Automation World Product Selection & Applied Technology Handbook April 2022

PRODUCT SELECTION & APPLIED TECHNOLOGY HANDBOOK 2022

If it’s in your panel, it’s at AutomationDirect.com...for less!

Simple PLC

Circuit protection including MCCBs, circuit breakers, and transfer switches (Circuit breakers starting at $13) Wiring solutions including cut-to-length cable, hookup wire, wire duct, conduit, terminal blocks, and cable entry systems (Wire duct starting at $6.75) Drives, soft starters, and motor control devices (Micro AC drives starting at $117)

Enclosure lighting and thermal management (Thermoelecric coolers starting at $649)

Industrial power supplies, transformers, and converters (DC power supplies starting at $19)

PLCs, field I/O systems, motion controllers, servo and stepper systems (PLCs starting at $79) Industrial Ethernet switches, gateways, and VPN routers (Ethernet switches starting at $83)

Safety products including safety controllers, safety relay modules, intrinsically safe isolators, etc.

(Safety relays starting at $99)

Modular and pre-fabricated enclosures (Modular enclosure kits starting at $648)

Don’t overspend elsewhere. With our everyday low prices you can build your panel for a lot less!

Plus motors, HMIs, pneumatics, a huge assortment of sensors and pilot devices, and so much more. All at great prices and with award-winning customer service and support.

Research, price, buy at:

CPU starting at only

$89 with FREE softw

Since 2008, and with close to a mill sold, CLICK PLCs have become an ind simple, affordable control. This popula now been supercharged with feature expect from a low-cost controller.

Wi-Fi, MQTT communication and in measures are just a few of the imp that make the new CLICK PLUS PLC have” for simple control...with a kick!

The NEW 2-slot C provide even m offering over 4 PLC I/O com plenty of analog and combinatio slot modules av add more serial ports with the serial commun slot module.

www.automationdirect.com Order Today, Ships Fast! * See our Web site for details and restrictions. © Copyright 2022 AutomationDirect, Cumming, GA USA. All rights reserved.

2204-AutomationWorld_Supp_Spread-CLICKPlus-MAG.indd 1

PRODUCT SELECTION & APPLIED TECHNOLOGY HANDBOOK 2022

l, it’s at m...for less!

Simple PLC control with a KICK

uding MCCBs, circuit breakers, (Circuit breakers starting at $13)

ding cut-to-length cable, hookup it, terminal blocks, and cable

t starting at $6.75)

nd motor control devices

$117)

d thermal management

ing at $649)

plies, transformers, and converters (antenna sold separately)

at $19)

, motion controllers, servo and

tarting at $79)

witches, gateways, and VPN routers

at $83)

ding safety controllers, safety ically safe isolators, etc.

)

icated enclosures

ting at $648)

eumatics, a huge assortment evices, and so much more. All at award-winning customer service

Research, price, buy at:

CPU starting at only

$89 with FREE software Since 2008, and with close to a million components sold, CLICK PLCs have become an industry favorite for simple, affordable control. This popular PLC family has now been supercharged with features you wouldn’t expect from a low-cost controller. Data logging, Wi-Fi, MQTT communication and increased security measures are just a few of the impressive features that make the new CLICK PLUS PLC series a “must have” for simple control...with a kick!

The NEW 2-slot CLICK PLUS CPUs provide even more versatility, offering over 400 stand-alone PLC I/O combinations with plenty of analog, discrete, relay, and combination I/O option slot modules available. Or easily add more serial communication ports with the NEW C2-DCM serial communication option slot module.

AutomationDirect

PLC Comparison

CLICK PLUS

(2080-LC50-24QBB)

$227.00

• Dimensions: 101.8 x 87.8 x 87 mm (4.01 x 3.46 x 3.42 in.)

