Automation World March 2023

Level Sensors

Starting at $13.00 (FLS-VM-100)

Level sensors monitor the level of liquids, pellets, powders, and other similar products in tanks and process systems.

• Ultrasonic level sensors

• Float, capacitance, and vibration level switches

• Rotating paddle level switches

• Guided wave radar level sensors

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Temperature Sensors

Starting at $20.00 (THMJ-B01L06-01)

Temperature sensors provide accurate and reliable feedback for temperature control and monitoring applications.

• Optris infrared pyrometers

• Temperature switches and transmitters

• Digital temperature switches/transmitters

• Thermocouples, RTDs, and thermowells

NEW! Float Level Switches

Starting at $17.25

(FLS-VM-700)

New ProSense float level switches include models for use in HVAC condensate lines and models with a 3/4 in. MNPT connection for 55-gallon drum applications. Additional topand side-mount options offer compatibility with a wide range of liquid types, temperature ranges, and system pressures.

Pressure Sensors

Starting at $87.00 (QPSL-AP-42)

Pressure sensors measure pressure at a specific point in the process and transmit the measured value or trip point to a control device.

• Pressure switches and transmitters

• Digital pressure switches/transmitters

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• Winters pressure accessories: siphons, snubbers, and isolation needle valves

Flow Sensors

Starting at $66.00 (FG1W-100PP-28)

Flow measurement devices monitor liquid media and provide reliable flow indication, detection or measurement.

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The Digital Twin Takes Shape 22

Industrial companies are creating digital twins aimed at boosting e ciency, productivity, and plant performance.

EtherNet/IP: A CIP-Based Protocol for Discrete and Process Applications 29

This installment in Automation World’s continuing series on key industrial network technologies clarifies what EtherNet/IP is and traces its development as a leading Ethernet-based industrial networking protocol.

Accuride Extends MES to Its Test Labs

By thinking about its test centers as part of its manufacturing operations, Accuride extends the manufacturing execution system module of its Plex Smart Manufacturing platform to provide visibility into test summaries and analytics.

EDITORIAL

David Greenfield Editor-in-Chief

dgreenfield@automationworld.com / 678 662 3322

Mat Dirjish, James R. Koelsch, Stephanie Neil, Jeanne Schweder, and Beth Stackpole Contributing Writers

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AUDIENCE & DIGITAL

Elizabeth Kachoris Senior Director, Digital & Data

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David Newcorn President, PMMI Media Group

PODCAST SERIES

Why Use Guide Wheels in Linear Motion Systems?

Bishop-Wisecarver explains why guide wheels are often used as a component of linear motion systems in automated machinery and why they’re considered critical to the dependability of such systems, especially in harsh environments.

AUTOMATION WORLD TV

Beckho ’s Hypervisor Technology

Doug Schuchart, global intralogistics industry manager at Beckho , explains the TwinCAT/BSD Hypervisor technology and what the use of virtual machines can bring to manufacturing control system operations.

TECHNOLOGY MATTERS

Artificial Intelligence Operates Chemical Plant

A look at how Yokogawa’s AI technology controlled a JSR chemical plant for 35 days and how manufacturers are using AI to analyze sensor data.

AUTOMATION WORLD E-BOOK

The Long-Term E ects of Remote Access

As the virtual world creates new end user expectations, OEMs and technology suppliers are required to partner in new ways.

WEBINARS

Why Automate – Manufacturing Considerations in Today’s New Normal

Explore the “how” and “why” of manufacturing from the vantage point of today’s decision-makers as they evaluate robotics and manufacturing within their business.

Leading Manufacturers Show How to Accelerate

Skilled labor shortages, risk mitigation, and supply chain disruption are ongoing issues across the manufacturing industry. Why are some companies succeeding while others struggle?

Has the Digital Transformation Reached an Inflection Point?

By David Greenfield Editor-In-Chief dgreenfield@automationworld.com

The concept of industry’s digital transformation is typically teased along the lines of new operational capabilities and business possibilities. Though such positioning is accurate, the reality is that digital transformation has fast become less of an optional enhancement and more of a requirement.

“It’s the only way to respond to sustainability, changing customer requirements, competitors who are in the process of transforming, increased operating resilience, supply chain volatility, cost control, and increasing product and packaging complexity,” said Greg Gorbach, vice president of digitalization and Internet of Things at ARC Advisory Group, during the ARC Industry Leadership Forum 2023.

Citing recent ARC Advisory Group research of industrial manufacturing and processing companies, Gorbach noted that 15% of respondents had thus far done little or no work around digital transformation and 26% were just beginning to automate but have not yet coordinated operations and analyses around these new automation initiatives. Only 11% of respondents said they had moved beyond integration of data from automated systems to drive real time insights that are being used to optimize processes and workflows and yield specific business results.

The picture these research results paint of industrial business is one where more than 40% haven’t begun the digital transformation or are just beginning to do so, with nearly 50% still somewhere in the process of transformation.

With 50% of industry at some stage of transformation, it’s safe to say we’ve passed the inflection

point of whether the digital transformation is truly real. Given this current stage of industrial digital development, what factors are driving the transformation at this point?

Research results noted by Gorbach showed that the four principal drivers currently behind digital transformation are 1) Growth—expanding into new markets, segments, or geographies; 2) Reducing operations and product costs; 3) Improved EBITDA and general revenue growth; and 4) Sustainability. Each of these factors were clustered within a few points of each other in ARC’s research.

A secondary tier of industrial digital transformation drivers are innovation around new products or services, security, attracting and retaining customers, and regulations.

Funding and skills development

Providing insights into the digital transformation underway at ZF Group during his presentation at the ARC event, Gabriel Gonzalez-Alonso, senior vice president and head of corporate production management at ZF Group, stressed that digital transformation activities should be funded “out of the normal budget (i.e., not out of a separate digital transformation budget). Otherwise, cuts will be made and directions will be changed that effect the transformation.”

ZF Group is a global supplier of automotive components and technologies.

Though money is the priority in making the digital transformation possible, according to GonzalezAlonso, the second most important aspect is skills. Even though specific skills in specific areas will be focused on at the start of the digital transformation, “you need the entire team to be upskilled and trained,” he said. “Not just IT and maintenance, you need to bring along all operations teams.”

Gonzalez-Alonso said ZF Group holds threeday basic training sessions built around use cases for all team members. He added, “We give every employee access to basic information via Microsoft Teams so they can all feel a part of the transformation.”

When it comes to the speed of transformation at your company, Gonzalez-Alonso stressed that

it must be done step by step. “It’s just like with smartphones,” he explained. “No one came to your house and taught you how to use it; but you started using them bit by bit and using new smartphone technologies as they were developed. Now we cannot imagine life without them.”

“It’s just like with smartphones. No one came to your house and taught you how to use it; but you started using them bit by bit and using new smartphone technologies as they were developed. Now we cannot imagine life without them.”

Mobile Robots for CNC Applications

By David Greenfield Editor-in-Chief

Whenever use of mobile robots in industry are discussed, it’s often in warehouse automation applications. But the use of mobile robots to deliver materials from supply areas to various production workstations is beginning to boom. For example, in 2018, Automation World was able to learn about Valpak’s uses of mobile robots to deliver materials to workstations in its printing and distribution facility in St. Petersburg, Fla. Now, we’re hearing about the growing use of mobile robots in CNC applications.

Fastems, a supplier of CNC automation technologies, says the demand for its CNC automation systems that include mobile robots continues to rise. The company specializes in supplying CNC systems to high-mix, low-volume manufacturing operations, installing 4,000 such systems with more than 90 machine tool brands around the world.

Such automated CNC systems from Fastems can include the use of AGVs (automated guided vehicles that follow a track to guide them around a facility) or AMRs (autonomous mobile robots that can navigate a facility freely using sensors to avoid collisions). According to Fastems, typical applications for mobile robots in CNC applications include: moving raw materials from storage to machining, transferring cutting tools between a tool room and machines, delivering semi-finished or finished parts to the next process phase, and moving workpieces between machines when floor space is limited.

“Today, the majority of our customer industries are using AGVs or AMRs in some way,” said Mika Laitinen, solution sales director at Fastems. “Whether in aerospace, defense, machine building, medical or subcontracting, there are automated vehicles in many production shops. When it comes to CNC automation and AGVs or AMRs, they can be of great help in reducing manual transfers and forklift operations, reducing bu er sizes, increasing the automation level, and making production flow more predictable and reproducible.”

Are you mobile robot ready?

If you’re thinking about adding mobile robots to automate the delivery of materials to CNC workstations in your facility, Fastems suggests referring to this checklist to help determine if your applica-

tion is suitable for mobile robot use.

• Amount of transfers. Create a list of your manufacturing mix and conduct a cycle time analysis to understand how many transfers are required within a certain time period. This helps determine which kinds of mobile robots have enough capacity for your operations and how many of them you’ll need.

• Consider the load handling capacities. Here, Fastems recommends evaluating the physical interfaces between your machinery with mobile robots. This is critical as the ability to achieve the highest machine utilization possible requires the mobile robot to be able to load items into the machine. Devices for such transfers can include conveyors or robot arms for moving the parts from the AGV to the machine. Also determine whether your CNC machine is or can be equipped with an automated door for access by a robot.

• Be sure you have space to allot for a bu er storage area to avoid unnecessary work-inprocess from collecting on the shop floor.

Software considerations

Mobile robot fleet management software is a key tool for creating point-to-point routes, as well as maintaining and charging the mobile robots. What these software systems lack, however, is visibility into production operations. To help address this disconnect and help users incorporate mobile robots into their CNC operations, Fastems developed its Manufacturing Management Software (MMS) to oversee all production orders, resources, and scheduling. According to Fastems, MMS schedules production based on customer orders and available production resources such as machine tools, cutting tools, and raw materials then prompts the mobile robots’ fleet management software to perform

the right transfers at the right time.

To handle production planning and scheduling, MMS checks the order backlog and available production resources in NC programs, machines, tools, raw materials, and work holding. MMS then creates a production plan based on the order due dates and available production resources so that everything will be ready on time with no unnecessary work in process. The software can create detailed schedules for up to 96 hours of operation, enabling users to assess details surrounding upcoming resource needs.

For mobile robot routes and material transfer management, the MMS tells the mobile robot fleet manager software which transfers to order and when. The fleet manager software then directs a mobile robot to make the transfer. Fastems says the communication between these software components ensures that all transfers are done just-intime to reduce the need for large bu er storages. The software also notifies operators in advance of any missing resources to ensure everything is in place when the robot arrives.

When production changes lead to a missing resource, an urgent customer order gets expedited, or a tool or program breaks or incurs a fault, the tracking performed by MMS allows for real-time adjustments to be made to the production plan so that no unnecessary work in process is created.

