PACE Feb 2020 by Prime Creative Media

FEBRUARY/ MARCH 2020 | VOL.74 NO.1 | Est. 1953

INSIDE PACE

Sustainable production

Power management

I/O performance rated

What it takes to minimise waste in a plant

Pros and cons of twoÂ systems

Importance of communication and speed in machines

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CONTENTS

CEO: John Murphy Publisher: Christine Clancy Group Managing Editor (Northern): Syed Shah

IN THIS ISSUE

Assistant Editor: David Loneragan Ph: (02) 9439 7227 david.loneragan@primecreative.com.au

Sales/Advertising: Danilo Cortucci danilo.cortucci@primecreative.com.au Production Coordinator: Janine Clements Ph: (02) 9439 7227 janine.clements@primecreative.com.au Design Production Manager: Michelle Weston Art Director: Blake Storey

Designers: Kerry Pert, Madeline McCarty SUBSCRIPTIONS: $99 p/a incl GST NZ: $A109 p/a & OS: $A119 p/a Subscriptions: Bobby Yung Ph: (03) 9690 8766

Editor’s Comment 4 Copyright PACE is owned by Prime Creative Media and published by John Murphy. All material in PACE is copyright and no part may be reproduced or copied in any form or by any means (graphic, electronic or mechanical including information and retrieval systems) without written permission of the publisher. The Editor welcomes contributions but reserves the right to accept or reject any material. While every effort has been made to ensure the accuracy of information, Prime Creative Media will not accept responsibility for errors or omissions or for any consequences arising from reliance on information published. The opinions expressed in PACE are not necessarily the opinions of, or endorsed by the publisher unless otherwise stated.

News 6

How robotisation and automation is making waves in horticulture

Automation 18

Industrial cables 30

Energy Management 22

Digital Connectivity 32

How are edge computing, machine learning and AI shaping the future of industry? Finding the right sustainable energy system for your facility Sensors 24

Using sensor technology to make packaging “smart”

Articles All articles submitted for publication become the property of the publisher. The Editor reserves the right to adjust any article to conform with the magazine format. Head Office 11-15 Buckhurst St South Melbourne VIC 3205 Ph: +61 3 9690 8766 enquiries@primecreative.com.au www.primecreative.com.au

Explore the latest in Ethernet technology Wastewater 34

Minimising risks in wastewater treatment New Products 36

The future of automation

FEBRUARY/ MARCH 2020 | VOL.74 NO.1 | Est. 1953

INSIDE PACE

Sustainable production

Power management

I/O performance rated

What it takes to minimise waste in a plant

Pros and cons of two systems

Importance of communication and speed in machines

AUTOMATION AT THE FRONT

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Which energy supply system is best when it comes to efficiency, reliability and security?

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Robotics 26

EXCLUSIVE: The control behind managing wastewater

Recent trends in automation technology have the potential to be gamechangers in the industrial sector, pushing forward productivity, efficiency and making processes more flexible and adaptable in real-time. But what are the specific features of some of the most forward-looking technologies? And how can they help industrial companies get an edge on their competition?

In this issue of PACE, we talk with Justin Farrell from Siemens and Simon Kearney from APS Industrial to discuss the recent trends in industrial automation technology. Farrell and Kearney explore the benefits of edge computing, machine learning, and artificial intelligence and how they are shaping the way companies carry out their operations.

FEBRUARY/ MARCH 2020 www.pacetoday.com.au 3

EDITOR’S COMMENT

EDITOR’S MESSAGE

Syed Shah Managing Editor

Getting automated

Industrial automation isn’t new. If anything, modern industry has been defined by the refinement of techniques, methods and machinery to boost productivity by finding ways and means of minimising the amount of labour required for ever-expanding production. In recent years, however, strides forward in information technologies, particularly in computer processing capacity and in data storage and analytics, are taking industrial automation to another level. In this issue of PACE, we explore some of the recent trends in industrial automation. Justin Farrell, general manager of factory automation at Siemens Australia, and Simon Kearney, APS director of sales, talk about how new datacentred technologies are bringing big changes to industry. Edge computing

is enabling data storage and analysis close the devices and machines onsite, improving connectivity and reducing the need to process data in centralised cloud locations. Farrell and Kearney also delineate some key differences between machine learning and artificial intelligence (AI), which are often mistakenly conflated. They also emphasise the need for partnership and collaboration in adapting to the changes wrought by technological change. While they acknowledge that adopting Industry 4.0 technologies requires a big shift in mentality, they also say that there are experts willing and able to provide guidance for the first step and, in time, the rest of the journey. Automation was also the focus of an event late last year – AgriControl 2019. Held in December, the event