• No built-in I/O • Supports 2 option slot I/O modules • Up to 8 expansion I/O modules • Ethernet, serial, micro USB ports • Data logging (microSD)

CPU

Max Discrete I/O Max Analog I/O High-speed I/O

156 points

132 points including base, plug-ins, and expansion I/O

60 channels

44 channels

including option slot modules and expansion I/O

including plug-ins and expansion I/O

8 inputs

8 inputs, 2 outputs embedded w/ 3 optional plug-in inputs

starting at

$54.00

16 modules available w/ analog, discrete, relay, and combination options

starting at

Expansion I/O

$37.50

100kHz for embedded I/O, 250kHz for plug-ins with up to 7 counters - 4 embedded counters + 3 plug-ins

starting at

$69.40

13 modules available w/ analog, discrete, temperature, high-speed, relay, and combination options

starting at

$121.72

27 modules available w/ analog, discrete, temperature, and relay options

13 modules available w/ analog, discrete, temperature, and relay options

 

X

FREE

FREE

MQTT Wireless Communication

$687.65

• Dimensions: 90 x 158 x 80 mm (3.54 x 6.22 x 3.15 in.)

• Built-in I/O: 24 Discrete I/O (14 inputs, 10 outputs) • Supports 3 plug-in I/O modules • Up to 4 expansion I/O modules • Ethernet, serial, USB 2.0 ports • Data logging (microSD)

including option slot modules and expansion I/O

100kHz with up to 6 counters, including option slot modules

Option Slot / Plug-in I/O

Allen Bradley Micro850

(C2-03CPU-2)

X

Wi-Fi (802.11b,g,n), Bluetooth (used with Mobile app to provision network settings)

Programming Software

C0-PGMSW

Connected Components Workbench

All prices are U.S. published estimated retail prices. AutomationDirect prices as of 11/30/2021. Allen Bradley hardware prices taken from https://export.rsdelivers.com/ on 11/30/2021.

Research, price, buy at:

www.CLICKPLCs.com

www.automationdirect.com Order Today, Ships Fast! * See our Web site for details and restrictions. © Copyright 2022 AutomationDirect, Cumming, GA USA. All rights reserved.

1-800-633-0405

PRODUCT SELECTION & APPLIED TECHNOLOGY HANDBOOK 2022

the #1 value in automation

3/16/2022 10:44:38 AM

Contents 08

Applying Value Drivers to Select Analytics Software

11

How to Choose a Controller

14

Deciding Between DC and AC Motors

18

Selecting Sensors for IoT Applications

22

Extracting Legacy Equipment Data for Industry 4.0

24

The Value Proposition Behind Combining SCADA and MES

28

Determining Your Need for Industrial Wireless

PRODUCT SELECTION & APPLIED TECHNOLOGY HANDBOOK 2022

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senior engineer, E Technologies Group

Allan Hottovy

retired (former sales training development manager), Schneider Electric

Laurie Cavanaugh

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Applying Value Drivers to Select Analytics Software Learn how assessing confidence in vendor, development effort, and platform cost can help you evaluate how software-as-a-service and open-source analytics platforms compare.

N

ew software-as-a-service (SaaS) analytics platforms enter the manufacturing industry every year. Each platform has unique value adds, ranging from preferred data types to modeling algorithms and feedback loops. Each platform can also solve many data needs in manufacturing. Open-source software is emerging with expanding capabilities as well.

Open-source software platforms offer basic functionality at very low to no cost. The choice between SaaS platforms and open-source software platforms is a decision based on purchasing capabilities versus internal development capabilities.

To determine which method will deliver the best results for your operation, look carefully at three key value drivers of analytics platforms: confidence in vendor, development effort, and platform cost. Then, consider how SaaS platforms and open-source software platforms compare in these categories:

features, and more support of their products. These platforms generally provide integrator certifications that ensure knowledgeable system integrators. These benefits build confidence in a purchase decision. Clients can rely on their integrators and the platform vendor.

Open-source software platforms have fewer learning resources and less documentation. Resources and documentation may be less organized than

CONFIDENCE IN VENDOR

SaaS platforms have more learning resources, more documentation of

PRODUCT SELECTION & APPLIED TECHNOLOGY HANDBOOK 2022

The choice between SaaS platforms and open-source software platforms is a decision between purchasing capabilities versus internal development capabilities.

Applying Value Drivers to Select Analytics Software

that of their larger competitors.

Clients lean on the knowledge of the integrator more than the platform vendor.

Here, the value advantage goes to SaaS platforms.

DEVELOPMENT EFFORT

SaaS analytics platforms are designed to span various industry verticals and layers of industrial control, allowing them to be marketed as versatile and flexible.