Watch this video about the 3 biggest robot trends.

Top load mobile robot delivering pallet to robotic workcell.

How Data Analytics Can Help Identify Energy Efficiency Issues

By David Greenfield Editor-in-Chief

Whether your company’s sustainability goals are being set solely to reduce costs or as part of a larger ESG (environmental, social, governance) program, there no escaping the need for data analytics to help achieve these goals. This applies even if you’re only focusing on basic energy e ciency improvements, which is a great place to start considering that nearly 20% of total emissions savings come from energy eciency improvements.

To illustrate how data analytics can make the most out of your energy e ciency e orts, Wouter Daniels and Luis Miguel Carretero García of TrendMiner, a supplier of data analytics technology, o er an example of verifying the e ciency of a retrofit.

In this example, engineers are looking to determine the e ectiveness of adding an integrated solar field to an existing combined cycle power plant. Such power plants are typically a group of two or more heat engines working together to convert one source of heat into energy for use by the plant. In the example provided by Daniels and Garcia, the power plant used separate gas and steam turbines.

To determine how e ective the addition of a solar field would be, engineers monitored the plant’s fuel consumption and its power generation abilities with an eye toward identifying the causes of any recent production losses.

A review of the plant’s key performance indicators showed that plant production had decreased. This led the engineers to determine if the drop was in any way connected to integration issues between the solar plant and legacy combined cycle power plant.

Daniels said, “The first step was to load the data that shows power production and consumption over a specified timeframe. Engineers could use that information to search for periods that demonstrated process behavior both before and after the retrofitting.”

Uncovering sources of energy loss

A comparison table in the TrendMiner software displayed production value information on the solar plant, indicating that fuel consumption had decreased during the past year while power production increased.

Though this was the sought-after result of integrating the solar field with the combined cycle plant, it did not help explain the loss in production.

In further reviews of the analysis delivered by the software, the engineers “found that the steam turbine was not producing as much power as it should, and they learned that the solar field had a performance problem,” said Garcia. “One of the dashboards in the advanced analytics software helped them determine this because it showed the power output of each turbine within the integrated power plant system. From that, engineers could see the steam turbine was not producing power the way it should.”

With this issue determined, the software was used to review the then-current steam production, which showed a fluctuating trend line resulting from the addition of the solar field. Such oscillations are “the result of the irregular patterns of renewable energy,” noted Garcia. “Engineers can use a daily production average for this value instead to run a smoother analysis.”

Formulas were then added to system tags to help the engineers spot points when the steam turbine power fell below its normal value. To compare this current data with historical data prior to the addition of the solar field, engineers used the cross-correlations function of the software to suggest root causes. This showed the engineers that:

• When blowdown decreased, outlet turbine pressure increased;

• There was a two-day window from when the blowdown started falling and before the turbine pressure increased; and

• Once the turbine pressure started to rise, process experts had three weeks until the process shut down completely. Daniels noted that this

was the result of calcium deposits inside the heat recovery steam generator pipes, which reduced the vapor production as well as the heat transfer performance.

Determining causation

Though this review of data showed the root cause of the power loss, the engineers could not tell how often the blowdown dropped to the point where it caused this outcome.

“They discovered the cause-e ect relationship was unique to this behavior anomaly,” said Daniels. “Therefore, they saved the information as contextual data so that engineers who encounter a similar problem can share the solution.”

Data reviews also showed that the new solar field had a cooling problem. The software helped resolve this issue as the engineers used it to create a linear graph of the solar field’s temperature over time.

“They found that, in one corner of the solar field, the panels were reaching 675 degrees Kelvin,” said Garcia. “Using that temperature, they were able to find similar periods where the temperature was that high or more.”

Engineers used a Gantt chart to show the relevant process events by asset—with extremely hot temperatures displayed separately from normal operations.

Daniels said, “This created an overview of plant performance. Now, when the solar field reaches temperatures outside the normal zone, an alert notifies process experts to resolve the problem.”

Chemical plant partially powered by adjacent solar field.

Amazon Enters the Predictive Maintenance Space

By David Greenfield Editor-in-Chief

One of the hurdles preventing some manufacturers from adopting predictive maintenance procedures is the cost of associated hardware and software technologies. But those costs have been coming down rapidly over the past few years and is leading to an explosion of new product offerings in this space, including from Amazon.

A couple of months ago we reported on how Amazon is expanding its offerings into the industrial space beyond its cloud data storage and analysis products. In that article we referenced Amazon’s new supply chain software technology. Now the company is introducing its Monitron predictive maintenance and machine learning (ML) products.

According to Amazon, Monitron is an end-toend system of wireless sensors and gateways to monitor equipment condition. Monitron’s wireless sensors attach to equipment with adhesive and are reportedly purpose-built to capture vibration and temperature data. The Amazon Monitron system also includes Wi-Fi and Ethernet gateways to transfer the sensor data to AWS.

The sensors and gateways are pre-configured to work with the Amazon Monitron service. Up to 20 Amazon Monitron sensors can be connected at a time with one Amazon Monitron gateway. The number of sensors connectable per gateway will depend on the distance between the gateway and the sensor.

The sensors measure 2.08x1.69x0.98 inches, weigh 54 grams, and have an IP69 rating (protection against objects, dust, and liquids entering the device enclosure). The Wi-Fi gateways measure 3.6x3.1x1.5inches, weigh 95 grams, and have an IP65 rating (protection against water entry into

the device enclosure). The Ethernet gateways measure 5.5x4.2x1.6 inches, weigh 230 grams, and carry an IP65 rating.

Near-field communication (NFC) technology in the Monitron system simplifies the setup process using the Monitron app on a mobile device.

Amazon says Monitron automatically detects abnormal machine operating states by analyzing vibration and temperature signals using the ISO 20816 standard for vibration along with MLenabled models. Key applications include monitoring use of fans, bearings, compressors, motors, gearboxes, and pumps.

Push notifications are sent to users when the service detects abnormal vibration or temperature patterns. These patterns can be reviewed and tracked within the app. User feedback on alerts, such as failure mode, failure cause, and action taken can be entered into the Monitron system, which learns from that feedback as well as the real-time data it collects to continually improve over time using its ML technology.

Monitron system can be purchased on amazon. com or through your Amazon Business account to buy in bulk through a purchase order.

Four current purchase options are:

• Amazon Monitron Starter Kit, which includes five Amazon Monitron sensors and one Amazon Monitron gateway for $715.00

• Five-pack of Amazon Monitron sensors for $575

• One Amazon Monitron Wi-Fi gateway for $140

• One Amazon Monitron Ethernet gateway (Ethernet) for $180

The company notes that the typical life of an Amazon Monitron sensor battery is five years.

Users include Amazon, Fender, GE, and Koch

Andrew Jassy, president and CEO, Amazon, recently visited one of Amazon’s sortation centers in Colorado, which uses the Amazon Monitron system to detect potential issues with the center’s machinery before they happen.

“Since a typical fulfillment center has dozens of miles of conveyors being driven by hundreds of motors and belts, keeping them running is super important to delivering reliably for customers,” said Jassy. “The orange sensors continuously collect temperature and vibration measurements and send these metrics to the AWS cloud to be analyzed in real time using machine learning modeling that can predict when a part might stop working.”

Jassy noted that the Monitron system recently alerted the team that one of the center’s induction belts used for sorting and moving packages might fail soon. This advanced notice allowed the sort center team to plan a time to look at the belt and perform predictive maintenance “saving hours of downtime and ensuring customer deliveries were made on time,” he added. “Amazon Monitron has reduced unplanned downtime by 70% at Amazon sites.”

Other users of Amazon’s Monitron system to monitor equipment assets include Fender, GE Gas Power, and Koch Ag and Energy Solutions.

Power, and Koch Ag and Energy Solutions.

Read about Amazon’s supply chain technology.

AWS Monitron sensors mounted on conveyor belt motors. Source: AWS

AWS Monitron gateway (top) and sensor. Source: AWS

3 Machine Vision Technology Trends

By David Greenfield Editor-in-Chief

As machine vision systems improve via advances in chip technologies, easier to use software, and lower cost, IoT Analytics (a provider of market insights and business intelligence) took a look three specific technology developments it sees as having the biggest impact on machine vision technology and applications today. According to IoT Analytics, users of machine vision technologies should make note of these trends as they are the main drivers behind machine vision systems’ increasing power and ability to deliver a proven return on investment.

Technology Advance #1: Advanced cameras

With many machine vision cameras featuring resolution of more than 45 megapixels, these cameras can capture objects at extremely high speed without distortion. Another advance powering new machine vision capabilities are event-based vision sensors.

According to IoT Analytics, these sensors process images similarly to how the optic nerve in the human eye processes information. More specifically, these event-based vision sensors detect changes in brightness of each pixel. This capability enables machine vision to be used in much darker environments than traditional frame-based vision sensors, in which a complete image is output at intervals determined by the frame rate, according to Sony, a supplier of machine vision sensors.

Sony Semiconductor Solutions Corporation recently released two types of stacked eventbased vision sensors designed for industrial use. The IMX636 and IMX637 sensors feature low power consumption and deliver high-speed, low-latency, high-temporal-resolution data output. According to the company, these sensors have also delivered the industry’s smallest pixel size of 4.86μm.

Technology Advance #2: Artificial intelligence

The incorporation of artificial intelligence (AI) into machine vision applications has been one of

the prime accelerators of industrial machine vision technology over the past few years.

Whereas rule-based machine vision proved useful in identifying quantifiable, clear, and very specific characteristics to answer yes or no questions (e.g., presence or absence), AI-based machine vision “can provide accurate results for non-quantifiable characteristics, discern defects in a wider range of backgrounds and lighting settings, and work flexibly with variations in product appearance and types of defects (e.g., dents or discoloration),” according to IoT Analytics.

An example of this can be seen in the work being done by Neurala, an AI technology company, and Flir Systems, a well-known supplier of imaging cameras and sensors, to deliver an AIbased industrial imaging system.

According to Flir and Neurala, this new imaging system allows users to “rapidly create deep learning models using Neurala’s Brain Builder on the VIA platform with little data and no AI expertise. These models can be directly uploaded to a Flir Firefly DL camera using the free Flir Spinnaker software development kit.”

Because the models can be deployed directly onto Flir Firefly DL camera, the companies claim an intelligent, automated inspection point can be placed practically anywhere in-line and quickly reconfigured for new applications.

Technology Advance #3: Automated training

This advance could be included under advance #2 above, as it is also a result of AI. However, it deserves a separate category since it not only improves the capability of the camera, but the experience for the user. In this case, we’re talking

about the incorporation of deep learning AI into machine vision to “train” cameras faster than ever before.

