PACE - Process & Control Engineering - November 2011 by Prime Creative Media

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PACE PROCESS & CONTROL ENGINEERING

Production management CPM is one of the hottest automation investment spaces in process today. Special Report 8

Automation digs deep Robotics guru Peter Corke discusses advances in mining automation. Conversation 9

Students strut their stuff BARRON GJM Pty. Ltd. P.O. Box 792 • Artarmon NSW 1570 Tel. +61 294361088 • info@barron.com.au

NOVEMBER 2011

VOL.64 NO.10

INSIDE THIS ISSUE OF: OFFICIAL MAGAZINE

INSIDE THIS ISSUE

Case Study 20

Machine vision An advanced image processing solution on the glass line at food manufacturer Simplot’s production line boosts quality control. Technology Report 24

Motors and drives Self-generating trailers and a trailer mounted control room give an ore crusher a more robust system. IICA News & Views 30

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Benefits of CIP The Corporate Industry Program enables the IICA to take on a more proactive role to support the industry.

BY KEVIN GOMEZ STUDENT teams from ten Australian universities recently competed in the inaugural National Instruments Autonomous Robotics Competition, a student competition focused on inspiring student innovation in the field of robotics. The winners of the 2011 competition were Team SUAVE from Swinburne University of Technology in Victoria, with Team RMIT CRITTER from the Royal Melbourne Institute of Technology taking out second place. The competition tasks and objectives required students to demonstrate their skills in the robotics application areas of navigation, object handling and obstacle avoidance by developing an autonomous robot that would complete a set of predefined tasks in the shortest amount of time at the live competition, and ultimately earn them the most points. Team SUAVE from Swinburne University, completed all the defined tasks in just over three minutes – a fantastic achievement given that each team was allowed up to ten minutes. Each team employed a unique approach to the development of their autonomous robot. The students demonstrated novel ideas and innovative concepts but a more structured approach and solid project management would have helped. Team SUAVE was the only one to complete the course (videos are on www.youtube.com/ user/NIARCAustralia). “We can’t wait to see how the competing teams in the 2012 competition build on the innovation demonstrated this year,” said Mark Phillips, Marketing Manager for National Instruments Oceania.

(Top) Competing robots had to autonomously navigate a checkerboard and transport objects. (Right) The team from Swinburne University annihilated their competitors and walked off with first prize.

All teams that successfully competed on the day will maintain ownership of the competition development kits provided by National Instruments, which included NI LabVIEW and an NI CompactRIO embedded acquisition and control system.

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National Instruments provided each team with a development kit featuring NI LabVIEW and a CompactRIO system. Maxon Motor also provided each team with a voucher for the purchase of precision motors. www.ni.com/robotics

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NEWS

EDITOR’S MESSAGE

PACE

Robotic strides

PROCESS & CONTROL ENGINEERING

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Next Issue • Asset Management & Maintenance • Sensors & Analysers • Process Control in Food & Pharmaceuticals • Information Integration

IT SEEMS to me as if the 2011 PACE Zenith Awards were handed out not very long back. Here we are in November, and our team is already finalising the entry forms and preparing to receive and process nominations for the 2012 ninth annual PACE Awards. Do check out our Awards page (www.pacetoday. com.au/awards) for regular updates. Student robotics competitions are very popular in the US with a host of events run for high school and university students. Australia has had its fair share of action in the international arena. In fact, exactly a year ago, the team from Flinders University in Western Australia took on three US university teams in the finals. The local team put up a good fight, but was vanquished by teams from the universities of Michigan and Pennsylvania. It’s not just fun and games in Australia’s world of robotics. Sydney company, Marathon Robotics, recently made headlines after winning a $57 million contract from the US military to provide autonomous robots for their live-fire training exercises. That’s no small change for a small start-up founded by three PhD students from the University of Sydney.

It was indeed good to see National Instruments organise its first Autonomous Robotics Competition for local university students. Held in September, the event evinced interest from ten universities. I spent an enjoyable day at the dramatic NIDA theatre, watching the student-made inventions traverse the checker patterned obstacle course. There was joy and glory (and cash) for the only team that successfully navigated the course. And heartbreak for the other nine that failed at various stages. But I’m sure the unsuccessful teams learnt as much as did winner Swinburne University Australia can play a lead role in selected areas of robotics. Professor Peter Corke from QUT is a fine example (see page 9, this issue). He is working on robotics for rural Australia and is interested in what automation and robotics can do for agriculture, horticulture, livestock production and also how it can assist in measuring the state of the environment. Solutions developed by researchers like Corke can benefit not just local farmers but change the face of rural communities worldwide. Kevin.Gomez@reedbusiness.com.au

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Where is the automation industry headed? BY JIM PINTO YOU might enjoy a summary of an article which has just been published to celebrate the 25th anniversary of the Canadian magazine, Manufacturing Automation. (http://bit.ly/nzhvs6) Today, automation growth is occurring primarily in international markets where new factories and plants are being built. In a tough, global environment, organic growth will not come easily, and the current crop of Top 10 automation majors will shrink by acquisitions and mergers. As China and India advance, expect one or both countries to make major automation acquisitions to enter

the US and European markets. Today’s factories and process plants are still a mess of conventional wiring, so it’s an easy extrapolation to forecast the continued growth of industrial wireless. The inflection point will arrive when one of the automation majors recognises that the high gross margins of conventional product pricing are producing only incremental revenues and profit growth. The companies that can yield low-cost industrial wireless will be rewarded with significant growth surges. Today’s new products and services produce relatively small productivity gains by comparison and, therefore,

produce only incremental growth. Substantial productivity increase with resultant revenue growth is overdue in the automation arena – look for it to break through in the next decade and quarter century. Who knows – the new growth may come from completely new directions, such as complex-adaptive-systems, bio-chemical electronics or tiny nanotechnology sensors. Happily, there are start-ups and visionaries who recognise the possibilities – and they will become the new leaders of tomorrow. Jim@JimPinto.com

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NEWS

WirelessHART or ISA100.11a? Which way is the industry headed? PACE posed this question to industry members on LinkedIn, the professional networking site (www.LinkedIn.com). An enlightening discussion followed and extracts are provided below. The Institute of Instrumentation Control and Automation (IICA) has set up a discussion group in LinkedIn that is open to Australian residents and overseas IICA members. Contact Cathie Tynan (admin@iica.org.au) if you need assistance in joining this group.As of August 4, 2011, LinkedIn had over 120 million professional members worldwide. It is fast becoming the preferred social media platform for professionals globally and in Australia as well. As of June 30, 2011, professionals are signing up to join LinkedIn at a rate that is faster than two new members per second.

Motti Gill

Moti Gill • As long as one understands the limitations of wireless communication networks and does not commit to use wireless sensing nodes in real time control applications, almost all existing standards will work perfectly well. We for example have excellent experience with ZigBee mesh wireless network operating in harsh environment, yet, I am sure some of the WirelessHART and ISA 100.11 supporters will repudiate it. If you look at the ISA 100.11 standard notes it is clear that they plan on interoperability between it and 802.11.X and 802.15.4 wireless protocols. It is probably safe to say that most protocols share the same basic characteristics. Technical variations were introduced by various organisations based on their experiences, engineering method and yes even marketing plays a role. At the end of the day it is the robustness of the wireless system that counts. Potential users need to be made aware of the existing wireless options and basic wireless education is essential. Although battery power has improved you still need to take into consideration the available battery power under worst case conditions. I would not recommend real time control or hazardous area applications for that matter. Yet, there are many other SCADA applications that can benefit from wireless sensing networks.

Graham Moss

John Immelman

Graham Moss • I see both standards existing in the market in the future. Both standards are designed for high wireless reliability. Many users prefer specific vendors and will follow their lead. It is important that users understand the limitations of wireless systems and the effects on performance as networks become more loaded, and also the need to manage the RF spectrum on their site. So it is important that vendors pass this information onto their customers. One of the problems I see at the moment is the lack of knowledge amongst the vendors' sales staff. No doubt this will improve with time however users should become wireless-aware to ensure they are not relying on poor advice.

John Immelman • Today the effectiveness of 'wireless' depends heavily on the desired application. In classical process industries like mining, oil and gas, water and wastewater treatment, it is a given that the technology must be robust, redundant and incredibly reliable. But to derive a commercial (read cost) benefit over the traditional hardwired systems, and more recently fieldbus networks (which also provide technical and maintenance benefits), a wireless technology must be truly 'wireless', requiring no cabling, and therefore all connected devices must be battery and or solar powered. I am not convinced that battery technology has progressed sufficiently to satisfy the demands of measuring instruments, actuators, positioners, etc. Consider a critical loop in a hazardous area - would a plant (and their insurers!) accept a battery powered pressure transmitter to act in an emergency shut down system? Not today ...