The drawback here is that, being everything to all verticals and layers means that such software is not of specific value to any one of them. As a result, these large platforms can require as much programming as smaller options.

This means that a standard implementation factor in industry is likely equal to the license costs.

PRODUCT SELECTION & APPLIED TECHNOLOGY HANDBOOK 2022

Applying Value Drivers to Select Analytics Software

Open-source software platforms require more development time relative to their license fees, if they have any license fee at all. This is generally due to the software having fewer standard features. As a result, development with open-source platforms may have a slower start because of base feature development.

Here, the value advantage between the two options is even.

tool costs $45,000 annually for 20 users. That price is equivalent to major site-wide HMI software packages with a similar number of users.

Open-source platforms can range from cheap to free.

Costs can be incurred from server resources, but many capable solutions are free. Some popular free analytics software packages are KNIME, Node-Red and Grafana.

Here, the value advantage goes to open-source platforms.

COST

BOTTOM LINE

The costs for big analytics platforms vary for a variety of reasons. These reasons can include feature set, tier of service, number of licenses, one-time purchase options, and SaaS options. In the past, many vendors offered prices that fit an IT purchase profile, but now costs are increasingly being structured or reduced to fit the manufacturing profile. Costs are still high relative to existing software used to operate a manufacturing plant.

For example, one well-known time-series data analytics

With the advantages across these three value drivers relatively even between SaaS and open-source platforms, buyer discretion is needed to fit the best software package to the industrial data use-case. While big platforms offer powerful features and many support resources, they may not be the right solution all the time. That’s why it’s important to also consider opensource platforms.

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PRODUCT SELECTION & APPLIED TECHNOLOGY HANDBOOK 2022

How to Choose a Controller Compare your application to the specific capabilities of each controller type to ease the decision-making process associated with PLC, PAC, and industrial PC controller purchases.

T

he heart of any automated system is its controller. This is where the decisions are made that signal actuators in the system to launch into action based on feedback supplied by sensors.

But implementing a controller requires a series of decisions by the integrator or end user based on the application. A key controller decision revolves around which type of controller to use—a programmable logic controller (PLC), a programmable automation controller (PAC), or industrial PC (IPC).

The primary difference between a PLC and PAC is that a PAC is similar to a PLC but with additional features. An IPC can run the same software found on a PAC, but with the full features of a PC.

PLC-PAC-IPC DIFFERENCES

PLCs are typically used to control a relatively small number of I/ Os, both analog and discrete, and in a PLC the physical I/O is often tightly coupled both to the programming language and to the PLC hardware itself. They can communicate with network devices such as

drives, but it often requires adding on additional modules to expand their [built-in] capabilities.

A feature typically associated with a PAC is its ability to be programmed in languages other than ladder logic. Languages such as structured text, function block diagrams, and flowcharts can be used to program a PAC. PACs also inherently use standard communication protocols to communicate with a wide variety of network devices more efficiently, such as remote I/O, remote panels, and devices like drives. They can also handle complex applications like motion, advanced process control, and integrated safety.

Another consideration are the address-based and tag-based memory structures of these controllers. Address-based structures, common in most major PLCs, come with a predefined range of integers, timers‚ or Boolean addresses. A tag-based controller is not restricted to using only those predetermined address ranges. In a tag-based controller (which most PACs are) you can give an address any name you want.

In this manner, PAC programming resembles higher level computer

PRODUCT SELECTION & APPLIED TECHNOLOGY HANDBOOK 2022

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How to Choose a Controller

programming languages like C, where variables are created as needed.

An IPC can also be programmed to run the same control software used on a PAC, but it runs on a full-blown industrial computer. With its more complete computing resources, an IPC typically comes with an operating system familiar to most end users and the IT department, such as Windows or Linux.

IMPORTANCE OF THE APPLICATION IN DECISION-MAKING

Ultimately, the application should dictate which type of controller you choose. Remember that PLCs are well-suited for standalone machines because they're robust and simple. This fact also makes it easier for maintenance personnel or technicians familiar with technical drawings—the basis for ladder logic commonly used in PLC programming— to troubleshoot PLCs rather than the PC programming languages often used in PACs and IPCs.

PACs are commonly preferred for controlling larger processes and integrating safety, motion, distributed I/O, and network communications.