Not long ago, training of machine vision cameras to detect flaws in a part or product required the vision system to be presented with hundreds of images of both acceptable and flawed products for it to be able to effectively determine the difference. New chips, such as the Neon-2000-JNX series from AdLink Technology with the Nvidia Jetson Xavier NX module built in, can process images and run AI-based computer vision algorithms. This has reduced the vision system training times from weeks to hours.

Rather than having the machine vision system rely on the rules created by an expert, AI-powered machine vision software can learn which aspects are important on its own and create rules that determine the combinations of features that define quality products.

“With neural network learning algorithms, users no longer need to handcraft a machine vision model for every production scenario,” says Anatoli Gorchet, co-founder and chief technology officer at Neurala. “They just need to collect the proper data—whether it’s for fruits, airplane parts, or ventilator valves—and train the model with it.”

Festo Solutions Boost Intralogistics Productivity

An inside look at Festo’s electric and pneumatic automation solutions for intralogistics.

By Franklin Vanderpool, Industry Segment Manager, Logistics Systems, Festo

Amid overlapping global crises and countless marketplace upheavals, companies from every sector are looking to shore up their operations against future disruptions. Industry insiders have long seen improving asset health monitoring and maintenance as a winning strategy to achieve resilience, agility, and efficiency.

In addition to reliable components and readyto-install systems, Festo also offers productivity tools, global support, and custom solutions. Partnering with Festo ensures interoperability of components and assists in bringing OEMs and integrator solutions to the market faster, with less engineering overhead. OEMs and integrators become more productive with Festo.

Electric automation

Festo offers the world’s most complete electric automation product range. Standardizing on reliable and interoperable Festo electric automation components not only provides design symmetry, but it also streamlines design and acquisition, lowers inventory, and ensures global technical support. Key intralogistics components include EMMT series servo motors for controllability and path accuracy in positioning applications. The EMMT’s space-saving single-cable solution significantly reduces installation effort.

EGC series axes are ideal for linear gantries and cantilevered axes. Linear actuators in the ELGA family deliver speed, acceleration, and accuracy in the most demanding applications. CMMT, a compact servo drive series, offers precise force and speed. Auto-tuning supports easy commissioning and automatically optimizes control behavior of rotary and linear motion.

Electrics with the simplicity of pneumatics

The Festo Simplified Motion Series (SMS) represents an engineering breakthrough that achieves

the simplicity of pneumatics with the benefits of electric automation. SMS axes offer an alternative to more expensive and complex traditional servo motion. SMS takes proven ball screw axes, toothed belt axes, mini slides, electric cylinders, piston rod, and rotary actuators and integrates them with an onboard servo drive. Users commission two-position functionality via onboard push buttons with no additional software needed. When controlled with IO-Link, which is a standard feature of SMS axes, positioning along the axis length is infinitely variable.

Core pneumatics components are always in stock

The company offers innovative and high-quality pneumatic solutions from servo pneumatics to the world’s first intelligent valve terminal, the VTEM, to the industry leading DFSP stopper cylinder. Festo pneumatic components include air preparation, tubing, flow control valves, high flow valves, valve terminals, sensors, mini slides, guided drives, direct interchangeability ANSI NFPA cylinders, and metric and imperial round and compact cylinders.

Festo’s core range of components meets most application needs and is guaranteed to be in stock for quick shipping. The availability of core components lowers supply chain risk. Festo has taken its core products concept to a higher level with the new Festo Pneumatic Essentials program. Festo Pneumatic Essential is a one-stop-shop for the 16 most-applied pneumatic components. These components feature innovative compact design for today’s smaller footprint machines and competitive prices.

AI for higher uptime, quality, and energy efficiency

The Festo Automation Experience (AX) is a

new artificial intelligence platform for predictive maintenance, predictive quality, and energy optimization. Using advanced analytics, Festo AX maps data to learn a component, machine, product, or energy system’s healthy state. Festo AX provides early warnings with actionable information to correct anomalies when data begins trending out of normal.

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Seamless Connectivity: Direct Integration into Host Systems

Festo servo drives, integrated drives, remote I/O systems, and valve terminals are integrated directly and seamlessly into both electric and pneumatic automation systems. OEMs and integrators combine Festo electrics and pneumatics into larger environments using Ethernet-based protocols, such as EtherNet/IP, EtherCAT, Profinet, and Modbus. Festo function blocks simplify integration with Rockwell, Beckhoff, Siemens, Omron, and others.

Festo emphasizes connectivity to Ethernet-based protocols through IO-Link. Its most advanced remote I/O solutions, including CPX-E and CPX-AP-I with their IO-Link masters, enable fast connection to host PLCs, enabling connection of the widest possible range of automation components from Festo and third-party suppliers.

CPX-AP-I, a new generation decentralized I/O, connects valve terminals and digital and analog I/O to the integrated system. CPX-AP-I can accommodate more than 80 digital and analog input blocks, valve manifolds, and IO-Link master modules per system, with cable lengths up to 50 meters (164 feet) between modules. Because of the extended distances available between modules, CPX-AP-I is ideal for intralogistics systems, where moving valves closer to actuators is essential for reducing cycle time.

Productivity tools

Using Festo online engineering productivity tools, such as Handling Guide Online, for configuration and selection, engineers can quickly and easily define mechatronic 1D, 2D or 3D kinematics. They can also select the matching motor and servo drive or valve terminals, plus the remote I/O system, and be assured of compo -

nent interoperability. These tools reduce design time from hours to minutes and ensure interoperability of components.

Learning

Festo Didactic—the educational arm of Festo— takes lifelong learning and mechatronic technical training to a new level. Festo Didactic provides lab-based equipment that replicates real world automation to two-year educational institutions and audits and trains at customer sites. The Festo Learning Experience (Festo LX) is a new online portal to make it easier to create individual learning experiences for personnel.

Electrics, pneumatics, seamless connectivity, productivity tools, AI, and training taken together make Festo the intralogistics partner that boosts productivity.

IIoT Technology Megatrends

A conversation with Phil Marshall, CEO of Hilscher North America, highlights the trends worth watching during industry’s digital transformation.

Q: What are one or two specific technologies and/or megatrends that will be shaping and enabling development of the IIoT in 2023 and beyond?

A: The Industrial Internet of Things (IIoT) requires quality communications, making both message queuing telemetry transport (MQTT) and Open Platform Communications Unified Architecture (OPC UA) key technologies. These technologies enable future IIoT developments and allow other technology solutions to work. MQTT is a communications protocol with very low overhead, which makes transferring massive amounts of information into cloud-based systems manageable. OPC UA is a universal way to exchange data between systems, supporting that flexibility on a system-to-system basis.

MQTT and OPC UA must also go hand in hand with security. Cybercriminals will continuously find attack vectors; to block threats, a collective effort is required. This means that embedded, layered security spanning every link in the communications chain—from the component manufacturer to the end user—is essential. This is where IEC 62443 comes in. With more than 30 years of communications experience, Hilscher has long supported security through products such as our netX 90 communications controller.

The netX 90 enables security functions to be embedded into automation products, protects CPU activity with “root of trust” techniques and isolates communications from applications to ensure that neither can be affected by the other. Its successors will be similarly enabled in order to match network security requirements as they evolve. We recently announced that the netX 90 supports Common Industrial Protocol (CIP) Security, an important next step for North American automation vendors.

Q: What are the specific technical benefits these technologies provide that will enable new IIoT application successes versus what is possible with typical applications today?

A: IIoT is evolving but it has not seen the quantum leap that many predicted. Instead, it has taken a decade to become mainstream because automation users are conservative about change, particularly concerning security. In addition to that hesitation, early IIoT implementations were cumbersome and extremely

expensive. These issues led many users, such as small machine builders, to be disinclined to get involved. Today, powerful IIoT solutions are both far less expensive and far more flexible.

The reality is that automation users have always pushed for better and more effective ways to operate and manage assets. Today, they recognize that they cannot compete unless they start offering IIoT features with their equipment. The latest products on the market today offer plenty of opportunity to deploy cost-effective solutions in innovative ways.

Q: What challenges for automation and control engineers do these technologies address?

A: Now, IIoT spans the entire manufacturing hierarchy. At the highest levels, global interaction of systems allows companies to manage their enterprises better and more effectively across global markets. And at the lowest levels, processing the data from sensors mounted on machines can help manage equipment more efficiently and send this data to where it can most effectively be used— locally or globally.

Gathering sensor-level data via smart IO-Link modules delivers continuous access to machine condition and performance. From a performance perspective, this opens exciting opportunities to improve processes such as enhancing workflows, increasing product quality and boosting manufacturing flexibility. Better monitoring can also uncover potential failure mechanisms that may be addressed before the failures cause downtime. Additionally, the digital twin version of a machine becomes a reality, enabling off-line diagnosis, process improvement and system design.

These technologies also allow vendors to monitor their machines from anywhere in the world. This presents new business opportunities because vendors can take greater responsibility for their equipment, wherever it may be. Machine rental, rather than purchase, becomes an option that is paid for on a per-use basis—which is an attractive option as staffing levels decrease and skills and experience are lost. Machine providers can also support continuous quality improvement and online upgrades.

Q: Given that the IIoT is already more than 10 years

in the making, what is your assessment of the progress and overall impact of the IIoT on industrial automation and Smart Manufacturing?

A: So far, IIoT has moved forward at a pace that I would expect. But now, I see it accelerating as the possible added value of new solutions become clearer. For a product vendor like us, it offers exciting new opportunities too. Our netX family, especially the netX 90 system on a chip, has become the foundation of a new range of Hilscher IIoT solutions called netField.

Our 30 years of communications experience plus the security offered by netX allows us to broaden our product range to include a variety of processing solutions that deliver fast results at the point of greatest need. These can be edge or cloud-based solutions and they are suitable for virtually any class of user. Furthermore, all of this can be delivered at a far lower cost than before.

In effect, products like netX and netField are typical of a new generation of IIoT solutions that are less costly, more versatile and easier to deploy. And, these solutions operate without compromising performance or security. Huge IT infrastructure is no longer needed to implement IIoT since solutions can now be tailored to exact needs and budgets. Fewer IT skills are required, existing software can often be reused, and users can focus on what they know best—their own processes—by utilizing solutions that are user-friendly and less expensive than any previous offering.

Q: What are key next steps and/or technologies that will enable more rapid development of IIoT applications?

A: Semiconductor developments will continue to drive IIoT forward as always. Solutions will become better and more secure while added value will continue to grow as users become more and more familiar with the options. It is certain that with the type of scalable and cost-effective IIoT solutions on the market now, users will become smarter in the ways they utilize the features. Innovation will play its usual role and the manufacturing world is likely to find plenty of new opportunities to exploit.