Peter Imison

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Peter Imison • It is not secret that the ISA & Wireless HART vendors have a 'steering committee' to plan and advance the concept of a technological merge of these two standards. However the issues are not insignificant, in that ISA was designed from the ground up and WHART was a communications stack overlay written for an existing protocol. In my mind the most obvious future for battery powered wireless, working within the limitations of existing and near future battery technology, are the various forms of energy scavenging such as solar, vibration and the like. A discussion I had recently with a major oil and gas company indicated the budgetary estimation of $5,000 per meter to lay cables in an existing brown fields site. These are the same cost/ benefit drivers that lie behind the carbon tax/ emissions trading concept (rightly or wrongly) and inevitably will change how we 'do business' ... interesting times.

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NEWS

INNOVATION

PACE Awards 2012: Enter now NOMINATIONS for the ninth annual PACE Zenith Awards are now open. Following on from the success of this year, the 2012 awards program is set to become the biggest yet. The annual PACE Zenith Awards was established by PACE magazine in 2004 to reward companies that show leadership in engineering, along with technological excellence and innovation. The awards evaluate projects in these industries and offers an opportunity for engineers, suppliers, integrators and industrial business-owners to be recognised publicly in front of their peers and potential customers. The official nomination kit can be downloaded from the PACE website or by emailing the editor Kevin Gomez at kevin.gomez@ reedbusiness.com.au Categories for the ninth annual PACE Zenith Awards are: Automotive & Manufacturing; Food & Beverage; Oil & Gas; Metal Products Manufacturing; Mining, Minerals and Exploration; Power and Energy Management; Transport, Power and Infrastructure; Water & Wastewater; Young Achiever Award; Lifetime Achievement Award. There is also a Project of the Year Award which is given out to the most innovative project overall. Entering the PACE Zenith Awards is free. It is the only awards program specific to process, control and automation in Australia. Entering the awards is a great way to boost your team’s morale by celebrating their work and exposing it to a large audience. Enter now!

PACE ZENITH AWARDS 2011: On June 16 this year, close to 200 industry professionals gathered at Doltone House in Sydney to cheer workmates and congratulate their peers.

www.pacetoday.com.au/Awards

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PACE.NOV11.PG006.pdf

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NEWS ANALYSIS

MINING

CSA mine upgrades flotation circuit CSA Mine got Outotec Services to replace 30 existing scavenger flotation cells. Michael Hughes writes.

HE CSA Mine underground copper mine in Cobar, Central Western NSW employs more than 300 people. The mine is operated by Cobar Management Pty Ltd (CMPL) – a wholly owned Australian subsidiary of Glencore International AG (Switzerland). CSA Mine extracts over 1,100,000 tons of copper ore and produces in excess of 180,000 tons of copper concentrate per annum. This concentrate is exported to smelters around the world. The project, involving replacement of 30 existing scavenger flotation cells at CSA, was already underway when Outotec Services personnel became involved. “When I arrived on the project it was clear there was a lot to do before it could progress. Mid-December was our deadline and in April, when I started, we had our metallurgical production criteria, but had a lot to finalise, including the scope of works,” explains Derek Beehan, Ore Processing Superintendent at CMPL. As CMPL and Outotec had already worked together in the past, most recently when Outotec replaced a thickener on a lump sum turnkey basis in 2005, it was recognised early that a collaborative, partnership approach would again benefit the project. This approach would deliver not only processing benefits, as the replacement flotation technology was state of the art – but equally importantly, a collaborative approach ensured open communication, with all parties having greater ownership in the project. Originally, Outotec was to replace ageing scavenger cells in the flotation circuit with new Outotec TankCells (three TankCell 30s). Although the flotation circuit at CMPL incorporated equipment from other suppliers, flotation technology from Outotec was chosen for the upgrade. This initial scope developed into a far more comprehensive supply, with CMPL soon requesting that Outotec supply engineering, design, install and commissioning of the cells, plus addi-

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SETUP: Installation of the Outotec tank cells at the CSA mine in Cobar, Central West NSW.

We are using three 45 kW motors with the new technology versus 15 motors drawing a total of 225 kW previously thus saving ourselves nearly 90 kW or 40 per cent. tional ancillary support (instrumentation, external launders, some piping). Concrete foundations were initially planned for the footprint; however, they proved too costly. The most cost effec-

tive solution was to upgrade the existing steelwork for the cell installation. This change from civil work to structural steel supports came late in the project, meaning that certain site elevations and dimensions were only confirmed six weeks prior to install so detailed planning and a dedicated teamwork approach was essential. The upgrade was further complicated by a limited footprint and also the layout of the installation, as demanded by the process. “It is always tight working indoors in a mill environment – and here temperatures were up around 38 to 40 degrees,” said Beehan. “Dust, confined space and working in an operational environment made it difficult at times. So good team-

work, clear communication (and a sense of humour), and a group focused on achieving our goals were required.” Further challenges arose due to factors such as limited crane access. The flotation cells, for example, had to be designed in sections no heavier than two tonnes to facilitate an overhead travelling crane. The restricted footprint also imposed a maximum height – thereby affecting not only the cells but also the support steelwork for the cells. An appropriate design was also required from a maintenance perspective – ease of serviceability being a key consideration. Installation commenced midOctober 2010 and was completed endDecember 2010, with commissioning

PACE.NOV11.PG007.pdf

early 2011. The installation was offline of normal production, apart from a tiein to the existing plant when the cells were dry commissioned. “Outotec pulled out all the stops to help CMPL meet its objectives. It was a big ask to bring it in on time, but this was achieved,” said Beehan. “The biggest benefit for CMPL is the reduced risk in cell structural failure causing unplanned downtime. Also, due to a more stable control system, we can accommodate the fluctuations in our feed grades and throughputs that we experience in the plant. “Another big benefit is energy savings. We are using three 45 kW motors with the new technology, versus 15 motors drawing a total of 225 kW previously. We’ve saved ourselves nearly 90 kW (40 per cent), which is very important. Furthermore, the site experienced significant savings on maintenance, with the 30 existing scavenger cell mechanisms replaced by only three Outotec mechanisms. Spare part costs have also

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SAVINGS: The most cost effective solution was to upgrade the existing steelwork for the cell installation.

been significantly reduced and there has been no unscheduled maintenance required on the new TankCells. Since the time of the installation, copper feed grade decreased from an

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average 4.9 per cent in 2010 to an average 4.0 per cent in 2011. Both the overall copper recovery, at 96 per cent, and the final concentrate copper grade remained constant, despite the lower feed

grade. This is a significant result, indicating an improvement in circuit stability and performance. Copper recovery is expected to improve when the copper feed grade returns to 2010 levels. The close partnering relationship between CMPL and the Outotec Services team produced clear benefits in overcoming initial challenges and delivering a key project on time and on budget. “Overall CMPL was very pleased with the Outotec Services team – we built a very good relationship from the start. We established early on the rules and boundaries of our teamwork and stuck by them,” said Beehan. “The Outotec Services people were more than helpful – it was like these guys were in an office next door and always there to help, right from initial work, through to installation and commissioning. [Michael Hughes is Senior Mechanical Engineer, Services Projects Division, Outotec.] www.outotec.com

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PACE.NOV11.PG008.pdf

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OPINION

MANUFACTURING

IT investments shift to plant The value proposition of Collaborative Production Management still applies, writes Janice Abel.

OLLABORATIVE Production Management (CPM) is one of the hottest automation investment spaces in today’s process industries. After a couple of tumultuous years, companies once again are ramping up spending in CPM solutions. There are many reasons for this upsurge. Most process manufacturers have already implemented ERP and other business systems and now realise they can gain additional value through better integration of plant and enterprise systems. Enterprise systems' primary focus is on demand forecasting, production planning, and material sourcing and tracking. Unfortunately, most plants today still operate as a standalone entity, focused primarily on real-time process control. Business systems have little influence on the plant other than gross target shifts and reporting. The gap between enterprise and plant systems reduces asset effectiveness due to overly conservative planning from uncertainty in process capability and asset availability. This results in wasted resources, surplus inventory, and lost business opportunities. Today, the emphasis of IT investment is shifting from ERP systems to manufacturing systems. Organisations are looking at the enterprise as a whole and making strategic purchasing decisions to roll out common CPM applications across all facilities. Organisations can achieve significant benefits through economies of scale, utilising IT resources more efficiently, aligning IT with business needs better, reducing implementation costs, lowering support and maintenance costs, and improving integration to create greater information visibility across the enterprise. Following the recession-induced cutbacks of recent years, companies are rushing in to purchase CPM solutions at a record pace. Many companies, having invested heavily in ERP and other enterprise applications, now find that they are

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Having invested heavily in ERP and other enterprise applications many now find that they are not achieving the expected ROI. not achieving the expected ROI. They understand that to extract more value from their investments and to compete more effectively in the global market, they must better integrate their enterprise and plant systems. Companies are standardising on best practices and application across their enterprise and making CPM purchasing decisions, not for just one plant, but for most