You can get a PLC to talk to network devices like a PAC, but you often have to add on hardware modules to perform those types of tasks whereas a PAC is designed to communicate with network devices by default. For example, PACs come with function blocks that deal specifically with motion and safety.

An IPC offers the same advantages of a PAC but with even more added capabilities, such as the ability to run middleware. You can run databases, protocol converters, recipe managers, and even SCADA and MES software on the same IPC you're using as the automation controller. However, because IPCs typically run an operating system like Windows or Linux, it’s important to realize these operating systems are not optimized for high-performance or deterministic industrial applications.

PRODUCT SELECTION & APPLIED TECHNOLOGY HANDBOOK 2022

Deciding Between DC and AC Motors A look at how AC motors gained ground in industry over the years and how to determine whether an AC or DC motor is the best choice for your application.

D

C motors were king in industry up until the late 1980s. They were popular because they could run to a variable speed setpoint and run at full torque from stall to base speed.

A DC motor was powered from either a constant potential supply or a Ward-Leonard system via a DC generator. The speed of a DC motor is defined by the voltage applied to the armature and other influencing motor design constants. Speed could be easily measured by calculating counter-EMF (electromagnetic frequency) using measurements of armature voltage and current.

There are two types of DC motors: brushed and brushless. Brushed

is the oldest type of motor and includes a field coil mounted to the stationary portion or frame, an armature rotating portion, and brushes to carry current to the armature. The direction and speed are controlled by the applied voltage. The torque is measured by the armature current.

Historically, AC motors were used primarily for fixed-speed applications.

AC motors could run at different RPMs of 3600, 1800, or 1200 for operation at 60Hz. Pumps and fans were run with across-the-line starters at a fixed frequency applied to the AC motor.

AC motors began to dominate the variable speed market in the 1990s due to the wide availability of inverter drives and vector

Ultimately, when deciding beween AC and DC motors in a brownfield site, it comes down to the upfront cost of conversion versus the long-term benefit of offsetting your maintenance cost.

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PRODUCT SELECTION & APPLIED TECHNOLOGY HANDBOOK 2022

Deciding Between DC and AC Motors

control. AC motors get their ability to change speed because of variable speed drives using IGBTs (insulatedgate bipolar transistor) for the power section, where the frequency can be varied. Torque control is now available with AC vector drives through mathematical modeling of an induction machine where computers calculate the magnetizing current vs. the torque producing current.

When choosing which motor would be best for your project, you need to weigh the advantages and disadvantages of each motor.

AC ADVANTAGES:

• NEMA standards for frame sizes.

• At least 95% efficient for typical applications.

• On an induction machine, the stator induces the current into the rotor.

The only physical contact between the rotor and stator are the

PRODUCT SELECTION & APPLIED TECHNOLOGY HANDBOOK 2022

Deciding Between DC and AC Motors

bearings. The motors can be commonly ordered “totally enclosed” so that it doesn’t get dirty on the inside, leading to less chance of an electrical failure.

• There are a significant number of manufacturers in the marketplace, so it’s easy to find an AC motor manufacturer.

• AC induction motors have no brushes reducing maintenance costs.

• Easy to repair and recondition.

• Typically outperforms AC motors for stall operations.

DC DISADVANTAGES:

• 88-92% efficiency range for most motors.

• Finding a DC motor to replace an old one is difficult, and reconditioning can be costly. Fewer manufacturers are making new DC motors for sale.

• DC motors are expensive to make and build.

• These motors are generally open to the environment, allowing dirt and dust ingress.

• High maintenance costs, as inspections and brush change should occur at least every three months.

AC DISADVANTAGES:

• An AC motor may need a digital encoder or tachometer to get torque from zero speed.

• For low-speed operations with a variable speed drive, an inverter duty rated motor is required.

• When replacing a DC motor with an AC motor, new wires and mounting are upfront costs which need to be considered, as they can be expensive.

• Limited operation above motor base speed.

DC ADVANTAGES:

• Fairly reliable and widely used in industry.

• Wide speed range available, often up to 5 times rated base speed.

• Torque control available from zero speed without an encoder.

Most motor experts recommend buying an AC motor if you’re building something new. For most applications in heavy industry, AC conversion from DC is the right choice in the long term if costs are in line for the business.

