep learning technology has started to move onto the factory floor bringing new and affordable possibilities for automating production lines. “You can now teach machines to carry out difficult, subjective product inspections and two big technical developments are making this possible,” said Dunlop. “The first has been the move by computer manufacturers away from using traditional Central Processing Units (CPU) towards Graphics Processing Units (GPU). This means complex deep
learning that once took hours can now be done in seconds. “Second, is the launch of more accessible software. You no longer have to be a developer fluent in code to use deep learning programming tools – a factory engineer can now learn to use deep learning inspection cameras without having to use a PC.” As a result, deep learning is now unlocking applications that were once considered just too complicated for anything other than human inspection. It is allowing us to replicate that ‘human’ learning process, but in a machine and it allows us to start apply two deep learning processes – surface inspection and categorisation – to production lines.
It can look for damage, errors or abnormalities on a surface, such as inspection of paintwork, textiles, printed text or car body parts and it can carry out complex categorisation – spotting damage on car body panels, detecting upside down products, removing misshaped foods on fastmoving conveyors. Tasks where you might currently have a trained, human operator on the line. “At the moment, deep learning requires training with a series of static images. In time, I am sure this will develop into ‘self-learning’ feedback, or learning through experience, with all of the new manufacturing possibilities that will come with that too,” concludes Dunlop. plus-circle
Surface quality check for bearing balls The Center of Device Development at the Fraunhofer Institute for Silicate Research has developed a fully automated checking system for bearing balls. High-precision ball bearings need to meet special tribological requirements to ensure their long-term, faultfree performance. Production requires high precision and process reliability. Even the slightest deviation from the optimum shape or the desired surface quality can cause bearing damage and failures. To minimise risk, the Center of Device Development (CeDeD) at the Fraunhofer Institute for Silicate Research (ISC) has created a fully automated, robot-based inspection system for one bearing ball manufacturer. The developers at the Fraunhofer Institute split the complete bearing ball check into two separate units – In the first step, the components’ roundness is checked in accordance with the standards, followed by quality control of the ball surfaces in the second step. The exact feeding of the bearing balls to the respective testing module, the passingon of defect-free balls and the ejection of faulty products is carried out by a robot. The required testing speed of the system resulted from the preceding manufacturing process: the developers’ goal for the entire system was 2,000 balls per hour. Besides the requirement for speed, the properties of the ceramic balls posed further challenges for the machine vision system. The surfaces to be measured are highly reflective and require a special illumination system that minimises the reflections in order to solve the various measurement tasks. In addition, the system had to be flexible, as various standardised ball sizes – with diameters of between 3 to Control Engineering Europe
10mm – had to be tested with it. These were very demanding requirements for a fully automated quality inspection system. The design team understood that the reliable inspection of bearing balls at the required speed would only be possible with the help of a machine vision system: “In the past, we have implemented around 50 systems in seven different application areas, each one tailored to the customers’ needs and in use all over the world,” explained Dr. Andreas Diegeler, head of CeDeD. “Machine vision has always been a core element of our measuring systems”. Despite the in-house expertise in plant engineering with integrated image processing and in-house software development, Diegeler did not consider himself and his team as being imaging experts – instead they rely on STEMMER IMAGING. In this application it was able to offer the special lenses used, the cameras and the software for evaluating the recorded images as a package that was precisely tailored to meet specific requirements, and they were also able to provide support in programming the system. The system is able to three-dimensionally measure with an accuracy of 0.3 µm. To achieve this level of accuracy, high-precision camera systems with a resolution of 1 µm are used. Deviations from the standardised roundness and various surface defects must be reliably detected. According to Diegeler, one of the major challenges is that the system works with high precision and is able to detect any deviation: “The system’s cleanliness is vital because otherwise even the tiniest grain of dust could be identified as a defect. This means that the bearing ball production must be optimised in this respect too”
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PID
UNDERSTANDING PID TUNING Proportional-integral-derivative (PID) tuning can be challenging to learn, but the experience gained can serve engineers well in other areas. Brian Fenn offers advice on what to do when a PID loop underperforms.