OEM Hacks for Mitigating Labor Shortages, Lowering Costs, and Accelerating Time to Market

It’s common knowledge that lifecycle management for machines can save time, effort, and resources. It can also increase reliability, decrease unplanned downtime, and extend the life of machines. The same is true for automation components including PLCs, robots, and HMIs.

By Rob Ruber, senior product manager, and Tim Hider, product marketing manager, Mitsubishi Electric

Today, it’s not enough to have high-quality automation components. Advanced engineering software is now an essential ingredient for remaining competitive. When selecting engineering software, look for these essential attributes.

• A single programming environment for every phase of development—from design, to programming, debugging, and maintenance;

• Advanced diagnostics for quickly identifying, communicating, and resolving issues even before team members arrive at the machine; and

• Advanced simulators that not only let you simulate the PLC logic, but also the HMI and 3D digital twins.

Design stage

This stage is all about reducing time-to-market. For the design stage, look for these time-savers:

• Intuitive drag & drop functionality makes configuration and programming much easier;

• Custom function blocks & libraries make it easy to standardize and reuse code across different machines;

• Advanced simulation makes it possible to program while the mechanical system is in design; and

• Modern HMI makes it possible to create advanced screens that intuitively communicate changes in status, which expedites testing.

Startup stage

Startup is all about reducing time-to-commission. A key way to reduce commissioning time is to create easy access to the data needed to fine tune your machine to the needs of the application. Web pages and other user interface tools give you access to the information needed to make adjustments. They can also tell you how those adjustments have affected your process.

For the startup stage, look for:

• System recorder module that simplifies troubleshooting by capturing and recording all

program state changes based on a trigger;

• HMI VFD/servo templates, so operators have access to key VFD (variable frequency drive) and servo data for quicker install and troubleshooting;

• PLC and HMI web server visualization, so you can accelerate troubleshooting with prebuilt system webpages;

• Custom web pages and interfaces that enable more efficient staff training by allowing staff to dial in a machine’s unique needs at a unique site; and

• Support for multiple languages, so startup tools can be used around the world.

Operate stage

During the operate stage, reducing downtime is key. All machines will go down at some point. Your software should have advanced diagnostic tools that help you quickly identify, communicate, and offer resolutions to team members before they even arrive at the machine. All of this is now possible and will only get better in the years to come.

One important capability at the operate stage are event recorder modules. These modules record and sync up the program state changes (electrical) and a camera (mechanical) for a set amount of time before and after an event takes place. This will give you a full digital and electrical record of what took place before and after an event and is key in identifying root causes for even the most elusive errors.

Other key capabilities to look for include:

• Predictive maintenance for monitoring critical sensor data and providing feedback when anomalies occur. Look for techniques such as high/low process control and guard band as well as advanced capabilities like MT or MLR. You should also be able to visualize feedback on the HMIs or the software should be able to send alarms via text or email via an IoT gateway.

• HMI backup and restore so that when lightning strikes, you can quickly download your VFD parameters from the HMI.

• Enterprise system integration for issuing service tickets and informing maintenance staff the way they want to be informed.

• HMI mobile and reporting capabilities for remote/offsite monitoring via tablet or PC and reporting events or operational anomalies.

Optimize stage

The final stage is all about having actionable data to drive intelligent business decisions. For the optimize stage, look for:

• Advanced data collection, which requires high-bandwidth connectivity for sharing vast amounts of data;

• Advanced data reporting that can produce the reports in real-time, so you have them when you need them;

• Advanced data analysis enabled by artificial intelligence; and

• Advanced process optimization for communicating data analysis back to the components to enable continuous improvement cycles.

Trouble-free engineering is possible with component-level lifecycle management. It can improve every phase of development and help you deliver high-quality, low-maintenance machines at scale. It can also help you mitigate risk in the technology lifecycle, extend your machine’s period of profitability, lower service costs with predictive maintenance, and increase customer loyalty.

Secure Your Industrial Ethernet With netX 90

Built-in Securi ty :

• Secure boot and cryptography Encryption via SSL/TLS for HTTPS, OPC UA, MQTT, VPN

• IEC 62443 compatible Enables layered security for Defense-in-Depth design

• Built-in diagnostics

Monitor operating conditions for predictive analysis

• Multiple processors

Logical separation of communication and application tasks

Single Pair Ethernet Ready:

IEEE 802.3cg standard

• 10 Mbit speeds and intrinsically safe with Ex equipment

Internal xMAC processors

• Enable protocol specific switching between two channels

Supports SPE

• Connect external PHY devices via MII interface

IO-Link sensor networks

• Connect two 10 Mbit channels with SPE port up to 1,000 meters

Real-time Ethernet connections

• Restricts software access to on-chip peripherals on either side

•

Partitioned design

• Pair existing 100 Mbit RTE with 10 Mbit SPE

Minimum ten-year availability

Switch Capabilities

• Use netX 90 as a switched device between 100 Mbit RTE and 10 Mbit SPE

Simplifying Industry’s Adoption of Time-Sensitive Networking

By Michael Bowne, executive director, PI North America

In my schooling, I studied physics for my major. The Holy Grail in this field of study is a Theory of Everything: a unifying theory of the forces that govern quantum mechanics and those that govern relativity (gravity). It makes me ponder if there will someday be a unification of industrial networks; one network to rule them all: from the IT side to the OT (operations technology) side. Maybe this will come to pass—though I expect it to be a very long way away.

Then again, maybe not…

Quantum mechanics and relativity separately have enabled immense advances in our civilization. Each is a different tool to solve different problems. The same situation exists in industrial networking today: different tools, purpose built for different use cases.

This strategy has certainly worked well for the most successful network in the history of humanity: the Internet. Here we use specialized protocols like FTP, HTTP or VoIP to accomplish different tasks.

Similarly on the OT side, we have specialized technologies like IO-Link, Profibus, Profinet, omlox, and others under the PI (Profibus/Profinet International) organization umbrella. These others include the Standard Robot Command Interface (SRCI) or Modular Type Package (MTP).

But just because these technologies accomplish

diverse tasks, doesn’t mean they can’t be combined to solve unique use-cases:

• IO-Link + Profinet is an obvious combination. IO-Link enables intelligent sensors to provide semantically rich data beyond a simple process value. Profinet can then transport this data with high determinism, while enabling other protocols to coexist plainly on the same Ethernet-based infrastructure. It is the perfect pair for a myriad of use-cases: OEE (overall equipment effectiveness) tracking, predictive maintenance, remote monitoring, and more.

• Profinet + SRCI is another obvious combination. The SRCI enables the programming of robots directly in the PLC. It harmonizes all the various libraries from different robot vendors into a single library. It is embraced by all the major robot companies extant today. The use of robots in industrial automation continues to grow rapidly. Therefore, the combination of easy robot programming (SRCI) with take-it-for-granted high speed communication (Profinet) makes perfect sense.

• With SRCI + omlox we can begin to solve unique use cases. It’s not just stationary robots that have grown in usage, but also autonomous mobile robots (AMRs). To track their location in a vendor-neutral way, omlox

specifies open interfaces for high-accuracy, robust, location tracking via Ultra-Wideband. Combined with the SRCI to easily program the robots, we now have helped make AMR integration easier.

• And with omlox + IO-Link we can solve unique challenges with open standards. The combination of omlox with RFID tags can be thought of as two sides of the same coin— omlox for location data and RFID for identification data. But in brownfield installations where many tags already exist, another solution presents itself: RFID tag readers with IO-Link. Combine these with omlox, and now these data can be linked to both identify and track the location of tags rather transparently.

Will we ever see one network to rule them all? Perhaps. It certainly would be an elegant solution. But would it be practical? Perhaps not. In the meantime, just as physicists have looked to combine theories as a bridge towards a Theory of Everything, so do we in industrial networking begin to combine technologies. The principal difference: In industry, it’s not just theory, it’s reality.

How a unifying “Theory of Everything” could be developing in industry via industrial networking, sensing, location, and programming technologies.

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Digital transformation of power plants for greater efficiency

TepSys quickly transitions from manual to automatic data collection and distribution using DataHub software from Skkynet.

Hydroelectric power plants in Japan have been vital to the national energy supply for many years, and today’s demands for low-carbon energy make these resources more valuable than ever. To maximize production, plant executives across the country are taking a critical look at their outdated business systems. Many tasks in these plants are not automated and must be carried out manually. On-site operators and other staff often send status reports by email or verbally over the phone. Production data arrives late or in fragments, making it difficult, and in

some cases impossible, to create a coherent picture of what’s happening. Without site-wide trend charts and other analytical tools, management has little knowledge of the real-time operational status of the plants. This leads to inefficient plant operations, high manpower requirements, and increasing costs.

The Tepco Systems Corporation (TepSys) of Tokyo, Japan, recently completed a digital transformation project to upgrade data collection, storage, and visualization for a customer operating a hydroelectric power plant in central Japan. Without

disrupting existing equipment or business procedures, TepSys was able to quickly transition the company from manual to automatic data collection and distribution, saving time and manpower, and providing a platform for advanced data analytics.

Although engineers and managers at these plants are typically aware of the inefficiencies, modernizing and digitalizing is difficult. Business systems and control devices are often inseparably tied to the plant machinery, making them very costly to replace. What is required is a way to automate and provide data visualization without

disrupting existing systems or equipment. The ideal solution is one that is quick to implement, integrates well with the systems in place, and—as much as possible—is free from errors. Mistakes are not an option.

TepSys meets the challenge

Last year TepSys was asked to solve this kind of problem. One of its customers needed to upgrade their data collection and utilization methods, which at that time relied on members of the control group sending emails and making regular phone calls to the company’s main offices to inform them of the latest status of the power generation system. This had been working reasonably well for a long time, but it was not very efficient.

What management wanted was to feed the data from their plant control systems directly to dashboards on the desks of headquarters maintenance and operations personnel, allowing them to make timely and accurate decisions and forecasts. They also wanted the option of sending supervisory control commands back to the control systems, if needed. The project had to be implemented in a short time frame, at minimal cost, and provide exceptional performance. And since this was critical infrastructure, it had to be secure.

To meet these requirements, TepSys turned to BellChild Co. Ltd., a system integration company located in Osaka specializing in security, robust infrastructure, and advanced operations capabilities. “After looking over the specifications for this project, we suggested DataHub software from Skkynet as the best solution,” said Mr. Fujiwara,

general manager of the iBress Division at BellChild. “DataHub technology offered three key advantages: connectivity, high-speed data storage, and visualization. Being secure by design makes it ideal for use in the energy sector.”

The TepSys team installed DataHub software on their self-hosted TepCube cloud service, and connected most of the control systems and plant equipment to it via Modbus TCP. Other data was logged to CSV files, which were read by the DataHub instance, then aggregated with other data into a single, universal data set. The team quickly configured InfluxDB, a real-time data historian, to collect the data and provide high-speed access for retrieval. They were able to easily build screens to display this logged data with the DataHub WebView HMI.