Ultimately, it comes down to the upfront cost of conversion versus the long-term benefit of offsetting your maintenance cost. Upfront costs should include mechanical conversions and new wiring. Longterm savings will be found in reduced maintenance and power savings.

PRODUCT SELECTION & APPLIED TECHNOLOGY HANDBOOK 2022

Selecting Sensors for IoT Applications Smart sensors are one of the cornerstones of the Industrial Internet of Things. That’s why it’s critical to understand their capabilities—from their embedded intelligence to their security considerations.

W

hile connectivity is the key ingredient in Industrial Internet of Things (IIoT) applications, sensors run a close second. After all, most IIoT projects are centered on aggregating and analyzing sensor data from an array of devices to improve maintenance and production operations. In fact, most IIoT applications involve deploying many more sensors than have traditionally been used as a means of collecting as much data as possible for analysis.

Because of their lack of intelligence, traditional analog sensors only convert a physical input such as stress, force, or temperature into an electrical signal. That means their signals need to be fed into a recorder or other device for analysis. These post-test analyses can be expensive and require attention from personnel.

One of the big benefits of Internet of Things (IoT)-enabled sensors is that they eliminate these post-test labor costs through their onboard intelligence and ability to communicate with a centralized computer.

This translates into an IoT sensor’s ability to perform automatic

calibration and monitor or collect information on a system's health, which results in decreased operational costs. The ability to process more information is the true power of the modern IoT sensor, which allows it to record, analyze, and make decisions with data. Traditional sensors had very limited capabilities in this regard.

EMBEDDED INTELLIGENCE

Another important feature of IoT sensors is their ability to self-identify on a network. The ability of IoT sensors to self-identify, coupled with their speed and analytics capabilities, means you can do a lot more processing in real time on the device. The data reduction and bundling of data through on-device analytics is an important feature when you’re trying to extract information and make decisions from it.

The embedded intelligence in IoT sensors also enables users to perform an array of additional tasks, ranging from the mechanical to the analytical. For example, you can use the embedded intelligence on an IoT sensor to perform mechanical tasks like creating a limit switch

PRODUCT SELECTION & APPLIED TECHNOLOGY HANDBOOK 2022

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PRODUCT SELECTION & APPLIED TECHNOLOGY HANDBOOK 2022

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Selecting Sensors for IoT Applications

for pressure to send a signal to turn the pump off when the pressure gets to 60 psi or to send another signal when the pressure drops to 40 psi. On the analytical side, you can use IoT-enabled sensors to examine the efficiency and current draw during a process or to do a filtered root mean square (RMS) conversion of vibration data to examine varying conditions.

COST FACTORS

The cost of any IoT sensor you’re considering should be reviewed considering the sensor’s capabilities to perform essential functions like self-identification and self-calibration, because these capabilities reduce operating costs.

It’s also important to remember that these sensors will likely be in use for 20 to 30 years. Therefore, it’s best to avoid proprietary or

one-of-a-kind technologies that create a lot of market buzz. Look for reliable, robust, tried-and-true technologies that can be installed and then forgotten about for 20 years.

This approach may cause conflict with the IT department, but the fundamental thing to remember is that this is capital equipment designed for decades of work and the transmission needs of the system must be supported.

WIRED VS. WIRELESS

Most experts advise being open to using wired or wireless IoT sensors.

A good guideline is to only use wireless when wiring is difficult or costly, as hardwired signals tend to be more secure. Plus, wired sensors tend to provide a stronger signal so you don't have to worry about a truck or palette getting in between a transmitter and receiver.

The ability to process more information is the true power of the modern IoT sensor, which allows it to record, analyze, and make decisions with data.

PRODUCT SELECTION & APPLIED TECHNOLOGY HANDBOOK 2022

Selecting Sensors for IoT Applications

SECURITY FACTORS

As with any connected device, connected sensors bring with them a host of security concerns. That’s why it’s best to stick with fundamental ideas (e.g., always have a good reason to connect to the Internet).

Make sure there’s a clear benefit and a clear need for it because every new connection is another access point a hacker could target.

When it comes to connecting devices of any type to an operations network, be overly cautious in system design and isolate and control access to the space as much as possible. Stick with the tried and proven standards with robust multi-path security checks.