4 www.pacetoday.com.au FEBRUARY/ MARCH 2020

showcased some of the leading research that has been undertaken internationally on the use of automation technologies in the agricultural sector. A highlight of the event was a presentation by Professor Hiroshi Shimizu on the potentials of robotics and advanced automation within plant factories and protected horticulture. The number of plant factories is growing globally. And the size of these facilities, also, is expanding rapidly, meeting the increased demand for food production located close to urban centres. Shimizu points out that a growing skills shortage in the agricultural sector is creating impetus for increased automation in plant factories. Today, advances in AI technology and machine learning are enabling

greater robotisation of these facilities. Shimizu’s overview of several plant and fruit harvesting robots can be found in this issue on page 26. Another feature of this issue is an interview with Total Construction’s James Bolton and Rob Blythman. Experienced in building facilities with renewable energy functionality, Bolton and Blythman provide guidance for food and beverage manufacturers for better management of their energy and water consumption, as well as their waste production. It is possible for manufacturers to achieve both financial feasibility and environmental responsibility. Perhaps the most important message is that there is no one-size-fits-all solution: each company needs to find what technology and methods will work best for their operation. PACE

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NEWS

Productivity improvements in the manufacturing sector will be worth $2.7 billion to GDP per annum.

Government funds training in advanced manufacturing technologies

he federal government has announced it will provide $3.6 million to trial the expansion of a one-year Diploma in Applied Technologies across six universities next year. Developed by Swinburne University of Technology and Siemens, the diploma will be expanded through University of Western Australia, University of Tasmania, University of South Australia, University of

Technology Sydney, and University of Queensland. Diploma students will be drawn from small and medium enterprises in key manufacturing industries. Federal education minister Dan Tehan said that training had to provide workers with the skills to keep up with technological advances, such as advanced manufacturing, increasing data capacity, robotics and automation. “This diploma will build a skilled

6 www.pacetoday.com.au FEBRUARY/ MARCH 2020

workforce in the manufacturing sector that will be vital to Australia’s future productivity,” Tehan said. “This research collaboration matches industry with the knowledge and research firepower of Australian universities.” Tehan said that Australia’s future productive will rely on educated workers able to access innovation and research to drive growth and productivity. “If we get this right, the

productivity improvements the sector can deliver will be worth $2.7 billion to GDP per annum. Helping young Australians to succeed at gaining employment will also grow Australia’s productivity and the economy overall,” he said. “The research done by our universities can lead to the development of new products and innovations that drive job growth, business opportunities and productivity gains.” PACE

NEWS

New ARC energy technology research centre launched

new research and training centre for advanced energy materials, batteries and battery-control systems has been launched at Deakin University. Researchers at the new Australian Research Council (ARC) Training Centre for Future Energy Storage Technologies will work with 11 organisations across government and industry, and five Australian universities to help facilitate small to medium-sized enterprises produce and adopt new energy storage technologies. The centre is being with $6.5 million from the Australian Research

Council (ARC) and industry and university partners. Federal education minister Dan Tehan said the research conducted at the new centre represented a significant opportunity to develop new energy storage technology for Australia. “This centre will put Australia at the forefront of innovative research in energy technologies, leading to the development of new products and innovations that drive job growth, business opportunities and productivity gains,” Tehan said. Henderson said that research outcomes from the training centre

would include new energy storage options such as Lithium metal and sodium-ion batteries with far-reaching applications. Liberal senator Sarah Henderson, who opened the centre, said that research outcomes from the training centre would include new energy storage options such as Lithium metal and sodium-ion batteries with far-reaching applications. “The training centre will equip the next generation of researchers and the energy technology workforce with the skills to drive innovation, exploration and investigation,” Henderson said. PACE

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FEBRUARY/ MARCH 2020 www.pacetoday.com.au 7