(if not all) plants globally. CPM offers impressive potential benefits. When organisations begin to align processes and strategies, technology, and people across the enterprise, CPM becomes indispensable. By using standards, the same strategic focus and best practices can be used in all processes and across manufacturing facilities globally. With integrated systems, employees can make better decisions based on more complete and real-time information. They can analyse data, identify problems, and identify and quantify results rapidly in terms of the potential business impact. In other words, using CPM, companies can integrate applications, business benefits, and strategies with actions using real-time information. Collaborative production systems can help users achieve significant savings

through better collaboration between plants, use of standards and best practices, improved knowledge management, improved workflow and process controls, and faster time to market for new or old products. CPM solutions improve information flow from the raw material to the manufacturer to the business system and to the supply chain. Best of all, the benefits are sustainable. CPM has three main functional areas: plan, operate, and inform. The “plan” segment consists of functions such as short-term production planning, plant simulation and modelling, and scheduling. The plan functions determine what products to make, when to make them, and what equipment to use. The “operate” segment emanates from the need to continuously find new and better ways to control process equipment, execute production, and operate plants more efficiently. This segment includes dispatching, electronic work instructions, resource management and workflow management The “inform” category gathers, stores, organises and communicates data and information. It includes data collection, performance analysis, reporting and role-based KPI visibility. At a fundamental level, CPM helps users cut costs, improve quality and efficiency, and drive innovation to get products to market quicker. In addition, CPM helps users to collaborate and improve real-time performance management initiatives, which in turn improves asset effectiveness and profitability. The latest CPM innovations can help manufacturers improve visibility into operations, provides better links to business objectives, and permit increased agility to respond to volatile market conditions. These features help companies optimise production activities and synchronise supply chains based on real customer requirements. [Janice Abel (jabel@arcweb.com) is principal consultant, ARC Advisory Group.] www.arcweb.com

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CONVERSATION

ROBOTICS

Automation digs deep Robotics guru, Peter Corke, discusses advances in mining automation. By Kevin Gomez.

“

PETER Corke is well known for his research in vision-based robot control, field robotics and wireless sensor networks. He is currently Professor of Robotics & Control at Queensland University of Technology. Corke is editor-in-chief of the IEEE Robotics & Automation magazine and a recipient of the Qantas/Rolls-Royce and Australian Engineering Excellence awards. Prior to QUT, Corke was senior principal research scientist at CSIRO where he founded the Autonomous Systems laboratory, a 50-person team undertaking research in mining, ground, aerial and underwater robotics, as well as sensor networks. He subsequently led a major cross-organisational “capability platform” in wireless sensor networks. Corke was the keynote speaker at the recent National Instruments Autonomous Robotics Competition in Sydney and took time off to speak with PACE magazine.

What interests you about robotics and mining? We’ve got to produce an increasing amount of ore product and just don’t have the workforce. The only solution is to make our existing workforce more productive and automation is the tool to accomplish that. A technology possible right now is self-driving trucks used in open pit mines. We developed the technology with CSIRO and licensed it to Caterpillar. It's now in production at a lot of mines around the world. There's also been work done on the automation of excavation on surface mines covering draglines, rope shovels and hydraulic shovels. Engineers have been looking at how automated shovels can automatically dump material into trucks. Automation of blasting is another thing I looked at when I was at CSIRO. How do you automatically load explosives into predrilled holes?

What are some of the challenges engineers are working on right now? I think the biggest challenge is building systems that are reliable. We need to involve companies that are in the business of delivering automation solutions into an industry like mining. There are lots of good ideas in research labs and universities, but getting it out into the field is going to require companies well skilled in automation technology and who have a good support network in some very remote parts of the country. There’s no point replacing a manned system with an autonomous system which then breaks down for want of spare parts.

Do you see any leading edge technologies that could be applicable to Australia’s mining sector? A lot of the good mining automation research is actually happening seems to be happening in Australia – at CSIRO at the University of Sydney and a couple of universities in the US and maybe Europe. There’s not many people working in this field. There has been a natural conservatism within the mining industry that they don’t want to go this way. But in Australia right now, because of this crazy resource boom that we’re having, they’re going to have to embrace automation in a big way. A lot of innovation is driven by mining companies rather than mining equipment manufacturers. The Rio Tintos or BHP Billitons want the technology, but their vendors oftentimes seem a little reluctant to provide the autonomous systems these companies are increasingly seeking. Maybe they don’t have the skills inhouse. Caterpillar would be an exception as they have a huge automation program and now own a large number of mining equipment vendors.

Have you developed any nonmining systems as yet? I've just started at university, at the beginning of 2010, so we have one project up which looks at automation in broad agriculture. So that’s wheat and chick pea crops and particularly chemical weeding. The current approach is to build bigger and bigger machines with huge booms, spray lots of chemical over the landscape. Maybe we can do it smarter – build

many more smaller machines that act more locally, maybe not waste as much herbicide. This is also a more robust solution. If you’ve got one big machine and it breaks you're in trouble. If you've got 10 machines and one breaks, you’ve still got 90 per cent capacity.

What would you consider to be your major contribution to mining automation? I’m really proud of two things. One is the underground navigation system that we patented and licensed to Caterpillar. This allows an unmanned vehicle to drive at pretty much its maximum speed safely through underground tunnels and get quickly from point A to point B and back again. That was a really nice piece of work. The other one involved automating a dragline excavator. We were able to demonstrate that this massive machine could be automated to dig as well as a machine controlled by a human operator. When the mine guys looked at the machine doing its work they couldn't tell whether the computer was controlling the dragline excavator or whether one of their operators was driving it. That was pretty impressive considering they were very sceptical when we started. We did an awful lot of field work. I think over the course of one two experiments, we moved 250,000 tons of dirt. I think we can say it’s the world’s largest exercise in robotic excavation or dirt moving. That record will stand for a while.

What unique technologies did you use?

”

The innovation was mostly it was in the sensing side. How do we understand the state of the environment? Where is the dirt? Where should we place the bucket onto the ground? When the machine is moving, where is the bucket with respect to the dragline because the bucket is suspended on cables? We need to understand where that bucket is, because it can swing from side to side with respect to the dragline. There are also elements of the operator’s skills that we needed to capture. Although the machine looks very slow and cumbersome, there are some aspects of its operations that are very important. The operators make it look very easy and there was a lot of conversations with operators, a lot of observing them to work out what were the elements of this skill and then capturing that in a large computer program that would emulate what they did. Then we’d run that; they’d look and critique it, saying things like ‘no, you did that too late’. So then we went back, modified the code and tested it again. It was a nice interaction between a bunch of technologists standing behind the operator while he’s doing his work and then the operator watching over us when our computer is doing its work. We overcame their scepticism and it’s nice, but I’d love to see it in production. So that means we need to find a company that wants to license the technology, build it, install it in draglines. There was interest at the time, but then the GFC hit. Fortunately, interest in mining productivity is ramping up again so its time will come soon. peter.corke@qut.edu.au NOVEMBER 2011 www.pacetoday.com.au 9

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OPINION

TECHNOLOGY

Behind wireless technology and The increasing threat of cyber attacks coupled with open enterprise wireless architectures have had the b

IRELESS technology and automation has attracted an equal share of both interest and scepticism within the industrial control systems industry. Despite easier installation and associated cost reductions, issues of reliability and security have persisted around the technology’s use; in its simplest form, industrial wireless technology needs to be robust, reliable, cost-effective and completely secure. Due in part to security concerns, the adoption of wireless networks has been gradual. The threat of cyber attacks, coupled with open enterprise wireless architectures, have had the biggest impact on electronic security fears. As a result, businesses are most concerned with protecting their vital assets, including operational processes, network architectures and business applications. Immediate savings and the ability to control and evaluate critical processes are some of the key benefits to wireless technology and automation. However, the technology also extends beyond data acquisition and process control; it adds increased value by providing effective solutions for workforce mobility, equipment monitoring, physical and cyber security, and personnel safety. One of the greatest benefits of industrial automation is that of human and equipment safety. Industrial wireless applications incorporate a host of safety monitoring and equipment health optimisation tasks, which can monitor situations ranging from tank overfill to pipeline corrosion. Wireless monitors can also detect vapours, fire, activation of safety showers and other events, as well as track the location of assets and workers in realtime, allowing personnel to prevent and respond more rapidly to incidents of threat to the business and its employees. Typical wireless applications include: ❏ Risk reduction ❏ Equipment health monitoring ❏ Incident tracking and positioning 10 www.pacetoday.com.au NOVEMBER 2011

BENEFITS: Wireless monitors can also detect vapours, fire, activation of safety showers and other events, as well as track the location of assets and workers in real-time, allowing personnel to prevent and respond more rapidly to incidents of threat to the business and its employees.

Industrial wireless applications incorporate a host of safety monitoring and equipment health optimisation tasks which can monitor situations ranging from tank overfill to pipeline corrosion.