“We had a pilot system running in a few days,” said Mr. Hiroki Suga, TepSys project manager. “Other approaches required combining multiple pieces of software and building an HMI, meaning high development costs and longer implementation times. The DataHub solution was the most cost-effective way to combine business automation and on-site visualization of the whole system.”

Success and future prospects

The final turn-key solution was approved and handed over in a few months, and the project was a resounding success. Plant management have streamlined their business procedures and enhanced data analytics. Staff now spend less time travelling to read data meters, and more time planning what systems to access and how to improve

their operation. “Our business procedures have changed significantly, and we have been able to make things more efficient,” said the lead plant engineer. “Until now, we would go to the site to check the data as needed, but now we decide what data we need by ourselves, and we link that data to the DataHub. As more of us begin using WebView we expect greater improvements in the future.”

TepSys credited customer and supplier involvement as key to the success of the project. “We spent a lot of time listening to plant engineers and managers, and adjusted project specifications accordingly,” said Mr. Suga. “Using a basic design, we confirmed the necessary DataHub functions and configuration with BellChild in advance, and then proceeded step by step, confirming at each point how to best implement DataHub features.”

BellChild expects to be working closely with TepSys to expand their use of DataHub technology. The need to integrate OT (operations technology) with IT is being felt throughout the Japanese industrial sector.

“We are counting on continued support from BellChild as we offer the OT-to-IT model from this project to other customers at power plants, factories, and similar facilities,” said Mr. Kouichi Nishikata, manager of the power control system division at TepSys. “DataHub advantages of rapid implementation, secure design, and built-in HMI, all in a single off-the-shelf package, will ensure they get a top-quality system at a reasonable cost.”

By Beth Stackpole, contributing writer

Industrial companies are creating digital twins aimed at boosting e ciency, productivity, and plant performance.

Fueled by the Internet of Things (IoT) and realtime data from connected industrial equipment, companies are beginning to advance digital twin strategies to identify and fix bottlenecks, improve product quality, and garner production e ciencies in the virtual world without the time and cost constraints of planning and problem-solving using physical assets.

The definition of digital twin has, at times been murky, but with the push for more sensors and connected devices, the opportunities to leverage the rich, real-time operational data historically unavailable or locked away in siloed systems is becoming clear. To help clarify things, a digital twin, as defined by Gartner, is a digital representation of a real-world entity or system, and the implementation of a digital twin “is an encapsulated software object or model that mirrors a unique physical object, process, organization, person, or other abstraction.”

A key point di erentiating a digital twin from a simulation is that a digital twin is connected to live, real-time data from the physical object it’s connected to and reacts correspondingly in real time.

Digital twins can model a single entity like a robotic arm or a specific quality process. However, the real power of a digital twin comes when manufacturers aggregate data from multiple digital twins to gain a holistic picture of a factory floor, warehouse or distribution center, field operation, or supply chain network, allowing them to generate real-time insights that lead to more productive and predictive actions.

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A Gartner survey from 2019 found that 13% of organizations embarking on IoT projects already used digital twins while 62% were in the process or planning to do so—a trend line Gartner analysts said indicated digital twins were entering the mainstream. While supply chain disruptions and production halts during the height of the pandemic slowed the trajectory of digital twin implementations, Grandview Research is predicting significant growth—hitting $11.2 billion last year with an expected compound annual growth rate (CAGR) of 37.5% from 2023 through 2030.

A CapGemini Research Institute survey on digital twins shed more light on the impact of digital twin deployments for both top- and bottom-line benefits. Organizations working on digital twins have seen, on average, a 15% uptick in metrics such as sales, turnaround time, and operational e ciency, the CapGemini survey found. They’ve also seen improvements on the order of 25% for system performance and in some cases, enjoyed a 16% boost in sustainability.

There are myriad use cases for digital twins, but for now, most manufacturers are focused on boosting plant performance and productivity. Following are insights from three companies using digital twins that o er hints about what comes next.

Thermo Fisher Scientific

In the aftermath of the COVID pandemic, technologies used in the manufacturing of new vaccines and biologics are a hotbed of growth, and cell culture media is no exception. As part of a manufacturing expansion plan, Thermo Fisher Scientific enlisted an unlikely partner—a digital twin designed to pinpoint bottlenecks and highlight areas for improvement with an eye towards throttling up capacity on its high-profile, high-process cell culture media production lines.

To meet the surge in demand, the Thermo Fisher division moved into 24/7 operations, which eliminated the ability to leverage overtime to increase production. Before making any investment in additional capital equipment, the decision was made to leverage PTC ThingWorx industrial IoT (IIoT) platform and its Digital Performance Management (DPM) tool in a pilot digital twin project that would help maximize the capabilities of assets already in the factory, according to Dan Fallin, senior process manager at the company.

As the pilot started, the Thermo Fisher line operated at what Fallin described as a below middleof-the-road overall equipment e ciency (OEE) score for like-sized companies. Using ThingWorx

to capture real-time data from select plant floor assets and production processes and the DPM tool to analyze bottlenecks, Fallin’s team came close to its goal of doubling the OEE figure in less than six months.

Fallin attributes Thermo Fisher’s success to several factors. For one thing, he says it’s important to have strong IT/OT (operations technology) capabilities in place. “In our case, we had a lot of OT. It was a matter of going out and connecting them, which is why we’ve been successful in pulling information directly from the machine and not having to rely on human intervention,” he explains.

The team also maintains a very structured approach to performance management, working with a consulting firm at the onset to perform diagnostics and leveraging that same work pattern as it expands use of the digital twin to three additional sites planned for this year.

While the diagnostics provided a start, it was the DPM tool that really pinned down the problems. For example, an initial diagnostic of the overall process keyed in on a downstream process as the bottleneck; however, once DPM was employed, it determined the real problem to be changeovers occurring within a pacemaker sys-

CenterLine (Windsor) Limited is using digital simulation and a virtual twin to optimize its robotic works cell designs prior to deploying physical equipment.

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tem. Through even more exploration with DPM, the team determined the holdups were happening between production lots—a common practice in pharmaceutical applications used for managing sanitizing and other processes.

“Now we’re getting more refined as to what is-

sues are occurring between lots and getting more definition there,” Fallin says. “It is still evolving.”

Starting with performance management can ensure an expanded digital twin strategy has maximum impact on factory operations, contends James Zhang, vice president, market develop-

ment, IoT Solutions at PTC. “You need a digital twin of performance to tell you where the bottlenecks or constrained areas are in your factory,” Zhang explains. “Then you can analyze and use that knowledge to address the problem with the next-level digital twin.”

Skjern Paper tapped GE Digital’s Proficy CSense to create a process digital twin of quality.

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Skjern Paper

Based in Skjern, Denmark, Skjern Paper has long been an innovator, making 75,000 tons of paper and board products each year from 100% recycled fiber, including old newspaper. Quality of paper products was paramount, and plant management decided to stretch its innovation muscle by tapping into the latest technologies—AI/ML (artificial intelligence/machine learning), analytics, and an evolving digital twin—to take production and quality to the next level.

Paper plants have hundreds of PID control loops that can lead to process variation, thus contributing to quality issues if not properly maintained. While Skjern Paper had a rigorous set of quality assurance systems and processes, there was no real-time way to measure paper quality. Operators checked quality samples for a whole reel of paper at the end of each production run, delaying the formal analysis and not allowing for production adjustments at key intervals in the process.

With the help of GE Digital, the Skjern team tapped Proficy CSense to create a digital twin for quality. The team constructed the CSense quality model, which draws from 20 data point inputs, around a parameter related to the Mullen burst strength of the paper, an industry standard test for measuring the paper’s physical strength and fiber bond.

“In general, manufacturers can get the most value from analytics by applying it to quality and throughput-related use cases,” says Corbus van Heerden, senior product manager, analytics, at GE Digital. Those particular use cases are directly tied to a company’s brand reputation as well as its ability to meet customer demand and deliver on other commitments, he adds.

Through use of the digital twin process models, Skjern has garnered critical insights, including that too much dewatering chemicals were being added to the

production process, which resulted in scrap. As a result of these insights, they were able to reduce the amount of chemicals used, which decreased costs, cut down on scrap, and aided in the company’s sustainability e orts.

Erik Møller, Skjern Paper’s technical manager, advises companies to seek out relevant data to construct a robust data set, identify pilot projects to get started, and begin training team members. He says it’s important to get started with the team you have, not wait for specialized data scientists to start the digital twin journey.

“Process engineers have exceptional domain expertise to put together and interpret process models,” GE Digital’s van Heerden says. “This is the foundation for improving competitive advantage and success with analytics.”

CenterLine Limited

When deploying custom automated welding and assembly line equipment, the ability to catch and address any problems with robotics cells prior to factory floor installation is critical to delivering seamless operations.

CenterLine (Windsor) Limited, a family-owned Canadian business, turned to digital simulation and a virtual twin to optimize its robotics work cell designs prior to deploying physical equipment on its customers’ factory floors. Using Delmia Robotics on Dassault Systèmes’ 3DExperience platform to simulate products, processes, and factory operations, CenterLine was able to visualize and verify robot movements to optimize use of shop floor space, fine tune material flow, and ensure ergonomic safety.

The virtual twin models helped eliminate the delays and costs of moving robots or fixtures around the factory and with actual processing operations, both on a cell and fixture level. “Having to re-sequence or re-distribute welding to find the optimal cycle time for a fixture can be painstaking on the floor,” says Craig Clayton, robotics simulation leader at CenterLine. “In the virtual world, we can easily swap welds between robots or within the same robot to find an optimal sequence.”

CenterLine opted for the Delmia platform for its virtual twin journey in part because it could handle the wide range of robot brands it deploys. The software also enabled shop floor operators to create robot system programs on the factory floor without tying up physical resources, which has led to substantial time savings in the commissioning phase.

“The ease with which a user can add teaching points to a program allows us to create a program in a timely fashion,” Clayton says. “Once a path is taught in the simulation, the equipment can easily be moved around to find an optimal position. These e orts would take far too long and be very costly on the factory floor.”

When rolling out and evolving a digital twin strategy, the biggest challenge is always resistance to change along with some specific skills gaps, Clayton says. CenterLine has made a point to showcase the results of the digital twin and Delmia Robotics e orts to customers and plant floor personnel to help drive support. The company has also tapped Delmia training classes and created its own training resources to get its simulation team up to speed on digital twin skills.

Clayton underscores how important it is to continually share information and communicate the small wins of a virtual twin program as it progresses. “Discussing new technology, processes, and Delmia tools are not just an important process among digital twin users, but also with the manufacturing floor and end users of the machine,” Clayton says. “These discussions lead to new and innovative ideas that are implemented into the digital twin, and eventually the factory floor.”