NEWS

Deakin University cyber security courses first to receive accreditation

eakin University is to become the first Australian university to offer fully accredited qualifications in cyber security, with five degrees and masters programs receiving recognition from the Australian Computer Society (ACS), Australia’s peak body for technology professionals. ACS, the only body in Australia with the power to accredit IT courses, has recently added cyber security to its accreditations. Currently,

many universities and institutions offer cyber security courses, but Deakin University’s five degrees and masters programs in the area will be the first to accredited by an external and independent body. Professor Karen Hapgood, Deakin University’s executive dean of science engineering and built environment, said the institution was proud to be able to offer students a fully accredited cyber security course that will be recognised

industry-wide and overseas. “It certainly endorses the highquality curriculum and the high quality of academic staff teaching our courses and validates Deakin’s decision last year to update its cyber security courses in line with industry and world needs,” Hapgood said. “As cyber security becomes more important to our national and global security than ever before, it is vital that students can take comfort that they are being taught at the

highest possible level.” Yohan Ramasundara, president of ACS, said the introduction of cyber security accreditation was a necessary step in addressing the increasing importance of the sector. “With the growing need for expertise in cyber security for our evolving and growing digital economy, introducing recognition for specialist cyber security qualifications and expertise was a must,” Ramasundara said. PACE

Acoustic sensing project to help Sydney Water prevent pipe breakage

he NSW Smart Sensing Network (NSSN), Sydney Water, SA Water and University of Technology Sydney (UTS) are collaborating on an acoustic sensing pilot project that aims to reduce leaks and breaks in water networks. The project, which involves acoustic sensors monitoring a total of 13 kilometres of pipes across the Sydney CBD, is part NSSN’s existing collaborative smart sensing technology research project with Sydney Water that uses a variety of smart sensing technologies and methods for leak detention and break prevention in water infrastructure. NSW water minister Melinda Pavey said the project to reduce water wastage due to pipe leaks and breaks was of high importance, particularly during the severe drought afflicting the state. “We are in the worst drought on record, every drop counts. Some of the pipes in this area are over 100 years

old and are understandably difficult to access,” Pavey said. “This new technology will help predict and reduce leaks and breaks around the city by listening to the network. In three years’ time, it is predicted to reduce major breaks by 50 per cent in the CBD.” Dr Don McCallum, NSSN development manager said that the fundamental engineering principles of the acoustic sensors are generally electrostatics, electromechanics or piezoelectric. “They are just like little speakers in reverse, like your stereo speaker at home. In this case, the membrane vibrates first and sends an electrical signal back to the signal recording box,” McCallum said. When water leaks it creates vibration due to the pressure differential between the inside and the outside of a pipe. The waves travel through both pipe material and water. Acoustics sensors measure the vibration inflicted on the material or

8 www.pacetoday.com.au FEBRUARY/ MARCH 2020

directly in the water column. “By using smart sensing and advanced acoustic technology not only we can sense leaks and do reactive maintenance, but we will be able to predict leaks and be able to do preventative maintenance,” McCallum said. Sydney Water managing director Roch Cheroux said that drought conditions were making detection and prevention water main breaks difficult. “This acoustic technology allows us to listen to the ‘music’ of the network, using advanced algorithms to hear the ‘songs’ of a leak,” Cheroux said. “Initiatives and partnerships like this across industry, provide us access to the best technology and innovations to proactively prevent leaks and breaks and improve our service for our customers and community.” “From next year, we will install more of these sensors across our water network, including in Liverpool, Bankstown and Penrith.” PACE

When water leaks it creates vibration due to the pressure differential between the inside and the outside of a pipe.

NEWS

Helping to put you in Control

Underspeed or Pulse Continuity Relay Suitable for all kinds of machinery to detect loss of speed and pulse continuity. It accepts NAMUR proximity switch, PNP sensor or clean contact input signals.

ARENA provides funding for second energy-from-waste plant The facility will be built just a few kilometres away from the country’s first large scale waste to energy plant in Kwinana.

he federal government’s Australian Renewable Energy Agency (ARENA) is providing $18 million in recoupable grant funding to develop Australia’s second large scale energy-from-waste plant in Western Australia. The East Rockingham Resource Recovery Facility is will be built in the Rockingham Industrial Zone 40 kilometres south of Perth, reducing waste currently going to landfill and generating dispatchable electricity for the grid. The $511 million plant is expected to process approximately 300,000 tonnes per year of residual waste from non-recyclable materials in the Perth metropolitan area to deliver 29 MW of baseload electricity capacity. Long term waste supply agreements have been struck with local councils in the