❏ Digital video surveillance ❏ Mobile visualisation ❏ Voice-over-IP systems ❏ First responder notification ❏ Eyewash and safety shower stations

For security purposes, it’s important to understand the difference between the requirements of a company’s corporate network and those of the control network. These then need to be

managed and operated separately to ensure information is not transmitted between the two. Products offering the most sophisticated levels of encryption will ensure that all applications operating off the control network are protected from human error, equipment malfunction and/or deliberate cyber hacks. The back-end functioning of these products lies in the development of sophisticated algorithms to ultimately maximise performance. Through innovations such as a mesh network system, these algorithms minimise latency in the system, meet speed requirements and maximise battery life to ensure operational longevity and performance. A range of challenges exist for process engineers and operations management in managing industrial automation systems. In addition to cyber security, Health, Safety and Environment (HSE) challenges are an increasing concern. Together, these issues have the poten-

tial to create heavy financial losses, as well as impact the operating company’s corporate image and brand. Therein lies the challenge of trying to balance maximising resource and equipment capacity utilisation and ensuring that operations are always operated at the highest safety levels. To add to the complexity, there are diverse sets of standards that apply to the many layers of the process safety ecosystem. Relevant industry standards include EN54, NFPA 72, ISA 84, IEC 61508 and 61511. Together with common HSE challenges, companies need to assess their operation requirements to ensure that plants are both safe and cost effective to operate. When it comes to installation and maintenance, wireless technology typically costs as much as 50 percent less than the wired alternative. However, not all operations are best placed to support and/or use a wireless platform. In this way, a thorough analysis of operation needs

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and industrial automation systems the biggest impact on electronic security fears and slowed down the spread of wireless, writes Ray Rogowski. and equipment, as well as the environment in which the operations are taking place, will ensure the right technology is applied to overcome common HSE challenges. The development of the right network infrastructure should not only offer solutions that replace wired transmitters but also provides a comprehensive plant-wide solution. These solutions help support a broad range of applications in the plant that together can help solve problems of safety, reliability and efficiency. These wireless networks should be developed to not only replace field instrumentation, but also take into consideration the functionality and life-

cycle of applications using the wireless system. This is to ensure the company can realise the full value and return on the equipment. Simply put, you’re looking at year-on-year ROI as opposed to one-time savings. For example, during start-up, commissioning or calibration of an instrument, an operator working in the field might have traditionally communicated via walkie-talkie with another operator working off-site in the control centre. Using a single device, that control operation can effectively be managed by the one person out in the field, immediately removing once given overheads. Wireless technology and industrial

automation systems have indeed transformed the way the industry operates. The technology has proven it can deliver, both in terms of security as well as providing solutions that match or exceed those of the wired alternative. As more and more plants start implementing wireless technology, it is vital to be aware of how the system, and the way in which it is maintained and operated, is able to protect valuable intellectual property, an organisation’s bottom line and, importantly, its people. [Ray Rogowski is Director Global Marketing, Wireless Business, Honeywell Process Solutions.] www.honeywell.com

Meet all your needs with one cost-effective controller. When you need a flexible, scaleable, integrated control and motion solution, Logix is the answer. From simple to complex machinery CompactLogix™ is Integrated Architecture in its simplest form helping reduce the volume of hardware Experience your future today, visit: www.RockwellAutomation.com/ think/yourfuture

you need, making it quicker for you to meet your customers’ requirements. www.RockwellAutomation.com.au www.RockwellAutomation.co.nz

NOVEMBER 2011 www.pacetoday.com.au 11

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IN FOCUS

Fuzzy controller delivers improved pi t The pitch control of wind is based today on PD or PID controllers. Due to the non-linear behaviour of the tu rb needs only an indistinct mathematical model and not a detailed one. Thus, the use of fuzzy controllers in futu re

ODERN wind turbines control the power extracted from the wind by changing the rotor blade angle. The wind generates a lift force at the rotor blades which results in a rotary movement of the rotor. However, from a wind speed of approximately 12 m/s (wind force 6 Bft), the power taken up as a result by the rotor would be larger than the rated output of the wind turbine and must therefore be limited. To this end, the inflow angle of the wind is modified by adjusting the rotor blades, thereby reducing the rotor output. This method of regulating the speed via the blade angle is usually called pitch

12 www.pacetoday.com.au NOVEMBER 2011

control. The associated control loop is highly non-linear, primarily as a result of the aerodynamic behaviour of the rotor blades. In modern wind turbines, therefore, the PID controller employed is supplemented by filters and further additional functions such as gain scheduling. In designing the mechanical construction of a wind turbine, the loads acting on the turbine are decisive. They form a spectrum of extreme loads and fatigue loads. The former can be reduced through intelligent operational management, the latter through careful parameterisation of the speed controller. The pre-configuration of the controller parameters takes place as part of the load calculation for a wind turbine. A turbine computer model is

subjected to standardised wind profiles in simulation runs. Competing optimisation criteria have to be taken into account in the controller design. The optimisation process can, therefore, be complex and protracted, since several iteration loops are required before the optimum can be determined. The “optimum” determined in this way is still only a best possible compromise. In addition to this pre-configuration, it is usually necessary to optimise the parameters determined in the simulation during commissioning of the turbine. This process can also be rather complex, since the required wind speeds are not available ‘on tap’ and, moreover, only occur for a limited period of time, depending on the site.

WIND POWER

OPEN SYSTEMS Manufacturers of wind turbines therefore face the task of retaining maximum flexibility in face of the continually changing demands of the market in order to keep their products competitive. Beckhoff PCbased control technology and automation components, which are nowadays in use in wind turbines up to a size of 5 MW. Beckhoff implements open automation systems on the principle of PCbased control technology. This openness enables turbine manufacturers to adapt their systems.

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i tch control for turbines tu rbines, the design of these controllers is usually a very time-consuming affair. The fuzzy controller tu re promises a faster and more efficient procedure, writes Nils Johannsen.

PROFILES: The definition of the speed bands.

Fuzzy logic characteristics Unlike the PID controllers that are predominantly used today, fuzzy controllers are already non-linear state controllers with a reputation for great robustness. It is known from other applications with similar boundary conditions that the use of fuzzy controllers in highly non-linear systems leads to better control characteristics. The difficult stability check and the lack of a systematic design procedure are often mentioned as disadvantages of fuzzy controllers. In order to check the stability, a model would be required, which could in turn be used for the adjustment of a PID controller. However, the fuzzy controller needs only an indistinct mathematical model and not a detailed one. In the case of wind turbines the model is always only a reproduction, since the real conditions of the wind, turbulence and aerodynamics can only ever be approximated. Changes in the air density, the rotor blades and the inertia in the drivetrain are already enough to cause great changes in the aerodynamic behaviour of the rotor. PID controllers are based on the model of the turbine, to which the parameters are oriented. If the model changes, the control quality is automatically reduced. Fuzzy controllers, conversely, are based on rules. Even if

the model were to change strongly, the fundamental process would still be the same and the rules would still be fully valid. The control value is calculated on the basis of these rules, for which reason no exact information about the system needs to be available. The controller reflects the human behaviour of the expert who designed these rules and enables an individual reaction to each state. As a result, fuzzy controllers are considerably more robust in relation to changes of the turbine, the setpoint or faults. In addition, parameterisation is considerably simplified, because cognitive, not mathematical knowledge is required.

Motivation Based on these experiences, Beckhoff designed a fuzzy controller for the TwinCAT automation software in order to regulate the pitch and, thus the speed of turbine rotors more effectively. Apart from that, the use of fuzzy controllers for wind turbines is expected to reduce the time and effort involved in designing the controller. Since the understanding of the controller is considerably simplified, the necessary time for optimisation can be significantly shortened. Moreover, it should be possible to use a controller for different turbines

without modification, irrespective of the rotor diameter or the tower height. Since the fuzzy controller is a multivariable controller, reaction to various states of the turbine is thus considerably more flexible. However, these advantages only become relevant if the control quality and the energy yield are comparable and the turbine loads are not increased as a result. If on the other hand the loads could be reduced, then the fuzzy controller would prove to be significantly more efficient.