PRODUCT SELECTION & APPLIED TECHNOLOGY HANDBOOK 2022

Extracting Legacy Equipment Data for Industry 4.0 Why MQTT and cloud computing are critical components of legacy equipment data collection and analysis as part of your digital transformation strategy.

I

f you’re involved in any kind of Internet of Things (IoT), Industry 4.0, or advanced manufacturing initiative, a key task will involve extracting data from older equipment. Given that many automated devices and pieces of equipment used in industry pre-date the development of centralized data aggregation standards, this task is not as straightforward as it seems.

Before you head out to collect all the data you can from your equipment, there are many important questions to ask, the first of which should be: What would that equipment data enable you to do if it was available in real-time?

This question is important because it addresses the way in which data is stored, accessed, and gathered. This ultimately determines what kind of changes you're capable of achieving with it. After all, if you have a factory floor with one hundred machines on it, you shouldn’t go after the data from all one hundred machines immediately. Instead, you should start with one machine to learn which data collection methods work best for you, and then scale that approach.

Once your company knows how it can use a particular range of data or data set from a particular piece of equipment it can put that data in a repository

and use it as a baseline to determine the best data extraction methods for other pieces of equipment. From there, it can be used to scale up.

DATA FORMAT AND COMMUNICATION DIFFICULTIES

Older equipment can be more difficult to extract data from, especially devices that communicate using serial communication protocols or proprietary protocols.

Most legacy devices will not have a built-in ability to transmit data using modern IoT communication protocols, nor will they be able to communicate with IoT platforms directly. This means you’ll likely have to install a translator between the legacy device and the edge-of-network device used to collect the data. You’ll want to translate the data from the legacy protocol into a more modern version, such as MQTT (message queueing telemetry transport), so that you can then use it in different ways.

Ethernet-based communications, however, tend to be easier to collect and transfer. Regardless, you should still pay attention to the format used for any extracted data. Formats such as JSON (JavaScript Object

PRODUCT SELECTION & APPLIED TECHNOLOGY HANDBOOK 2022

Extracting Legacy Equipment Data for Industry 4.0

Notation) will typically be more viable with IoT platforms than files in .csv or .xml formats.

POWERING...

AUTOMATION

THE IMPORTANCE OF MQTT AND THE CLOUD

Most industry experts agree that MQTT is going to be the most common and readily supported data messaging service for the foreseeable future.

A publish/subscribe message broker, like those used for MQTT, are scalable and built for the future. Plus, all software systems, whether they’re SCADA (supervisory control and data acquisition), CMMS (computerized maintenance management system), or ERP (enterprise resources planning), can connect to MQTT message brokers.

Once you’ve targeted and are collecting the data you need, don’t overlook the importance of aggregating the data you collect in the cloud. Though some people in industry still have reservations about cloud data storage, the cloud is integral to industrial data collection and analysis because, once your data is in the

cloud or another data repository, there are a host of services and software applications that can help you with it. This can entail data visualization, something like Microsoft’s Power BI or Tableau, and specific applications for tasks like predictive maintenance.

These tools go beyond what humans can do in terms of drawing insightful conclusions.

They’re also a good way to make the data available to those with credentialed access wherever they may be located.

The bottom line is this: You want to be able to get your data when you need it and putting it in the cloud does that the best.

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The Value Proposition Behind Combining SCADA and MES System consolidation offers several cost and complexity reduction benefits. But when it comes to mission critical systems such as SCADA and MES, do the benefits outweigh the risks?

T

echnology convergence is well-known in nearly every sector. We’ve all seen it happen in the consumer tech sector, most notably as our cell phones transformed into smartphones that allow us to make and receive phone calls, visit websites, provide GPS travel directions, conduct video meetings, take high quality photos, and much more.

This kind of convergence happens in the industrial sector too.

A couple of high-profile examples include the programmable automation controller, which extends the capabilities of a programmable logic controller with broader industrial computer capabilities and, more recently, the growing combination of robot and vision technologies to expand and enhance industrial robotic picking and placing.

This combination of existing technologies, particularly in industry, serves two purposes—to extend the capabilities of each technology beyond what each could do on its own and to reduce the number of systems that operators or managers need to rely on for information. With respect to the latter purpose, it’s as much a technology consolidation as a combination.