EtherNet/IP: A CIP-Based Protocol for Discrete and Process Applications

This

Terms can sometimes play tricks on the mind. Take EtherNet/IP, for example. Many people will read “IP” as internet protocol and think that EtherNet/IP refers to plain old, standard industrial Ethernet. It doesn’t.

EtherNet/IP and standard industrial Ethernet are related, but not the same thing. Ethernet is the protocol for the physical layer that makes the connection to the network, and EtherNet/IP refers to an Ethernet-based industrial communications protocol managed by ODVA Inc., a member-based standards and trade organization.

In EtherNet/IP, the IP stands for industrial protocol, which makes sense because EtherNet/IP relies on the Common Industrial Protocol (CIP), another industrial standard managed by the ODVA. CIP defines an object-oriented approach for presenting data, managing connections, and exchanging messages at the session, presentation, and application layers of the Open Systems Interconnection (OSI) model. As such, CIP fosters the integration of au-

tomation services and applications, such as control, synchronization, motion, and safety.

EtherNet/IP adapts CIP to work with key elements of standard Ethernet (IEEE 802.3 combined with the Internet Engineering Task Force’s TCP/UDP/IP suite). For example, it uses the transfer control protocol (TCP) and the user datagram protocol (UDP) at the transport layers— TCP for complex messages, such as those used in diagnostics, and UDP for simple messages, such as those used for I/O. IP packets route messages vertically through operations so the data can be consumed by manufacturing execution systems (MES), enterprise resource planning (ERP) software, and even cloud-based applications.

“Using TCP, UDP, and IP ensures that EtherNet/IP is IT friendly,” notes Steve Fales, director of marketing at ODVA. “Furthermore, the same class of switches and routers used in established enterprise networks can also carry EtherNet/IP OT (operations technology) tra c.”

By James R. Koelsch, contributing writer

Fales credits reliance on industry standards and the experience of ODVA’s diverse membership for making EtherNet/IP suitable for a range of industrial automation and control networks. “EtherNet/IP can accommodate everything from a single controller, machine, or skid to entire facility installations across discrete, hybrid, and process automation,” he says. The technology can handle tasks from standard I/O and sensor connectivity to specialized applications such as synchronized motion and safety.

Origins

The development of EtherNet/IP can be traced back to the 1990s, a time when industry was still wrestling with introducing open industrial networks with an eye toward moving away from proprietary systems. It was then that Rockwell Automation developed the Control and Information Protocol, as CIP was initially known before being renamed to Common Industrial Protocol. Rockwell Auto-

installment in Automation World’s continuing series on key industrial network technologies clarifies what EtherNet/IP is and traces its development as a leading Ethernet-based industrial networking protocol.

EtherNet/IP is one of four CIP-based networking protocols managed by ODVA. The Ethernet physical and data link, IP network, and TCP/UDP transport layers of the OSI model are what make EtherNet/IP di erent from DeviceNet and the other CIP networks. Source: ODVA

mation would put this object-oriented communications protocol at the heart of two other open networking protocols, ControlNet and DeviceNet.

These two networks implement CIP in di erent ways. ControlNet is a fieldbus networking protocol that implements CIP over a concurrent-time division, multiple-access (CTDMA) data link layer. It o ers precise determinism and permits both scheduled and unscheduled tra c, but didn’t go far because of its 5-megabaud speed limit. DeviceNet is faster, being a digital, multidrop fieldbus network protocol that applies CIP over controller area network (CAN) hardware.

To promote both protocols as open standards, Rockwell Automation turned their ownership and

management over to two independent organizations. ControlNet went to ControlNet International and the Open DeviceNet Vendor Association, which would later change its legal name to ODVA Inc.

By the late ’90s, the Ethernet age was well underway. The technology was already exploding in the o ce space, and the automation industry was thinking about how to use Ethernet in industrial networks. This led ControlNet International and ODVA to pool its resources to adapt CIP to Ethernet. The two organizations entered into a joint technology agreement in 2000, applied CIP to TCP, UDP, and IP, and jointly launched EtherNet/ IP in 2001.

“By using Ethernet as the underlying physical layer, data can move faster with better uptime than with traditional CIP,” notes Mark Russell, tech application support manager at Allied Electronics and Automation (now known as RS to better reflect its operations as a brand of RS Group plc). “Once a fully Ethernet physical layer was established, we were able to evolve away from binary data that was stored in registers to a more object-oriented approach that allowed for quicker integration.”

He adds that IEC-61158 and 61850 standardized the protocol further. “That made communication between brands that support EtherNet/IP much more e cient,” he says.

A few years after EtherNet/IP was released, the

A high-level EtherNet/IP TSN architecture—like this one—will be possible once IEC/IEEE 60802 is finalized and ODVA releases a CIP application profile for TSN. Source: ODVA

That was “Simply easy!”

This engineer just set up several ultrasonic sensors for a new machine line. Despite the varying ranges he had to set, he used a single software application. He set the distances. He adjusted gain. He filtered out anomalies. And those settings will remain for future replacement sensors.

...and SMART!

MAKING SENSE OF INDUSTRIAL NETWORKS

joint technology agreement between ODVA and ControlNet International ended, and the two organizations merged, consolidating under the umbrella of ODVA. Today, ODVA manages all four CIPbased networks: EtherNet/IP, DeviceNet, and ControlNet, as well as CompoNet (which applies CIP on a time division, multiple access (TDMA) data link layer).

Though some in industry have expressed concern that EtherNet/IP’s development is closely held by Rockwell Automation, Fales notes that Rockwell is one of more than 375 industrial automation companies that belong to the ODVA. “Rockwell Automation remains heavily involved in the organization through its standard rights to participate as an ODVA member,” he explains. “The publication of the EtherNet/IP technology and its enhancements has been done through ODVA’s rigorous collaborative development and approval process.”

Continuing evolution

Since EtherNet/IP was introduced by ODVA, the standard has continued to evolve. For example, ODVA has exploited CIP’s object-oriented architecture to develop services and device profiles for real-time control of automation. “Over time, the addition of CIP extensions such as CIP Safety, CIP Security, CIP Sync, CIP Motion, and CIP Energy

have greatly expanded the capability of EtherNet/ IP,” says Fales.

Meanwhile, ODVA has also been enhancing EtherNet/IP for process automation. The most recent of these enhancements has been support for Ethernet-APL (advanced physical layer), an intrinsically safe version of Ethernet for field devices located in hazardous areas. This two-wire, single-pair Ethernet technology extends 10BASE-T1L (IEEE 802.3cg2019) and brings both power and communications to instruments as fast as 10 Mbit/s over cables as long as 1 km (IEC 61158). “Ethernet-APL devices adhere to IEC TS 60079-47 (two-wire intrinsically safe Ethernet) in order to ensure intrinsically safe ignition protection,” says Fales.

ODVA has made conformance testing available for EtherNet/IP-enabled devices that communicate over Ethernet-APL. The testing verifies the Ethernet-APL physical layer functionality by ensuring the di erent port types properly adhere to the relevant specifications. Testing also confirms the functionality of the EtherNet/IP communication network. “Together, both tests ensure maximum interoperability between vendors as well as di erent types of instruments and infrastructure components,” says Fales.

“The full extension of EtherNet/IP into the process industries,” he continues, “is critical to ensure

that end users have a single industrial communication network for all of their potential automation applications, regardless of whether they are in the discrete, hybrid, or process markets.” He notes that NAMUR (an international association of process industry companies) named EtherNet/IP as one of the minimum binding requirements for the process industry.

Another way EtherNet/IP is evolving with the times is the development of a new CIP application profile for time-sensitive networking (TSN), a set of IEC/IEEE 60802 bridging standards now being developed and promulgated to allow time-coordinated and regular tra c to coexist on Ethernet.

Fales reports that ODVA is participating in the development of the TSN standards and will release its new CIP application profile sometime after the first edition of the TSN standards is published later this year. At that time, end users will be able to natively implement the TSN application profile or leverage a gateway to allow for converged communication via TSN.

“Either approach will allow for fair network-level access with other IEC/IEEE 60802-compliant devices,” says Fales. “Existing EtherNet/IP devices can also work on TSN networks, but their quality of service on the wire may be degraded when compared to a non-TSN network.”

A properly designed EtherNet/IP network is segmented into zones connected by vertically layered switches. This design ensures that a failure in one zone or within one switch doesn’t a ect the entire operation, much like sealed compartments protect a ship when the hull is breached. A fully switched network also eliminates collisions and improves deterministic behavior. Source: ODVA

One of the benefits that TSN promises to bring to EtherNet/IP is the ability to adapt CIP Motion by aligning the network with a motion control planner using a common notion of time. Once CIP Motion and 60802 are aligned, network transport can be facilitated using scheduling as necessary to meet the needs of the network and coexist fairly with existing tra c.

Proven on 5G

Because EtherNet/IP relies on CIP at the application layer as well as IEEE standards, it has enjoyed some independence on the choice of physical communications medium. EtherNet/IP can be deployed on copper, fiber, fiber ring, or wireless technologies.

In fact, wireless support for industrial private 5G has been recently demonstrated in a joint test bed conducted by Rockwell Automation, cellularinfrastructure provider Ericsson, embedded-device supplier Qualcomm, and network-service provider Verizon. Based on test results, the researchers concluded that 5G shows promise for augmenting, and even replacing, conventional wired connections within industrial networks.

“5G was designed from the ground up with ultra-reliability, low latency and a broad range of spectrum options in mind for industrial IoT (IIoT) and industrial automation,” explains Gregory Wilcox, principal application engineer for innovation and technology at Rockwell Automation. “Using millimeter wave [mmWave] spectrum and private networks, 5G delivers these benefits for standard and safety control applications with numerous industrial sensors, actuators and controllers.”

The test bed was constructed using a Rockwell Automation GuardLogix safety controller to represent an area controller and Flex 5000 standard and safety (CIP Safety) I/O to represent skids, machines, and equipment. The radio access network infrastructure consisted of Ericsson’s mmWave spectrum base station and Private 5G core (3GPP Release-15, non-standalone, on-premise). A Qualcomm mobile test platform for data collection and tra c flow analysis served as an industrial 5G-toEthernet adapter.

“The test results demonstrate that the current state of industrial private 5G has low enough latency and jitter to support RPI [requested packet interval] settings that are better than the Rockwell

Automation default settings for EtherNet/IP standard and safety I/O connections,” reports Wilcox. “These RPI settings will support many untethered, fixed industrial asset applications that use EtherNet/IP standard and safety I/O communications.”