Pitch controller structure In principle, the fuzzy pitch controller for TwinCAT monitors the rotor speed and outputs a pitch adjustment rate. The deviation of the speed from the set value and the acceleration of the rotor are calculated internally. The two inputs are assigned fuzzy quantities, also known as “fuzzification”. This assignment takes place via bands placed around the value. A speed deviation of zero would be the centre point; a slight deviation would be assigned to the first band and larger deviations to the higher speed band in each case. A total of three bands are used for the respective input, wherein a distinction is made between negative and positive deviations and it is determined whether the value possibly lies outside

The fuzzy controller fulfils expectations even when the parameters are only broadly configured and has proven itself to be ideal for pitch control. the defined bands. In turn, three bands are created for the output – the pitch adjustment rate – from a slow rate to the maximum rate of adjustment, in each case positive and negative. The width of these bands is specified via parameters. This produces three parameters for the speed deviation, three for the acceleration and three for the adjustment rate. The rules are then evaluated on the basis of these fuzzy quantities or speed bands. A total of 49 rules were created, one for each possible state. These rules are defined on the basis of the assignment to the respective bands of the inputs and to the output used. Processing takes place by means of the so-called decision logic. One rule would be, for example: if the speed deviation is in the first positive band and the acceleration is in the second negative band, then the pitch adjustment rate is > NOVEMBER 2011 www.pacetoday.com.au 13

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CONFIGURATION: General structure of the fuzzy pitch controller.

set to the first negative rate. A negative pitch adjustment rate would mean turning the rotor blade into the wind and increasing the power coefficient. This rule demonstrates the flexibility of the fuzzy controller. A proportional controller would have stubbornly output a positive adjustment rate in the case of positive speed deviation. However, since the rotor already exhibits a negative acceleration, i.e. the speed is dropping; the rotor would be decelerated further, leading to underspeed and a reduction of the energy yield. The rule of the fuzzy controller, however, deals with the negative acceleration. Instead of reducing the rotor speed further, the controller attempts to work against the acceleration in order to avoid underspeed. The aim is to regulate more specifically toward the nominal speed and to increase the energy yield. Weighted outputs are determined and the pitch adjustment rates are calculated by the evaluation of all rules whose conditions are fulfilled. This process is known as â&#x20AC;&#x153;defuzzificationâ&#x20AC;?. In order to avoid excessively fast changes of the control value, the pitch adjustment rate is additionally 14 www.pacetoday.com.au NOVEMBER 2011

smoothed via a first-order filter. The input quantities, rules and output quantities together represent the knowledge base of the controller. The rules are permanently implemented and cannot be changed, since they ensure the stability of the controller and contain the expert knowledge of the process. The input and output quantities can be changed via the bands and thus adapted to the rotor employed, if necessary. The smaller the speed bands, the stronger the controller reacts. The controller behaves in the same way for the other bands. The knowledge base is thus very simply structured and comprehensible, even for those who are not control technicians.

Practical controller verification The fuzzy controller design from Beckhoff was verified in co-operation with WINDnovation GmbH, based in Berlin, Germany. The fuzzy pitch controller was compared with a conventional PD controller in the BLADED design software from GL Garrad Hassan on the basis of an existing turbine model. WINDnovation had already carried out the complete load calculation and

designed the PD controller for this turbine. The results are therefore comparable with one another without reservation. It must be pointed out that several days were required in order to parameterise the PD controller so that the rotor speed could be stably regulated. After that, several more weeks were required in order to determine the optimum control parameters. The fuzzy controller was implemented into this load calculation and used with a standard rule set. The rotor speed was stably regulated immediately and the parameter set was not changed any further for the subsequent load calculations. The 69 load cases used for the simulation were generated according to the Germanic Lloyd guidelines for the certification of wind turbines and contained wind profiles with wind speeds from 3 to 25 m/s according to wind class IIA. These time series were simulated in each case for the conventional controller and the fuzzy controller, and the control quality, extreme loads and fatigue loads were evaluated and compared with one another. The control quality was determined by the evaluation of the rotor speed, the electrical power and the pitch adjust-

The difficult stability check and the lack of a systematic design procedure are often mentioned as disadvantages of fuzzy controllers. ment. The average values and deviations from the set values were calculated for all load cases. The results show that the average deviation of the rotor speed from the set value is smaller when the fuzzy controller is used. In addition, the average rotor speed and the electrical power were increased. To this end, the fuzzy controller requires increased activity of the pitch adjustment. The extreme loads achieved comparable values with both controllers. The loads on the rotor blades also correspond. The evaluation of the fatigue loads shows that the loads are reduced when the fuzzy controller is used. Exceptions

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to this are the loads acting on the tower. The loads on the drive train and the rotor were reduced by an average of 4 per cent and in some cases even up to 13 per cent. Despite the increased pitch adjustment, the loads on the hub, rotor blade and blade root were also reduced.

to be ideal for pitch control. In the future, the results must be verified in further load calculations and the controller must work satisfactorily on a real turbine. In addition, there are still further possibilities to extend and optimise the controller. Extension by filters could reduce the loads further. Circumstances could be dealt with and reacted to with foresight by means of the evaluation of additional inputs. Additional outputs could be used to enhance the functionality of the controller and enable greater intervention in the process. Combination with a neural network, also known as a neuro-fuzzy system, would enable automatic optimisation of the parameters. [Nils Johannsen works in the Wind Turbine Application Software Department at the Beckhoff Wind Expertise Centre in Germany.]

Outlook The comparison of the load calculations shows that the fuzzy controller delivers comparable and in some cases even better results, although no optimisation of the parameters took place. Trial changes to the parameters also prove the robustness of the fuzzy controller. The adjustment of the parameters is simplified due to the understandable knowledge base, and time and effort are substantially reduced. Further optimisations based on the respective turbine would surely lead to further improvements. In summary, it can be said that the fuzzy controller fulfils the expectations, even when the parameters are only broadly configured, and has proven itself

ALIGNED: Comparison of the blade angles of the PD and fuzzy controller.

Beckhoff Automation 03 9912 5430 www.beckhoff.com.au www.beckhoff.com/wind

NOVEMBER 2011 www.pacetoday.com.au 15

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Future-proofing SCADA Communica t The most immediate and substantial returns for utilities and distribution network operators can be found in in SCADA equipment, writes Nicky Dibben.

FIGURE 1: Utility balancing act and stakeholders.

FIGURE 2: Increasing visibility and control in the distribution network.

support SCADA deployments that utilities have an opportunity to make smart, future-proof investments. A smart point-to-multipoint communication network addresses commercial and operational concerns by delivering three things: • A single, scalable, upgradeable network • Equipment designed for longevity • Comprehensive, upgradeable security measures A single, scalable, upgradeable SCADA communications network means that transitioning from serial to IP can be done in stages, with a mix in the network as required, while working concurrently with both existing and new equipment. This avoids the need for separate serial and IP networks for legacy RTUs. With smart SCADA point-tomultipoint radios as the backbone for a communication network, DNOs can control where and how the network is

TILITIES today face unprecedented change, both internally and externally. Distribution network operators (DNOs) are both responsible for and are required to prepare for the challenges of the smart grid. Challenges include increasing demand, distributed generation, environmental concerns, peak management, security and more stringent regulations, an important component of which is ensuring the suitability of infrastructure investments for the long term. The investment challenge is further complicated by a lack of consensus as to the future landscape. Waiting for clarity is not an option due to the time constraints of deploying network wide infrastructure and the imperative to quickly realise performance gains and, perhaps more importantly, the balance sheet. A futureproof investment policy is needed, with 16 www.pacetoday.com.au NOVEMBER 2011

a focus on ensuring that infrastructure: • Is dimensioned for today’s needs yet scalable to meet tomorrow’s. • Addresses both commercial pressures and operational realities to deliver the most effective performance and efficiency improvements. • Takes into account long term, multistakeholder asset management plans and capital investment cycles that require network equipment to be deployed for 20-30 years or longer. While industry forums resound with talk of renewable energy sources, electric vehicles, AMR and peak shaving; it is widely accepted that the most immediate and substantial returns for utilities and DNOs can be found in increasing visibility and control of the distribution network through deployment of additional and better SCADA equipment. Furthermore, it is in deploying the communications networks required to

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ABOUT 4RF Distributed in Australia by Madison Technologies, 4RF solutions are deployed by utilities, oil and gas companies, international aid organisations, public safety, military and security organisations, transport companies, broadcasters, enterprises and telecommunications operators. The Aprisa SR is a smart, secure, point-to-multipoint radio for SCADA and monitoring and control communications.

scaled, when to deploy new units or add previously unmonitored assets. Investing in a communications network dimensioned for current needs yet can scale easily and cost effectively as the future landscape becomes clear and

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a tions for the Smart Grid in increasing visibility and control of the distribution network through deployment of additional and better needs evolve, is a smart decision, operationally and commercially sense. A controlled rollout is then enabled through software upgrades, not truck rolls. The reduced maintenance cost advantages of improved monitoring and control will not be eliminated by having to spend time and money maintaining the communications network itself. A network of smart point-to-multipoint SCADA radios from a reputable manufacturer will ensure that wherever the equipment is deployed, from high temperatures on overhead lines to freezing conditions, the network will continue to operate. Planning and deploying communications infrastructure in line with lengthy

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tions, the network interfaces and security fundamentals. Investing in a communications network that takes security and evolving standards into account, ensuring that critical infrastructure is safe and within absolute control, both now and into the future, while still making commercial sense by minimising upgrade costs. By choosing a communications platform that provides a future-proof investment, DNOs will be rewarded with: • A single network, able to deploy enhanced functionality as needed, regardless of future uncertainty • Reduced maintenance costs with equipment designed for the lengthy deployment periods that utility infra-

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structure demands • Seamless rollout of the latest and most stringent security mechanisms across the SCADA communications network Most importantly, owning the future-proof communications platform gives absolute control over the network, from both a commercial and an operational perspective, however long it is deployed for and whatever the future holds. When it comes to critical infrastructure, a future-proof investment is not just smart, it is essential. [Nicky Dibben is Vice President Marketing, 4RF.] Madison Technologies 1800 66 99 99 www.madisontech.com.au

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IN FOCUS

Loadrite delivers reliability Measurement errors between estimates and actual production can be costly with errors up to 20 percent.