One early example of this can be seen in the evolution of MRP (materials

requirement planning) into ERP (enterprise resource planning), as more front office and plant applications were combined with what was originally a production planning and scheduling tool.

Now, we’re beginning to hear about the potential of combining MES (manufacturing execution systems) and SCADA (supervisory control and data acquisition) technologies.

DIFFERENCES AND OVERLAPS

Looking at the differences and similarities between MES and SCADA to better understand where possibilities supporting this potential convergence make the most sense, the first thing you see are the overlaps.

Both MES and SCADA systems are software tools designed to perform different functions. MES manages your production orders and the data relevant to them; it also analyzes your raw production data and transforms them into more useful information, such as track-and-trace information.

Similarly, an MES may summarize raw data into KPIs (key performance indicators). MES also needs to communicate in real time to your SCADA

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PRODUCT SELECTION & APPLIED TECHNOLOGY HANDBOOK 2022

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The Value Proposition Behind Combining SCADA and MES

systems and work transactionally with business and ERP systems.

On the SCADA side, this connection to MES is defined by the ability to connect to plant floor equipment, particularly PLCs, sensors, and other shop floor devices. Raw data records from these devices are often kept in that SCADA layer. Most importantly, SCADA provides the means for human operators to see what’s happening with the plant floor equipment and help to control it.

The main driver behind the idea of combining MES and SCADA is reducing hardware and license costs.

PURDUE MODEL PERSPECTIVE

Since both systems are focused on device data acquisition and visualization, it helps to view them with respect to the ISA 95 or Purdue Model.

At Level Zero of the Purdue Model are the physical production processes that happen in real time. At Level Four, business system communications are more transaction based and operate in terms of weeks and quarters.

Therefore, a SCADA system at Level Two needs to be able to communicate much faster when interfacing with PLCs. That’s why it can communicate at sub-second rates.

MES works on a slightly longer time scale; it is not usually going to be getting into sub-second level control data. Instead, it's more focused on hours, shifts, days, or even weeks.

This difference in speeds between the two systems affect the protocols that each of the systems use. SCADA needs to be interfacing with industrial protocols like OPC, EtherNet/IP, or Modbus, whereas MES has an even wider range of communication protocols it needs to

support because it talks to SCADA systems—usually through OPC or database connections—but also to the business systems through a firewall using web services and other protocols. Those connections enabled by OPC and database connections are where the potential to connect MES and SCADA lie.

Also, both systems are used to manage production assets. However, they do so at different scales. For example, think about the temperature of a batch tank. A SCADA system wants to know the temperature of the batch tank tag and it wants to monitor this every second because if it starts to drift in a bad direction, the SCADA system is going to be where you’ll issue your correction to bring that temperature back into control.

PRODUCT SELECTION & APPLIED TECHNOLOGY HANDBOOK 2022

The Value Proposition Behind Combining SCADA and MES

The MES is going to care about the temperature of the tank too, but it likely only cares if it went out of spec and it needs to know an exception for future quality review. So, while they’re focused on different aspects, they are both connecting to the same type of data.

THE UPSIDES AND DOWNSIDES

Ultimately, the main driver behind the idea of combining MES and SCADA is reducing things like license costs and hardware overhead.

Another benefit involves reducing the number of screens and the process complexity that operators must deal with daily. Any time you have an opportunity to streamline operations or bring things to a single

control point to make sure that people don't need to be monitoring multiple screens to get the information they need to do their job, there are huge benefits.

Despite such benefits, industry experts advise caution if you’re thinking of combining MES and SCADA, largely due to the compute resources need to combine these independently large systems. By putting them all together, you're making a super system and you need to make sure that you have the physical compute power to monitor and maintain them. This is especially important for SCADA because it’s working in real time and is absolutely mission critical. You don't want slow network speeds to affect your ability to control your process.

PRODUCT SELECTION & APPLIED TECHNOLOGY HANDBOOK 2022

Determining Your Need for Industrial Wireless Questions to ask when considering the deployment of industrial wireless networks in your production operations.

I

ndustrial wireless technologies have been used for dozens of years to transmit data from personal devices or fixed assets based on specific job functions or where wired communication was not feasible. However, the proliferation of smartphones, tablets, and Industry 4.0 technologies such as digital twins, augmented reality, and the Industrial Internet of Things (IIoT), have expanded industrial wireless systems and capabilities with a much broader range of users and use cases—from shop floor users and geographically dispersed asset management teams to C-suite executives.