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roportional-integral-derivative (PID) loop performance is often overlooked once the system is commissioned and seems to be functioning. Those loops are often not thought of again as a means of continuous improvement. They function ‘properly’ and so they are often ignored until something goes so out of whack that it pops up to the top of the issue pile. Those incidents are few and far between and they do not get much attention. However, operational incidents are often responsible for critical components of product quality and production rate that can have a sizeable impact on operational efficiency. There are some definitive engineering and mathematical steps to take when tuning a loop, but there is also a lot to be said for experience and understanding how to tweak things based on the loop makeup and response. It can certainly be a challenge those first couple times, but that hard-won experience on one application or process can often serve engineers well in other areas. System integrators typically interact only with the tuning parameters of a loop during the start-up. Once the control system commissioning is complete, what happens to those loop tuning parameters and overall loop performance is unknown and falls into the category of mysterious. We always wonder, do operators turn loops into manual (or even off) to control the system themselves? Do different operators feel they
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have a better handle over the process than others and frequently tweak the loop to their right numbers? Do those loops responsiveness lessen over time due to degrading equipment and realworld conditions? Finally, does the initial system process design always capture all phases and modes of operation where alternate PID tuning parameters would be better than the originals?
Correcting PID performance Control loops often are set up and tuned initially and then forgotten or ignored unless something major happens. If nothing major happens, the lack of attention to loop performance creates a breeding ground for quality issues, significant efficiency losses and operational inconsistency. This is often what helps to drive some of that manual intervention as things aren’t bad enough to cause obvious issues, but still sub-optimal enough for operators to try to make it a little better. There are many reasons why a loop might be suffering from suboptimal performance. One reason is mechanical wear or failure. These loops contain a variety of physical components subject to wear and breakdowns. It could be that proactive maintenance work is not being done on those components. Regardless of whether users follow a time-based preventive maintenance schedule or a condition or analysis-based predictive maintenance schedule, proactive tasks
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and replacement of worn parts is important to optimal performance of control loops.
What to do? Whether it’s applying grease to prevent physical binding or replacing an actuator that isn’t moving as quickly, each element needs to be properly functioning to give the control logic its best chance at success. When a PID loop is under-performing: • Take a look at the physical situation first. It is easier to re-tune than rebuild a control valve, but the underlying issue remains and will get worse. • The logic supporting the PID block also should be considered. There are many programming approaches and techniques that can be coupled with the PID algorithm to improve the loop’s consistency and performance. For example, users might have a loop that finds itself a good distance away from the setpoint relative to the potential process variable change due to changes in recipe or loop dynamics. In this case it can be beneficial to have the code drive the loop in manual at a high output until they get into a defined range. When that happens, users switch the loop into automatic mode and allow the algorithm to take control. • Another beneficial coding component when a PID loop under performs is alarming. Setting alarms around taking too long to reach setpoint or too much variance while Control Engineering Europe
PID
‘at’ setpoint can help flag issues in real time and/or trigger additional programmatic interventions. This is useful in minimizing response time when we do need to do some of that reactive maintenance. • Signal filtering also is an important consideration when PID loop underperforms. During startup, users are concerned about getting the loop to control and respond correctly. It might not be obvious that noise or other minor fluctuations on your process variable are causing the loop response to be jittery. A knee-jerk reaction would be to de-tune the loop to provide a damped response, but you can better deal with it by filtering the process variable (PV) signal. • There also is the PID algorithm itself to consider. It is important to make sure that the control doesn’t stretch the capabilities of Control Engineering Europe
the loop. If the tuning parameters are set too aggressively, users run the risk of causing physical issues in the process. For instance, users might cause water hammering by slamming valves fully closed or open too quickly. This can lead to damage of other elements in the system. • There also might be different scenarios the loop has to operate under. While the setpoint might not change, there might be other things going on in the process that affect the loop differently at separate times, such as seasonal or productbased changes in viscosity. This might lend itself to having different sets of tuning parameters that can be loaded in depending on the surrounding circumstances.
available, it is easy to gather loop information to provide better insight into how they are performing and where improvement is available. By aggregating this data, it is possible to identify changes and dips in performance that aren’t as apparent monitoring the loop in real time. More manufacturers looking to use machine learning (ML) to evaluate their process-critical loops performance over time. This evaluation yields great insight to improve operations and know what is happening with the system when no one is watching. This approach provides a more structured and scientific defense to combating control loop performance than just the tinkering art of old.
Given the current advancements in data and analytics technology, we are in luck and have options to solve this issue. With data capture and storage
Brian Fenn is COO at Avanceon.
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This article originally appeared on www.controleng.com April 2021
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LEVEL SENSING
SMART LEVEL SENSING SOLUTION FOR REMOTE STOCK MONITORING Doug Anderson discusses a new breed of battery powered, IIoT sensors that are helping streamline the task of remote monitoring of stock.