OADRITE specialises in highly advanced scale systems for loaders, excavators and conveyor belts as well as reporting software. “There are so many uncontrollable variables in mining, our Loadrite monitoring systems give miners a measure of certainty and accuracy to improve the business efficiency of any operation,” said Loadrite Australasian region manager, Bruce Warner. “If you don’t know what your production rate is, then you don’t know if you’re getting the most out of your operation. Loadrite products will increase profitability, improve operational efficiency and let miners take control of their production. “Mine designers can now compare the actual production rate of the mine to the rate expected when the mine was being developed. This enables cash flow to be more accurately forecast.” Mines often contract out parts of their operations. “In the production areas, most contracts have agreed provisions for production throughput levels. Loadrite systems give highly accurate methods for monitoring throughput. This can dramatically reduce the likelihood of disputes between the contracting parties.” Loadrite scales for wheel loaders, excavators and conveyors have been making a big impact at mines across Australia, according to Warner. “Measurement errors between estimates and actual production can be costly and it’s not uncommon for mines to have errors of more than 20 per cent. With a Loadrite scale solution the mine can eliminate this uncertainty. Loadrite scales reduce the uncertainty of a mine’s monthly reconciles and in doing so improve overall production.” Loadrite scales used in conjunction with data modems and reporting software are versatile. “Production data can be shared quickly and efficiently with both the contractor and the mine owner. This allows managers to make tough, real-time informed decisions to increase productivity and reduce cost by 18 www.pacetoday.com.au NOVEMBER 2011

Companies can cost effectively identify bottlenecks and pinch points in their production processes.

TRACKING: Production data can be shared quickly with both the contractor and the mine owner.

removing problems and bottle necks,” says Warner. Loadrite recently launched the new generation C-Weigh 3860 belt scale integrator and Insight reporting system to its Loadrite family. Keeping track of production from crushing and screening plants is essential for business efficiency, but up until now has been costly and very difficult. According to Warner, Loadrite’s IM-Series Insight software makes it easy to produce a range of useful reports.

“With Insight, companies can cost effectively identify bottlenecks and pinch points in their production processes. Users can track tonnes per hour through the plant, track inventory and assess the wear rate of parts. They can also exactly track the time when the plant is running but not producing and keep tabs on downtime,” said Warner. “Having access to this information means companies can properly assess their procedures and confirm the impact of the changes they introduce.”

A lot of mines have already very expensive PLC/SCADA systems installed which are able to monitor the production. Loadrite’s solution provides similar production reports at a fraction of the cost. “Loadrite is helping miners mine smarter and the Loadrite system can cater for any size operation small or large. Loadrite has a range of weighing systems designed for wheel loaders, from entry-level through to advanced functionality options. Whether you require basic weighing information for a small loader, or greater accuracy and data capture capabilities for productionsized loaders, we have the solution for you,” said Warner. Loadrite’s versatility has also seen its wheel loader system widely used for boggers in underground mining operations. Loadrite’s excavator scales have been designed and engineered specifically for bucket excavators and can be fitted to excavators to measure production down at the face. The Loadrite X-Series excavator scales use Multi-Dimensional Compensation weighing technology to achieve accurate weighing performance with no disruption to the operation of the excavator. “We’re all looking for better ways to improve efficiency,” said Warner. He says the Loadrite reporting tools installed on a computer can turn a Loadrite Onboard scale into a modern business management tool. “Loadrite systems enable you to gather load data from your Loadrite scale and transfer it across a site in a secure, paperless manner.” Loadrite 1800 655 860 www.loadritescales.com

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BEHIND THE SCENES

Machine vision boosts productivity Advances in machine vision technology for manufacturing environments can deliver significant quality control and productivity benefits, writes Hartley Henderson.

CHECKED: The system has to inspect 320 glass jars per minute as they pass through the gripper conveyor. PROFILE

IMPLOT Australia, which offers a range of food products under well known brands such as Edgell, Birds Eye, John West, Leggo’s, Ally, Seakist, Harvest and Chiko, has six manufacturing facilities around Australia including at Echuca in country Victoria. The company says there is a constant effort to maximise quality control systems and processes through new and

20 www.pacetoday.com.au NOVEMBER 2011

innovative technologies. At the Echuca plant, which employs some 140 people, machine vision technology from Omron has been installed as part of the quality control system on the glass line that produces Leggo’s pasta sauces. The design and implementation of the system was undertaken by an in-house team led by mechanical project engineer Jimmy D’Alessio who

advised the team on how to implement the system. Other team members included electrician and programmer Paul Baker who was involved with the actual programming that needed to be coded, and control system engineer Wes Brown who was also involved with the programming codes. Input to the project was also provided by electricians from the elec- >

OMRON From micro-relays to advanced sensors, Omron Asia Pacific’s Industrial Business Group offers a range of control components and automation products. As part of its efforts to becoming a green corporation, Omron has achieved ISO 14001 certification at all of its 30 manufacturing sites.

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BEHIND THE SCENES

COMPLETE: The ZFX Machine Vision Sensor is a total image processing system that includes everything from a camera with an integrated light source to an image processing unit.

trical department to wire the system, and fitters from the mechanical department to manufacture bracket fittings to support the system. The system consists of a ZFX-C15 vision controller with one camera connection, PNP, IP20, integrated 3.5” TFT LCD colour touchscreen, RS232, 422, USB2.0, Ethernet outputs, 32 banks, 24Vdc supply 1.5A, together with a FX-S vision monochrome camera, and a programmable logic controller (PLC) (also from Omron) to automate the system at high speeds. Other elements of the system include CCTV lenses to suit FZ series vision, a red LED backlight, a S8VS-12024 power supply, a photo-electric sensor, and a reflector for long distance photoelectric switch. D’Alessio says that the purpose of the vision system is to give even greater assurance on the quality of the glass jars containing the product supplied to customers. “The system has to inspect 320 glass jars per minute as they pass through the gripper conveyor and if an imperfection is detected the system output displays the detected jar and signals the operator to physically inspect the item. The vision system is then reset to continue inspecting each jar under automation,” 22 www.pacetoday.com.au NOVEMBER 2011

These problems were overcome by utilising a micro PLC with high speed time delay and programming it to deliver a high speed signal to the vision system from the photo-electric sensor.

he explained. “As the jars pass along the conveyor, the system takes a 2D monochrome photo and inspects for any imperfections on the glass with the aim of ensuring that only good quality glass goes through to the filler. “This new automated vision system provides another element to our focus on total quality control, adding to the existing critical control point (CCP) safeguards, including X-ray machine checks at the end of the line.”

Challenges D’Alessio points out that the team was faced with some significant challenges in

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flowing from the project, particularly by ensuring first time quality of all products and eliminating the need for rework.

Advanced technology

PLAN: The theory was to create a loop within a loop in order to automate each system under a deterministic time nature.

designing and installing an effective vision system. For example, the speed of the conveyor that grips the jars can vary, which created issues. “Every jar has to be photographed, so operation of the system needs to be precise. Initially, the sensor was positioned at an angle to the field of view of the inspection system, making it difficult to take an accurate photo. “The solution was to move the sensor away from the camera field of view and relocate it 40 mm away in a parallel line to the field of view. “This eliminated the time delay fluctuations created by the gripper conveyor and enabled accurate detection of the following jar coming up close with a small gap, making both critical points parallel to cope with high speed inspection of each jar.

High-speed time delay According to D’Alessio, another issue was that the main PLC was doing a lot of processing, which caused delays, particularly when the line was running at high speed. These problems were overcome by utilising a micro PLC with high speed time delay and programming it to deliver a high speed signal to the vision system from the photo-electric sensor, thus forming a close loop system

away from the main PLC to deal with the high speed operation. “If detection occurs, a signal goes out of the loop enabling the main PLC to initiate ‘inspect jar condition’, stopping the jar at a pre-determined inspection point. The theory was to create a loop within a loop in order to automate each system under a deterministic time nature,” he said.

Machine vision specialist at Omron, Panfilo Tarulli, says the ZFX Machine Vision Sensor is a total image processing system that includes everything from a camera with an integrated light source to an image processing unit. “The ZFX can use a C-mount camera which enables you to choose the correct lens to match the field of view, and it can be used in combination with optical lighting, such as transmitted lighting, low angle lighting, and bar lighting to support different inspection types,” he said. “The ZFX Machine Vision Sensor stores up to 100 files of image data in the main memory without slowing measurement speed, and images data can be remeasured, so even with a high speed line the results of the measurements can be checked at leisure afterwards.