Consequently, many new installations are no longer constrained by the need to install the costly wired infrastructure that has been required to connect skids, machines, and other tethered, fixed assets to an industrial network. “It’s a game changer in terms of cost, flexibility, sustainability, and timeto-market for industrial operations around the world,” says Wilcox.

The researchers plan to continue their investigation. For example, they have been evaluating EtherNet/IP time synchronization (CIP Sync) and distributed motion (CIP Motion) applications over 3GPP Release 16, standalone, industrial private 5G. Wilcox reports promising results from the initial proof of concept tests.

Accuride Extends MES to Its Test Labs

By thinking about its test centers as part of its manufacturing operations, Accuride extends the manufacturing execution system module of its Plex Smart Manufacturing platform to provide visibility into test summaries and analytics.

By David Greenfield, editor in chief

Source: Plex Systems

Accuride is a supplier of wheel end systems to the global commercial vehicle industry. It operates steel and aluminum wheel manufacturing plants in North America, Europe, and Asia.

Considering Accuride’s Steel Armor coating and corrosion warranty and a focus on developing highly durable products, testing and validation centers are central to Accuride’s business.

In 2015, the company sought ISO-17025 accreditation for its four test labs dedicated to destructive testing of new and existing products. Accuride knew the limited data and processes in its legacy systems would be a barrier to accreditation at this level. The systems used by Accuride at that time consisted of multiple on-premises systems

used to execute and manage manufacturing operations. The most common technology used in the testing centers was BPCS 6.1, a green-screen system aided by custom applications and manually created spreadsheets.

During the company’s investigation of new software systems for its test labs, engineers and management changed their way of thinking about the kind of software they needed. They realized that if they thought about their testing operations as manufacturing operations—rather than a separate function—they could use the Plex Smart Manufacturing Platform the company already used to manage its wheel and wheel-end manufacturing and distribution operations.

Accuride employee performs destructive testing.

Source: Plex Systems

Though the Plex Smart Manufacturing Platform includes ERP (enterprise resources planning), MES (manufacturing execution system), and supply chain management functionalities, Dave Morfas, vice president of product marketing and corporate communications at Plex Systems, said Accuride was able to “take advantage of the modularity of Plex’s platform to extend just the Plex MES production management capabilities into its testing/validation facilities.”

Core Plex MES components, such as the job system and control panel, proved to be a good fit for test requests, schedules, and operations, as the hardware and setup procedures needed for each test could be tracked and displayed.

Accuride employees utilize Plex MES system in destructive testing.

“While test deviations were painful exceptions in the legacy system, in Plex they flow into the standard dispatch queue, with one-o instructions provided in real time to the operator,” said Morfas. “Additionally, because program management, suppliers, and parts were already integrated into Plex workflows, they could include natural validation points such as new products, product revisions, and new supplier material as steps in those workflows.”

Business impacts

Digitizing Accuride’s test lab process using Plex has delivered several positive results, in addition to helping the company achieve the ISO accreditation it sought in 2015 and sustain it for seven years now.

“Whereas Accuride’s legacy application recorded only basic failure groupings, Plex’s classifications are dynamic, and tests can store images, resulting in tests recording precisely where, when, how often, and at what cycle cracks and failures occur,” Morfas said. “While this enhances Accuride’s ability to recognize patterns and analyze details, the company also uses Plex APIs (application programming interfaces) for PLC integration and VisionPlex for reporting, giving them holistic visibility into live

station status and cycle counts, and near-real-time visibility to test summaries and analytics that had been impossible to extract from the legacy system. Plus, each test center can now review on-hand and in-transit inventory and request missing inventory in real time while creating schedules.”

Other business functions within Accuride also benefited from digitizing the testing centers. Previously, when a plant needed to ship samples to a test center, the entire process was manual, with communication, scheduling, picking, and shipping performed o ine. This required company accountants to monitor the in-transit inventory and manually adjust it out when it arrived.

“However, because sample requests are now treated like standard intercompany orders, this has become a standard process, and the shipping plants work o their usual dock schedule,” said Morfas. “This reduces logistics labor but also eliminates the accounting labor, as SCAR (standard cost activity report) in Plex handles the accounting. More importantly, it has provided Accuride with opportunities to recognize and consolidate intercompany freight rather than shipping samples on expensive LTLs (less-than-truckload shipments).

Adding facilities

In 2021, Accuride’s test lab operations became the first in the company to transition to Plex UX—the newest version of Plex’s software. Since all Plex software products are delivered via SaaS (software as a service), the software “provides a modern user experience to manufacturing shop floor and front o ce workers on par with the software experience they can expect from their personal devices and other industry workplace software,” Morfas said.

The SaaS delivery of Plex software enabled Accuride to launch it in two new facilities in Europe in 2021.

“This would not have been possible for on-premises software or systems that are not equipped for global use,” said Morfas. “Because Plex is cloudbased and serves as a single, consolidated source of truth, Accuride can provide each of its facilities with immediate visibility into each other’s current and historical tests, as well as the path of products through production and testing sites.”

EXT UNLEASH INNOVATION

Scan to learn more!

Thermography Workflow Software

Fluke’s new version of its cloud-based Baseline software automates route planning and reporting of preventive maintenance testing.

The new Baseline workflow software from Fluke is designed to help thermal imaging teams automate their work and route execution and reporting to optimize asset maintenance. Fluke claims that Baseline is the first cloud-based, thermal imaging system.

Baseline software allows users access to the software from any smart device without installing a desktop app. The software supports technicians and their supervisor’s workflows to improve scheduling, planning, and tracking, allowing service organizations to realize significant efficiency gains.

The following steps outline how Baseline can be used by supervisors to produce thermography reports:

• First, asset details—including maintenance and service records—are entered into Baseline

where they are stored and ready to reference when work events are built.

• Next, a work event is created based on where the work will take place and for whom. The supervisor adds the relevant assets to be inspected. Once the work event is published, the supervisor assigns it to a specific technician who will perform the work.

• Onsite, the technician pulls up the work event on their Baseline mobile portal via their phone or tablet where the pre-planned route is waiting for them. The technician then follows the instructions and records their observations and results as they work directly on their mobile device.

• After the work is performed, the technician

uploads the images, which are automatically synced to the correct assets in the report. The technician or manager can review and analyze images and indicate a result of the inspection such as pass, fail, watch, or skip, and fill in any recommendation. A PDF report can then be generated to share and distribute.

According to Fluke, by allowing supervisors to create work events with clear instructions, job details, and a planned route, the Baseline platform simplifies communication between supervisors and technicians, ensuring all necessary tasks are completed while reducing reporting time by up to 75%. For more information, visit: software.fluke.com.

Thermal imaging team member capturing data per Baseline workflow directive.

Images captured on Fluke Thermal Imager device are uploaded to the Baseline workflow software.

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Mini Planetary Gearmotors

Applied Motion Products, electromate.com

Applied Motion Products new PH Series mini planetary gearmotors are used with small step motors in NEMA 8, 11, and 14 frame sizes. The small design allows them to not adversely affect the outside dimensions of the combined gearmotor. In comparison to other small motors, these offer an increase in torque and better inertia matching. These gearmotors are offered in three frame sizes: 22, 28, and 35mm. They can accept input speeds up to 6,000 rpm. Other features include true planetary design, precision cut gears, all metal construction, and standard ratios from 4:1 to 36:1.

Multicolor Beacons

Banner, bannerengineering.com

The K100 Pro Beacon series has two 100mm models: Pro Daylight Visible and Pro Indicator for advanced indication applications. The K100 Pro Daylight Visible model offers a clear lens for indication even in sunlight, and with an IP66 rating, it is suitable for most outdoor applications. It features three color options for indication and operator guidance. The K100 Pro Indicator model has a diffused lens that appears white when inactive, features 14 color options, and the DC model is programmable using Banner’s free Pro Editor Software for device status, colors, and animations. Also with Pro Editor, both the Daylight Visible and Indicator models have 12 selectable audible tone options to choose from.

Plug-and-Play Industrial Meter

Leviton, leviton.com

Leviton’s VerifEye Series 6000 panel mount meters are designed to monitor a data set of electrical parameters for industrial applications. These meters allow users to set thresholds to allow for automatic load curtailment and participate in demand-response programs. Their interface and standard 92mm x 92mm panel mount cutout allows for quick installation in OEM panel shop applications. This series of panel mount meters also include an integrated configuration wizard and are offered with a range of split core and Rogowski smart current transformers. Because these meters are designed to be integrated into the electrical panel, no external mounting or wiring is needed.

Shaft Measurement System

OGP, ogpnet.com

The addition of the new TurnCheck Series-14 to the family of TurnCheck shaft measurement systems from OGP increases the range of TurnCheck systems to handle parts up to 140mm in diameter and 1000mm in length. The system’s telecentric field of view optics, combined with highly collimated light at a constant wavelength, results in a uniformly magnified image with no edge effects or exclusion zones. TurnCheck systems scan and measure all points and features automatically, handling the full range of dimensions and tolerances found on shafts and cylinders.

Power-over-Ethernet Transmitter

Emerson, emerson.com

The Micro Motion 1600 coriolis transmitter from Emerson is designed for facilities wanting to make a gradual transition to remote flow data collection, monitoring, and configuration. Power over Ethernet (PoE) can deliver power and data to and from the transmitter via an Ethernet cable, but the 1600 model can also use a separate DC power input. Emerson claims the Micro Motion 1600 is currently the smallest PoE coriolis transmitter on the market and it is available in aluminum or stainless steel. Additional features include a multilingual four-line local operator interface, a suite of software, an additional licensable channel that can be configured for analog, frequency, or discrete output, as well as a USB-C service port.

Organic Carbon Analyzers

Endress + Hauser, endress.com

The CA78 and CA79 online total organic carbon (TOC) analyzers from Endress + Hauser provide continuous real-time monitoring using UV-oxidation and differential conductivity measurement. The CA78 comes in multiple configurations—the standard version measures water with conductivity values up to 2 µS/cm. Meanwhile, the instrument option measures water with conductivity values closer to 10 µS/cm. When multiple TOC measuring points are required, the 3-channel configuration allows for multiple streams to run through one analyzer. The pharma-compliant CA79 meets or exceeds all requirements of the U.S. and European Pharmacopoeias, and comes in compact stainless steel housing. Depending on the instrument configuration, online calibration and system suitability tests can be initiated with one button, and the records automatically stored. These analyzers each store critical process, calibration, and sensor data locally, with transmission to a central process control and documentation hub.

6-Axis Robot Series

Epson, epson.com

Epson Robots expanded its VT6L-Series lineup with the VT6L-DC all-in-one 6-axis robot and increased the functionality of its no-code Epson RC+ Express programming software. A DC-powered version of the VT6L is an industrialgrade, 6-axis robot that can be mounted to an autonomous mobile robot or on a mobile platform. It features a built-in controller, reach of up to 900mm and a payload of up to 6 kg. The VT6L-DC comes with Epson RC+ for programming and Epson RC+ Express for no-code programming. Epson RC+ Express offers a visual-based teaching environment, block-style format, and ready-to-use templates to get Epson SCARA and 6-axis robots up and running.