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imple and streamlined remotemonitoring of stock has been the ultimate aim for engineers in the bulk logistics, supply chain and purchasing sectors. However, getting a stock-oversight system in place and producing valid and useful data can be a challenge. Yet at the same time it represents an opportunity for massive logistics benefits – perfected timing, fuel and time savings and optimised stock levels at all times. It also helps to avoid pitfalls like returned loads, emergency/ expedited deliveries or process shutdowns. Whether it is a liquid or a solid in a silo, tanker or truck, the dimensions and often dedicated nature of bulk shipping means that having the capability for accurate remote monitoring would offer a rapid payback. Almost immediately purchasing, ordering and billing processes would be more streamlined and supplier-customer partnerships would become more effective.
Pieces of the puzzle Although an efficient stock oversight system represents savings in fuel, time and CO2, bulk liquids and solids monitoring applications don’t come in a ‘one-size-fits-all’ solution. Each one offers its own specific combination of requirements – whether that be access, product compatibility, or container and infrastructure tracking. And, while many contracts are based on supply and delivery, others operate removal and disposal services. From fixed silos and tanks, to vessels at temporary or semipermanent sites; mobile transportation to waste collection containers – each situation presents a unique challenge. For all of these reasons the implementation of remote monitoring
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Smart farming and agriculture – grain and feed silos monitored, collection and deliveries automated, saving farmers valuable time and money.
has, traditionally been complex to develop and manage. Faced with a need to understand which screens, graphics, reports and notifications may be needed , it can be tempting to reach out to technology companies who offer seemingly capable software as a service (SaaS) solutions.
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While these systems combine mobile data and intelligent big data analysis into one neat package. Often, their technology relies on modified, low-cost, ‘off the shelf’ sensors or components to make a measurement. And many of these service providers will not have a good understanding of the Control Engineering Europe
LEVEL SENSING
application, or the reality of the longterm performance demands of remote monitoring of stock. The data output of these sensors can be affected by typical operating challenges, of which there are many. They can be environmental – wind, rain, dirt, spray – build up on sensor or related to the medium – foaming liquids, vapours. Dust and condensation can also occur inside vessels, containers and silos on a regular basis which can pose a challenge for some sensors. In a remote stock monitoring application it is crucial to have confidence in the data that is being received because major decisions and logistics movements are made based on this data. An incorrect journey or schedule will likely have many knock-on effects for the business. Without doubt, small, low-power, smart sensors are the answer for the future of applications in the bulk logistics, supply chain and purchasing industries. However, the data measurement technology needs to be robust, long term and reliable; requiring minimal maintenance even in challenging applications. Uninterrupted operation of a stock oversight system in these conditions represents huge gains via optimisation, for both supply (of materials) and collection (of waste and recycling items).
Sensing experience A new hybrid sensing technology is emerging from the field of process and control, that can offer a greatly simplified and self-contained remote stock monitoring solution. The best type of solution will combine experience with cutting-edge technology. You will find both in the emerging new breed of non-contact, battery-powered level sensors, which incorporate Industrial Internet of Things (IIoT) capabilities. Incorporating dedicated microprocessors, these sensors can provide remote data in an easy-toaccess format and can also offer wireless communication, stand-alone battery power for up to 10-years, are ready to communicate via standard global Control Engineering Europe
IBC level monitoring through the top of a plastic tank and location tracking, all from one single smart sensor.
wireless networks and locate via GPS. All from a single, compact and autonomous device. These sensors can take on almost all challenges associated with level measurement of the content of vessels that store or transport a variety of bulk liquids or solids – from waste, to water, to chemicals, powders, granules, foodstuffs and oils. They are also simple to install and easy to set up – quickly and flexibly delivering stock management information, in a variety of formats to suit application requirements.
Simple and scalable Whether you are installing the solution at one site or hundreds, implementation should be made simple. After installing the sensor on the chosen monitoring point, container,
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tank or silo, accessing the data and beginning to manage stock remotely should be as straightforward as simply logging in. Data suppliers who have experience of manufacturing the sensors and making measurements in the field are more likely to take care of everything from sensor to server, and right to your screen, taking responsibility for it all. They can help realise the ultimate goal of having a truly visible, global inventory management solution that is able to connect you an ingredient tank on site, a fuel distribution depot, international chemical supplies, or an animal feed hopper on the other side of the world. plus-circle Doug Anderson is UK marketing manager at Vega Controls. April 2021
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FINAL WORD
ONE VOICE, ONE VISION While UK manufacturers seek to recalibrate from one of the most challenging financial years in a generation, the emergence of new machine vision technology is driving the greater adoption of automated inspection technology and vision-guided robot systems, says Neil Sandhu.