There are four major wireless platforms in use within the industrial

space today: Wi-Fi, Bluetooth, cellular, and Zigbee. These can be used independently or as hybrid systems.

For wireless to be considered a strategic part of your network, a comprehensive wireless technology plan is required that includes development of internal standards for your platform, installation guidelines, security, and ongoing management and maintenance.

Following are a few key questions to have answered to adequately develop your operational industrial wireless standards.

A comprehensive wireless technology plan is required that includes development of internal standards for your platform, installation guidelines, security, and ongoing management and maintenance.

PRODUCT SELECTION & APPLIED TECHNOLOGY HANDBOOK 2022

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Determining Your Need for Industrial Wireless

WHO WILL BE INVOLVED?

For any corporate standards initiative, there must be at least one executive sponsor who will provide updates to the rest of the executive leadership team and align the wireless standards with the organization’s current policies. In addition, the executive sponsor will offer the organization’s 1-, 3-, and 5-year business and financial goals and set funding expectations.

The remainder of the team should include representatives from departments such as IT, engineering, operations, safety, human resources, and finance. These diverse perspectives will help ensure thorough consideration of the technical requirements, system selection, return on investment, vendor qualifications, cybersecurity requirements, and staffing for ongoing maintenance and support. If a company does not have a lot of experience with wireless technologies, it is suggested they retain an outside organization with depth of knowledge in wireless technologies and security to participate in this process.

WHAT WIRELESS TECHNOLOGIES ARE IN USE AND WHAT VALUE DO THEY PROVIDE?

If the team developing your wireless standards is small or not fully dedicated to this initiative, an outside company may be needed to help identify and assess the current wireless technologies already in use today in the facility. This includes a technical evaluation addressing platform firmware and software components, lifecycle and obsolescence analysis, internal and external support, and cost of use and maintenance. In addition, an

operational or impact evaluation should be performed to determine the value provided in the form of cost or risk reduction, or revenue increase, and if this value is short-term or ongoing. The combined technical and impact assessment for existing wireless technologies will identify the systems requiring remediation, and those that may be considered as part of the wireless standards moving forward.

WHAT FACTORS ARE MOST IMPORTANT?

Every organization will value features and functionality differently, so it is important to establish not only the list of factors for evaluation, but their weighted value. For example: Is reliability more important than speed? Is durability more important than cost?

Once these factors are established, you can scorecard current and proposed wireless technologies. In some instances, where wired versus wireless is being discussed, these factors may also be helpful in that evaluation. Examples include: • Coverage range: What is the distance required? Will you need continuous coverage or is frequency hopping acceptable? Will the network be indoors or outdoors? Will public and/or private spaces or properties be a part of the wireless coverage area?

• Environment: Temperature ranges, weather conditions, potential for interference or damage, installation or placement requiring special consideration (e.g., confined space); also, will wired or hybrid wired and wireless be required?

PRODUCT SELECTION & APPLIED TECHNOLOGY HANDBOOK 2022

Determining Your Need for Industrial Wireless

• Security: Ensure you are following established and proven security measures, consider remote installation, physical and cyber-attack risks, and determine a plan for security breach responses and responsibilities.

• Speed and reliability: Identify the data packet volume and frequency required, as well as the criticality of data being collected.

• Installation, security, and maintenance costs: Evaluate the initial cost for all aspects related to ownership and use of the system, including ongoing licensing fees, hidden charges, or variable rate contracts, as well as ownership of intellectual property for all

PRODUCT SELECTION & APPLIED TECHNOLOGY HANDBOOK 2022

contracted systems. Remember to also assess the current depth of knowledge within your organization to help determine the cost and time to train personnel as needed.

• Compatibility: Determine how the wireless technology will co-exist with existing systems from the point of installation through to maintenance.

Allow time to test existing wired or wireless technologies.

• Product lifecycle: Where is the platform you’re considering in its lifecycle. Do upgrade paths exist? If the supplier is relatively new to the market, closely assess their history of maintenance and support.

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PRODUCT SELECTION & APPLIED TECHNOLOGY HANDBOOK 2022

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