Omron Electronics www.omron.com.au 1300 766 766 Simplot Australia www.simplot.com.au 03 5485 5614

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Memory banks D’Alessio explains: “The biggest difficulty with the project was re-programming each product with different specifications, time delays and memory banks data under automation so that when a particular product was selected through the main PLC it also changed the selection at the vision system. However, with Omron providing support and assistance, we were able to get the system up and running. “It was found that the best way to detect defects in the glass was to illuminate the jars from the back, and laboratory testing helped us to determine which camera and lens needed to be used.” According to D’Alessio, total investment cost of the vision system, including labour, was $25,000 and significant productivity improvement benefits are

“Omron’s ZFX unique sensitive search capability can observe and detect the smallest detail in an object and display it on a screen, including smears, scratches, chips and burrs. The system can provide a valuable quality control function for a wide range of manufacturing industry applications.” Omron recently released the new FZ4 Machine Vision Sensor which has a large touch screen and has many filtering features as well as code reading functions. It also has HDR (high dynamic range) function and OCR (optical character recognition) capability, as well as remote access, which enables the user to log into the vision system to take full control, either from their office or off site.

Call us now for a copy of our catalogue.

NOVEMBER 2011 www.pacetoday.com.au 23

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BEHIND THE SCENES

Modular ore crushing system A multi-trailer ore crusher required a robust control system. AI Automation was able to deliver a setup consisting of self-generating trailers and a trailer mounted control room, writes Isaac Leung.

MACS: All components of the Mobile Aggregate Crushing System complement each other to maximise production and efficiency.

ILENCE, they say, is golden. And for AI Automation’s owner Colin Heath, silence on the part of the Western Australian client who ordered a multi-trailer ore crushing system is testament to Mitsubishi Automation’s equipment reliability. “We haven’t heard a peep from them, so there can’t be too much wrong,” Heath said. AI Automation delivered a system which consists of six self-generating trailers, and a trailer mounted control room. In each trailer, AI Automation imple-

24 www.pacetoday.com.au NOVEMBER 2011

mented Mitsubishi Q series and FX series PLC equipment as well as Mitsubishi HMI touch screens. Mitsubishi’s variable speed drives were used to provide finer control, as were Mitsubishi’s variable speed drives. At final count, the full plant consisted of one primary jaw crusher, one tertiary cone crusher, one secondary cone crusher, one fines vibratory multideck screen, one scalping multi-deck screen, and three height-variable roving radial stackers with ultrasonic material level sensing. Each section of mobile plant can be

independently operated, or coupled together for various plant configurations, for example to deal with different material grades or types.

Communications Local configuration and control for each trailer was afforded by the PLC system and touch screens present in every unit. This is in addition to the standard central control. “The main control room with 15inch touch screens is where the client can oversee the lot,” Heath explained. “The screens themselves are quite intelli-

Local configuration and control for each trailer was afforded by the PLC system and touch screens present in every unit. gent: they handle the transmission of data between the systems and works quite well.” All the trailers provide operational

AD_PACESEWNOV_11.pdf

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PACE.NOV11.PG026.pdf

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BEHIND THE SCENES

feedback of critical system pressures and temperatures back to the control room HMI unit, and the system is expandable. For example, video plant surveillance can be installed later, as can direct remote access capabilities which will allow even more flexible monitoring and configuration. Communications between the trailers and control equipment is handled by radio Ethernet, which eliminates the need for pesky re-cabling when the modules are reconfigured for new applications. Given the application, the speed and reliability of radio Ethernet technology was more than satisfactory for the project. “The data speed varies depending on what we’re transmitting,” said Heath. “We do not shift a large amount of data around. It was more necessary to bring the system together into a single HMI screen and controller; we’re only periodically looking at the information or sending out bits of data.”

Mobility and flexibility Mobility was a big consideration for the project, with the modular nature of the trailers allowing the client to mix and match the plant according to its needs. For example, the client can choose to exclude plants when they are not necessary for the process. “[With this project], you can change the plant’s configuration easily. [With] a fixed plant, you can’t do that, you’re stuck with what you’ve got, and it’s a major exercise to reconfigure,” Heath told PACE. “This plant could be reconfigured in a number of ways, depending on what grade of ore you are processing, or what you’re trying to achieve.” The self-contained nature of the plants was boosted by the use of diesel electric generators on each trailer, meaning the system did not have to be tethered to a central powerhouse, a fixed power plant or power source, further improving the flexibility and configurability of the solution. According to Heath, a system of the scope specified would normally be a fixed plant, but the need for two or three different configurations meant a fixed plant was out of the question. “You wouldn’t be able to achieve that configurability with a fixed plant – the plant would have been massive,” Heath said. 26 www.pacetoday.com.au NOVEMBER 2011

SOLVED: AI Automation was able to build an implementation to address the client’s need for a flexible solution.

While the trailers lend themselves well to being transported, the project in Western Australia was intended for just one mine site. However, Heath acknowledged the potential of such a system for higher end sectors, where the plants may need to be shifted to various sites on a needed basis, or around the site. In addition to the flexible configuration of the plant, additional control over processes like material feed control, screening efficiency and stock piling was provided by the use of Mitsubishi variable speed drives. This combination of equipment allowed the client fine-grained control over its operation, with the processes entirely adjustable according to the grade of ore it had to deal with. The variable speed drives also provided energy savings, ensuring a full tank of diesel lasts as long as possible.

Reliability In mining applications, with its tough conditions and when dealing with ore of various hardness, reliability is key – especially when any downtime can represent millions of lost dollars. By all accounts, the Mitsubishi equipment package has taken the 800 to

1,000 tonnes per hour production rate, extreme heat, dust, vibration and precipitation in its stride, with reliable and efficient performance. Heath swears by Mitsubishi equipment. “I personally used Mitsubishi for some 15 or more years, and its systems are highly reliable,” said Heath. “Their equipment is advanced, and is considered a world-wide market leader. Certainly it has a reputation of reliability and one that is well-earned.” Reliability is certainly good news for the client. Depending on the grade of ore being crushed, these plants can be set up and run for ten years or more. For distributors, happy customers are a good thing, but Heath wryly points out that this reliability means rarely will he get sales out of replacing broken equipment. Most of AI Automation’s work now comes from either expansion or superseded equipment replacement.

Advantages Heath summed up the advantages of the project for the client as “mobility, reliability, configurability and cost”. Through the use of Mitsubishi’s equipment and control technology, AI Automation was able to build a solu-

Communications between the trailers and control equipment is handled by radio Ethernet which eliminates the need for re-cabling when the modules are reconfigured for new applications.

tion to address the client’s need for a flexible solution. By mounting the plants on selfpowered trailers, the firm opened the door to a solution which can be quickly and cost-effectively rearranged to deal with a wide variety of tasks and material. This innovative form factor, along with the proven reliability of the equipment, meant AI Automation’s client has been blissfully quiet about the project since its delivery. AI Automation 08 9528 7598 www.aiautomation.com.au

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SPOTLIGHT

7best of the

PACE showcase of the best engineering technology releases of the month.

Smarter particle sizing with Mastersizer 3000 The new Mastersizer 3000 from Malvern Instruments delivers unique performance and productivity advantages in a compact and practical instrument design. With an extended dynamic range that spans 0.01 to 3,500 microns, the Mastersizer 3000 laser diffraction particle size analyser delivers precise wet and dry measurements right across the milli-, micro- and nano-meter size ranges. The Aero S dry powder dispersion unit reliably disperses a wide range of dry materials, even friable and fragile powders without inflicting particle damage. Intuitive software drives every Mastersizer 3000 measurement, bringing operator- independent analysis and offering data generation and presentation options tailored to individual customer needs. The process of method development has been streamlined, with access to Malvernâ&#x20AC;&#x2122;s extensive know-how provided when and where it is needed. ATA Scientific 02 9541 3500 www.atascientific.com.au

Maintenance software on iPad MEX is a Computerised Maintenance Management Software (CMMS) provider in Australia and has released their software on the iPad. The company siezed the opportunity to integrate MEX with the iPad and give customers a new platform to manage their maintenance. MEX claims to be the first CMMS provider to make the Work Order software available on the iPad. The system

runs on iPad 1 or 2 and consists of the complete Work Order module of MEX. It enables operations to implement a paperless workflow. It also increases time efficiency as there is no longer a need to wait to get back to oneâ&#x20AC;&#x2122;s desk to enter or receive data. MEX 07 3392 4777 www.mex.com.au