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believe that there is plenty of room for optimism despite the UK’s exit from the largest single market and the onset of Covid-19. It’s about having the right long-term vision that delivers a sustainable and competitive advantage. I believe that sometimes it can take something of the magnitude of the coronavirus pandemic to both move and realign the goalposts and encourage people to think outside of the box. Since 2016, the UK manufacturing industry was suspended in mid-air; not knowing which way to turn or which decisions to make for the best. And while Covid-19 has only served to complicate matters, companies are now better placed to review their business operations and make capital purchases based on fact, opposed to political hearsay. Due to the complexities borne out by Brexit, labour shortages, and increasing supply chain demand, machine vision technology will only increase in demand as the industry moves towards automating more of its process and procedures. The challenge, however, is not what can be achieved through vision, but being able to close the knowledge gap of people’s understanding of it; and how the technology and software can be used.
A red herring There has long been a school of thought that, to automate a process, you need to have an in-depth understanding of the technology, which is a red herring. Yes, it’s important to know what you’re buying, but it’s more important to understand what you’re
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looking to achieve from the outset and avoid the propensity to change too much too soon. While the areas of application in industrial vision are diverse, advances in vision technology are now a driving force behind industrial automation; providing machines with a humanlike ability to detect defects on products, guide robots, improve health and safety, and help optimise factory operations. Following changes to the immigration rules and right to work in the UK, we can expect robotisation to become commonplace throughout industry as quality control is tightened, margins get squeezed and competition increases from overseas suppliers. Autonomous mobile robots (AMRs), for example, is one area of change. They are already starting to replace automated guided vehicles (AGV) within high volume UK logistics environments through the advance of 3D vision technology. Gone are the days when
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a manual handling machine should be used to move parts to us in a delivery area, and then involve a manual process to pack the goods. It’s a laborious process and does not stimulate employees’ mental and physical wellbeing. The buzz words from the last two machine vision conferences in the UK revolved around artificial intelligence (AI) and deep learning. The capacity offered by AI is immense; however, the industry still has some work to do to place context around AI and the full scope of 3D vision technology and applications available; then and only then will vision move from perception to reality across the wider manufacturing community. It all comes down to what application you are looking to automate and the reason for doing so. The cost of the technology and capital equipment needed to automate is also coming down, which lends itself to a more favourable return on investment to ease the justification. Whether through the outcome of Brexit or Covid-19, there is a renewed sense of urgency to gain a competitive advantage. Therefore, the question that manufacturers perhaps need to ask themselves is why they wouldn’t now invest in new robot and vision technology to avoid potentially languishing behind? To find out more you can register for the forthcoming Machine Vision Conference & Exhibition (15 July 2021) at: www.machinevisionconference.co.uk. Neil Sandhu is chairman of UK Industrial Vision Association (UKIVA). He is also a product manager at SICK (UK). Control Engineering Europe
PRODUCT FORUM •
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Rotork launches a cloud-based Intelligent Asset Management system Rotork has launched a programme of advanced analytics for the management of intelligent flow control assets. Intelligent Asset Management is a cloud-based asset management system for intelligent actuators and the flow control equipment they operate. It is a system of advanced analytics to improve reliability and availability of key assets (such as valves) across all industries that use flow control processes. Failure of key equipment on any site or plant can result in unplanned downtime, poor performance, reduced output yields and reputational damage. By collecting data and monitoring asset status, Intelligent Asset Management can lead to longterm operational stability. Intelligent Asset Management uses the information downloaded from the data logs recorded within intelligent actuators. It is a robust, safe and secure online platform with a simple to use intuitive interface that can run on all operating systems. Summary views and colour coded maps simplify complex analytics into easy to understand visuals. The key areas of information that are taken from data loggers and uploaded to Intelligent Asset Management are torque, temperature, vibration and event log information (such as open and close starts log, movement log and alarm log). Live diagnostic actuator data is available for sites that use a Rotork Master Station (via the Gateway computer), such as alerts and actuator status.
Control Engineering Europe
The advanced analytics within Intelligent Asset Management remove the need to manually review data, saving time. Early detection of issues will allow resolution before costly failure, aiding Rotork’s customers in saving money and reducing downtime. Intelligent Asset Management is available both as a standalone offering and as part of a combined solution to meet individual customer needs. Performance, process criticality, product and operational data are combined to assess asset condition and determine if any intervention is required to prevent performance degradation or failure. Intelligent Asset Management is suitable for use with all intelligent actuators across multiple applications, including oil and gas, water and power, and chemical, process and industrial markets. Intelligent Asset Management is an extension of the existing Lifetime Management service offering. Lifetime Management is the suite of services within Rotork Site Services which help manage the life cycle of flow control assets; Intelligent Asset Management is the advanced analytics arm of this service programme. It is also available as a standalone option.
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+44 1225 733200 information@rotork.com www.bit.ly/RotorkCEE
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April 2021
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