Variable Frequency Drives

IDEC, idec.com

IDEC Corporation offers a new line of VF1A Doesa variable frequency drives (VFDs) capable of driving an induction motor or a permanent magnet synchronous motor. The product family features a compact form factor in a UL open-type construction, nickel- and tin-plated bus bars, conformal coatings for corrosion protection, and a maintenance alarm signal. Electrical input is rated as three-phase low voltage AC 400V (with an input voltage range of 380-480V AC), and the VFDs come in 14 models with a capacity range of up to 139A. The VFDs also include seven digital inputs, two analog inputs, three digital outputs, and two analog outputs. A standard option port and RS-485 terminals are included, and the VFDs accept removable terminal cards for standard, 5V, and 12V/15V operation. Other features include an onboard keypad, logic programming with 55 functions, control of mechanical brakes, a built-in braking transistor, regeneration avoidance, low-voltage ride through, and safe torque off.

Key Technology Trends for 2023

By Craig Resnick ARC Advisory Group

2022 was a year when industrial markets, despite slower growth, declines in stock valuations, and fears of recession, did not typically suffer from demand problems but were often impacted by supply chain issues and the ability to find both skilled and unskilled workers to fill many open positions. These factors are creating demand for technologies that ARC feels will grow more mainstream in 2023 and beyond, helping industrial companies increase their revenue and profits as well as their sustainability and operational resilience.

Industrial control-as-a-service

Moving the traditional PLC/PAC from the machine to the industrial edge allows critical control applications to be better managed in an IT-like environment, while keeping them close to the process. To support the deployment and management of whole fleets of virtual PLCs/PACs, automation suppliers will offer tools that add flexibility and scalability, allow cloud-based PLC/PAC file storage and backups, enable management of traditional and virtual PLCs/PACs in the cloud, and provide automated code deployment. This will be an important step toward providing “IndustrialControl-as-a- Service” in the future.

In 2023, look for the growth in virtual and edge control deployments, which will begin to lay the foundation for future industrial control-as-aservice applications.

Closed digital loops

The digital thread involves a communication framework to connect the silos and provide data flow across the manufacturing domains. This enables an integrated view of the asset’s information, documentation, and data throughout its lifecycle across the traditionally siloed functional perspectives.

In recent years, technologies have been providing companies with new tools to turn the digital thread into closed loop, providing continuous

improvement to all manufacturing domains. Having a closed loop digital thread provides a common denominator for connecting the raw operational and asset data converted into actionable intelligence to all design, engineering, operational and maintenance domains that enable humans, software applications, and machines to take the right actions at the right time to continuously improve operational, asset, and supply chain performance.

Enterprise visualization interface

With the convergence of IT, operations technology (OT), and engineering technology, more sophisticated data visualization tools must be added to display more diverse information that allow for faster interpretation and better decision-making. These tools must support “on-the-spot” data and information analysis leveraging complex analytics and provide a presentation format that delivers the highest user comprehension while allowing selections in real-time of whether the information visualized is from the process, production management, or other information sources. This has led to a new category of tools known as Enterprise Visualization Interface (EVI) solutions that can consume multiple types of information and structure it into a complete view.

A differentiator of EVI solutions is their ability to exchange data with any application and shape it into a higher-level view. These solutions employ tools to help assist IT and OT personnel in accessing the data they seek to solve problems without retraining or adding data science capabilities to industrial organizations. EVI solutions will be both on-premises and cloud enabled, unlocking the ability to consume and aggregate data from anywhere.

No-code/low code

Industrial companies are looking for tools to help simplify their workers’ jobs and empower them to perform their jobs safely and effectively, while making sure the company continues to improve performance. This has led to the use of low-code and no-code technology being incorporated into industrial solutions with the objective of enabling these solutions to be deployed by less experienced employees versus being programmed by data scientists or experienced engineers.

There are differences between low-code and no-code software development platforms, however. Low-code software requires minimum coding

to configure and deploy and is often used in applications such as control, HMI, and MES.

No-code software development platforms differ as they are tools that allow application development without having to write any code. These platforms typically provide a graphical user interface (GUI) that allows users to drag and drop components to create applications. They also often provide a library of pre-built components that can be used to more quickly create applications.

Operational resilience

These software suites often include capabilities that, for example, help companies break down physical and organizational boundaries to better engage their workforces, connect teams, and enhance real-time collaboration between operations and energy management. These solutions also include capabilities that help supply chains to be managed in real time to maintain their integrity, agility, and flexibility, enabling the company to respond immediately to market demand and shifts in material availability.

Companies are deploying these solutions to protect against unscheduled downtime and asset failures, ensure product fulfillment, protect personnel, sustainably manage their workforce, and enhance security architectures, all of which provide a clear alignment behind their operational resilience journey.

Having a closed loop digital thread provides a common denominator for connecting raw operational and asset data converted into actionable intelligence.

Is Industry 4.0 the Answer to Workforce Retirements?

By Dan Riley Interstates

According to The Manufacturing Institute, by 2030 one in five Americans will be 65 years or older. By 2035, for the first time in U.S. history, retirement-age Americans will outnumber Americans under the age of 18. What this means for the manufacturing industry, which already suffers from labor shortages, is simple and worrisome: A highly skilled, experienced workforce is on its way out, and, in many cases, they are taking their knowledge with them.

While younger workers will likely lack their predecessors’ hard-earned know-how and deep

T�ink long term and consider the operator or plant manager two or three years into the future. W�at vital information will they need to solve the problems of the plant? W�at can you do today to set them up for success?

understanding of equipment and operations, they will have a potent tool on their side—data. Smart plants running on analytics and Industry 4.0 will, by necessity, help bridge the labor and knowledge gap as older workers retire and new, inexperienced hires take their places.

Labor transitions and knowledge loss

Due to the technical nature of manufacturing production work, the manufacturing sector suffers acutely from labor shortages in an environment of population aging and labor market tightness. This effect is deemed the manufacturing “skills gap.” Many retiring engineers and operators have grown up with their plants and have intimate knowledge of the sounds, smells, temperatures, and sights of optimal operations. You cannot replace so much experience with one hire. The potential adverse effects of this labor transition include increased downtime, incorrect diagnoses of issues, increased time to solve problems, and a lack of understanding of how hardware can and should operate.

Many firms are rightfully worried that their older workers will retire before passing their entire body of knowledge to the next generation. This is especially concerning for organizations whose cultures rely on passive information transfer and interpersonal connections to share knowledge. If organizations don’t have a playbook for institutionalizing and preserving such information or fail to utilize mentorship and apprenticeship programs properly, this vital knowledge may be lost when older workers depart.

At the same time that jobs are left unfilled and workers age out of the industry, ongoing technological advances, like robotics and artificial intelligence, are transforming the use of labor. They are also exacerbating the skills gap by requiring continuous training, but the benefits of new technology will help solve the labor crisis in manufacturing by driving agility and productivity.

How data can help

Many organizations are transitioning to become smart plants to better deal with labor and skills shortages. To do this, plant operators need easily translated and reviewable information. Using data and analytics to run plants more efficiently can also ease the burden of the labor shortage because data-rich companies will attract the best

new engineers. Today’s students live and learn in a data-driven world. Engineering colleges often include data analysis courses, and the application of data is a growing expectation of new graduates. Data is quickly becoming a native method for new engineers to troubleshoot issues.

In addition to preparing your factory for the future, following are just a few of the operational benefits of harnessing your plant’s data:

• Power data can help you know how and where power is being drawn. This can help you make upgrade decisions, diagnose manufacturing line issues, and more.

• Monitoring plant performance will help you dig into problems, such as why batch quality is off, a line is not making enough product, etc.

• Deploying vibration, temperature, sound, and vision sensors can augment the knowledge lost from retiring skilled workers.

• Visible data, put in the context of each manufacturing role, can reduce downtime and the time spent troubleshooting.

• More advanced analytics, such as PID loop analytics, predictive maintenance, and model predictive control, can improve plant efficiency.

Where to start

Ultimately, Industry 4.0 is about investing in information. That’s why creating a smart plant means starting with the metrics that matter most. As time passes, the history of data you accumulate will help you better understand and run your plant. You can then use that data for reporting to troubleshoot, identify, and resolve issues. Essentially, you need to start collecting data now that will be valuable to the next generation of workers.

Thinking long-term and considering the (possibly inexperienced) operator or plant manager two or three years into the future is key. What vital information will they need to solve the problems of the plant? What can you do today to set them up for success?

Dan Riley is the Analytics Manager at Interstates, a certified member of the Control System Integrators Association (CSIA).

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Even simple network topologies are often more complex than they may first appear, carrying hidden protocols and control data that can o er insight into what may be causing network issues. Managed switching provides visibility into these protocols and can point the user to exactly where the issue is and allow them to resolve it.

Corey Scho of Malisko Engineering on manageable switches.

Despite lingering impacts of the COVID-19 pandemic and current economic uncertainty, industrial transformation (IX) shows no signs of slowing down. In fact, LNS Research states that 83% of companies say they are maintaining or even increasing their IX initiatives in the face of all of 2023’s economic uncertainties. Why? Early adopters have realized significant return on investment from their e orts. These leaders account for the top 20% of companies reporting real success or significant progress in IX—and their results are evident.

Diane Sacra of LNS on industrial transformation initiatives.

Rather than having the machine vision system rely on the rules created by an expert, AI-powered machine vision software can learn which aspects are important on its own and create rules that determine the combinations of features that define quality products.

David Greenfield on machine vision technology trends.

A controller upgrade complication can stem from the other PLCs and HMIs that the target PLC communicates with. The HMI applications will need to be updated along with the controller, and it’s likely that other PLCs on the plant network will need some minor tweaks to communicate with the new PLC. Usually, these tasks are simple, but only if you have those applications and the development software that accompanies them.

Frank Burger of Avanceon on controller upgrade strategies.

To make this Smart Manufacturing model applicable to realworld situations, MESA is modeling the interactions between the various lifecycles and detailing the technology threads that span across the lifecycles. In the new model, these threads are referred to as “cross-lifecycle threads” and “enabling technologies.”

John Clemons of Maverick Technologies on MESA’s new Smart Manufacturing Model.

We see

empowered operators solving anything, anywhere, anytime, at warp speed.

Think of it as a modern command center for your plant. Make better, more informed decisions with context to drive more precise actions. Monitor your facility’s health. And do it all knowing your valuable data is secure. It’s the future of warp speed automation. Watch the video at Emerson.com/DeltaV