Documenting Process Calibrators Flukeâ&#x20AC;&#x2122;s 743/744 Documenting Process Calibrators have been widely used for advanced instrument calibration, especially in rugged environments. Operating the new 750 Series is similar enough to the 743/744 that existing users will be able to immediately start using the 750 Series with no required training to get substantially increased performance from the new models. These field tools calibrate temperature, pressure, voltage, current, resistance, and frequency and have three operating 28 www.pacetoday.com.au NOVEMBER 2011

modes: measure; source; simultaneous measure/source. The three operating modes let technicians troubleshoot, calibrate or maintain instrumentation with one tool. Improvements over the original model include a graphical display that is bright enough for readings to be seen in any light condition. The new rechargeable Li-ion battery pack provides enough power for an entire shift. Fluke Australia 02 8850 3333 www.fluke.com.au

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Email your product news to editor@pacetoday.com.au

Four port module Advantech has launched its APAX-5090P, four port (RS-232/422/485) communication module for its APAX-5570 Programmable Automation Controller (PAC) series. Two APAX-5090P modules can be attached to a single APAX-5570 unit expanding the number of communication ports to eight. The serial ports of the APAX-5090P are industrial grade connectors with high isolation protection. It also supports a general communication port library and can be programmed using Visual C++, .Net and KW thereby shortening project development time Advantech 1300 308 531 www.advantech.com/NC

Stainless IP69K actuator Motion Technologies are distributing a full servo actuator to replace air cylinders in hard to control or arduous applications. These applications include where predictable and controlled motion is essential and where maintenance and surface degradation is an issue such as in the food, pharmaceutical and chemical industries. Unlike air cylinders, there are no seals to wear out. There are no plated surfaces as construction is all 316 stainless. There is a water jacket also included for extra cooling in higher dynamic applications. Peak forces up to 88 kg with strokes available up to 1,000 mm. LinMot Stainless actuators can be configured as a standalone system or can be integrated into most PLC and industrial communications systems including SercosIII, Ethernet IP, EtherCAD, ProfiNet, Powerlink, Profibus DP, DeviceNet, CanOpen RS232/485. Up to 255 separate motion commands and up to15,000 motion profile set points can be stored in the drive system itself. Up to 95 per cent power savings are possible over current technologies. Motion Technologies 02 95244782 www.motiontech.com.au

Valves more reliable Georg Fischerâ&#x20AC;&#x2122;s Ventilating and Bleed valves have been made more reliable. A PP-H float on the Ventilating and Bleed valve type 591 ensures complete and reliable venting of the pipe system. The many different dimensions and optimal sizes allow the valves to be used under nearly all space conditions and in any system design. The valves are positioned at the absolute or temporary high points in the system, after pumps and at turning points. The valve types 591 and 595 control the aerating and de-aerating of piping systems and tanks with high precision and absolute dependability. The check valves type 561 and 562 have been redesigned and complement the companyâ&#x20AC;&#x2122;s line of plastic valves. Georg Fischer Piping Systems 1300 130 149 www.georgfischer.com.au

Preassembled RJ45 Profinet patch cable Phoenix Contact has developed an RJ45 crimp connector for Profinet. Profinet cables with conductor cross sections of AWG 22 can be used as preassembled patch cables when using this connector. Until now, it was only possible to assemble Ethernet cable using the QuickCon RJ45 plug connector with insulation displacement connection. This is because in the office environment, RJ45 connectors are used with cable cross sections in the range of AWG26. However, this is not sufficient

for Profinet cabling. Here, a cable cross section of AWG22 or 0.34 mm2 is required. The crimp connector is available in an angled version to address special installation requirements. The corresponding patch cables for applications involving Sercos III or EtherCat are comparable. These only differ by sheath colour or marking on the corresponding cable. Phoenix Contact 1300 786 411 www.phoenixcontact.com.au NOVEMBER 2011 www.pacetoday.com.au 29

PACE.NOV11.PG030.pdf

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EVENTS & EDUCATION

WHAT’S ON

REVIEW

Invensys Australia & New Zealand OpsManage’11 User Conference 14-16 November 2011, Gold Coast www.seeyouthere.com/userconference2011 Mission Critical Network Design Seminar 16-18 November 2011, Gold Coast www.beldenapac.com/mcnds.html IICA/ISA - Project Management for Automation Engineers 16 November 2011, Brisbane www.iica.org.au IICA/ISA - Safety Instrumented Systems 16 November 2011, Sydney www.iica.org.au IICA/ISA - Introduction to SCADA Systems Integration 17 November 2011, Sydney www.iica.org.au

A Practical Introduction to Matlab Programming Matlab, 2nd Edition: A Practical Introduction to Programming and Problem Solving By Stormy Attaway Elsevier $58.95 The book presents programming concepts and MatLab built-in functions side-byside, giving students the ability to program efficiently and exploit the power of MatLab to solve problems. In depth coverage of file input/ output is offered – this is a topic essential for many engineering applications Systematic, step-by-step

GIVE

For daily updates visit www.pacetoday.com.au

AWAY

Gas Well Deliquification, 2nd Edition By James F Lea, Henry V. Nickens & Mike R Wells Elsevier $74.95

approach, building on concepts throughout the book, facilitate easier learning. Also included are sections on ‘common pitfalls’ and ‘programming guidelines’ direct students towards best practice.

The book features turnkey solutions for the problems of liquid loading interference. It is based on decades of practical, easy to use methods of de-watering gas wells and expands on the first edition’s useful reference with new methods for utilising production automation and managing coal bed methane. Among the topics covered are: Recognising Symptoms of

Liquid Loading in Gas Wells; Critical Velocity; Systems Nodal Analysis; Compression; Plunger Lift; Use of Foam to Deliquefy Gas Wells; Hydraulic Pumping;; Gas Lift; and Electric Submersible Pumps.

You could win one of these books by answering the following question: On which page of this magazine will you find "Sercos" mentioned? Email your answer to kevin.gomez@reedbusiness.com.au

Both books are available direct from Elsevier Australia Customer Service, 1800 263 951 or customerserviceau@elsevier.com

IICA NEWS & VIEWS

Corporate Industry Program CIP enables the IICA to take on the role of greater pro-activity, writes Brett Simpson. OVER the past three years, the Institute of Instrumentation, Control and Automation (IICA) has been engaged in the challenging but rewarding task of placing all aspects of the Institute under review and then re-shaping them where necessary. The sole purpose of this task has been to ensure that our Institute is ready and able to meet both opportunities and challenges in the years ahead. This article singles out just one particular reform that has just been completed that we know will be of particular interest and relevance to corporate readers of PACE magazine. I am referring to the IICA’s Corporate Industry Program, or CIP for short. CIP has updated, and considerably expanded the Institute’s original Corporate Membership facility and now 30 www.pacetoday.com.au NOVEMBER 2011

offers very attractive reasons for a much wider range of companies in industry and manufacturing to seriously consider the IICA as their professional industry association of choice. Specifically then, the Corporate Industry Program is aimed at companies that are for example - contractors, consultants, end users, maintenance providers, vendors, suppliers as well as tertiary education departments or schools. Such companies or organisations will have particular focus in instrumentation, control systems and/or automation and will be engaged in diverse areas of professional engagement such as: Aeronautics; Defence/Military; Mining; Automation/ Robotics; Education; Oil & Gas; Automotive; Energy; Water;

Construction; Manufacturing. Corporate Membership opens the door to the Institute’s key areas of influence, advocacy and focus. Benchmarking ❏ Advocacy for enhancing Instrumentation, Control and Automation input into tertiary curricula (TAFE and University) ❏ Influence all layers of Government legislation for our industry sectors ❏ Raise professionalism in our industry ❏ Voice for Australian and International Standards Networking ❏ Peer Communication for professional value add ❏ Vehicle for promoting direct interaction between Suppliers and End Users in a neutral and informal

IICA environment Education Professional Development ❏ Professional Development tailored to specific company needs ❏ Access to Internationally recognized ISA professional accreditation for: - Certified Automation Professional (CAP) Program - ISA Certified Control Systems Technician (CCST) Program This summary is indicative of what CIP offers. It now enables the IICA to take on a more pro-active role, particularly in areas of representation and advocacy, on behalf of companies in Tour industries. To discuss the CIP Membership with us, please contact our Ecevutive Officer Maruta Rodan on 0414 645 415. www.iica.org.au

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Nominations now open for the 2012 PACE Zenith Awards The PACE Zenith Awards recognise companies and professionals who show innovation in engineering projects and technological excellence in one or more of ten industry categories:

Submit your entry today.

14 June 2012, Melbourne

All finalists will be invited to celebrate their success amongst peers at a gala dinner in Melbourne on 14 June 2012. Finalists will also receive significant publicity in PACE magazine and website.

Categories • Automotive & Manufacturing • Food & Beverage • Metal Products Manufacturing • Mining, Minerals & Exploration • Oil & Gas • Power & Energy Management • Lifetime Achievement Award • Transport, Power & Infrastructure • Water & Wastewater • Young Achiever

Nominations close 1 April 2012. Visit www.pacetoday.com.au/awards to download the entry kit. For further information please email kevin.gomez@reedbusiness.com.au Sponsorship opportunities are available, contact Tim Richards on (02) 9422 2818 or at tim.richards@reedbusiness.com.au

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