area, including the Eastern Metropolitan Regional Council and the City of Cockburn. French waste management company Suez has also signed a long-term deal to supply up to 65,000 tonnes per annum of commercial and industrial residual waste. The project has entered into a power purchase agreement for 25MW of its capacity. ACCIONA and HZI have been appointed to design and construct the facility. Suez and HZI will operate the facility under a 20-year operations and maintenance agreement. The facility will use moving grate combustion technology supplied by HZI. HZI’s technology has been installed in more than 600 projects worldwide and meets the most stringent environmental requirements. The project is expected to employ 300 workers during construction, and up to 50 operations staff on an ongoing

basis when complete. The project has the ability to generate large scale generation certificates for eligible feedstock in accordance with Clean Energy Regulator requirements. The facility will also recover 70,000 tonnes of bottom ash which can be processed and used in road bases and other construction materials. The facility will be built just a few kilometres away from the country’s first large scale waste to energy plant in Kwinana, which is now under construction. ARENA acting CEO Nicola Morris said energy from waste projects represent a significant opportunity in growing Australia’s bioenergy sector, which is the focus of a roadmap being developed by ARENA. “As the second state-of-the-art energy from waste facility in the country, East Rockingham represents a progression along the pathway towards commercialisation for the sector. The project will be delivered by a consortium with global expertise which will drive competition in the Australian market. We expect this project to demonstrate that large scale metropolitan energyfrom-waste plants are now a bankable asset class in Australia,” Morris said. “Furthermore, the recycling and waste-reduction efforts of local councils and other residual waste providers are supported by the “waste-arising” contractual structure, which is a key commercial innovation of the project.” PACE

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WiFi to Modbus TCP/RTU

MW5501C Industrial Wireless Modbus Gateway will provide you a flexible platform to convert bi-directionally Modbus RTU/ASCII/TCP through wired and wireless Ethernet Networks.

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Ethernet and USB Multifunction DAQ Unit The T4 is a USB or Ethernet multifunction DAQ device with up to 12 analogue inputs or 16 digital I/O, 2 analog outputs (10-bit), and multiple digital counters/timers.

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UR35 Industrial Cellular Router

Integrating embedded cellular modem and dual SIM function, the UR35 provides 3G/4G cellular network with 150 Mbps download and 50 Mbps uplink. It also has 5 ethernet ports and WiFi(optional).

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Single Phase Voltage/Current Transducer DIN-rail mount measurement transducer for single phase AC power. It can measure voltage, current, power and frequency. It has 4 to 20 mA and 0 to 10 V retransmission outputs and RS-458 and USB for Modbus RTU communication.

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Hydreon RG-11 Optical Rain Sensor

Senses rainfall with no moving parts. 6 different modes of operation. Works as a tipping bucket, skylight rain sensor, wiper control, drop detection or irrigation control sensor.

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For Wholesale prices Contact Ocean Controls Ph: (03) 9708 2390 oceancontrols.com.au Prices are subjected to change without notice.

FEBRUARY/ MARCH 2020 www.pacetoday.com.au 9

NEWS

Federal grants open for space control centre projects

rant applications are now open for the establishment of two control centres that will support the space industry in South Australia and Western Australia. The Mission Control grant opportunity will award a single grant of $6 million to establish the Mission Control Centre at Lot Fourteen in Adelaide. This centre will allow start-ups, small to medium enterprises, and researchers to control satellite missions and access space-enabled data. The Robotics, Automation and AI Command and Control Centre grant opportunity will award a single grant

of $4.5m to establish the Robotics, Automation and AI Command and Control Centre in Western Australia. This centre will allow start-ups, small to medium enterprises, and researchers to control autonomous operations in space. The funds come out of the federal government’s $19.5m Space Infrastructure Fund (SIF), which is to target seven infrastructure projects for common-user platforms that industry cannot provide alone. Applications for the Mission Control Centre and the Robotics, Automation and AI Command and Control Centre grants will close on 4 February 2020. PACE

The Mission Control grant opportunity will award a single grant of $6 million to establish the Mission Control Centre at Lot Fourteen in Adelaide.

Melbourne Water to install IoT devices for pipe protection and air monitoring

elbourne Water has developed a pipe protection and air monitoring device to help protect its infrastructure network and provide information on air quality. Developed in collaboration with the Environment Protection Authority Victoria (EPA) and Green Technology Services, the device is IoT enabled and has the ability to alert Melbourne Water to any corrosion in its pipes and tanks. It is also fitted with an air particle counter to help the EPA monitor air quality and examine the impact of smoke from bushfires. Beginning this month, approximately 200 of the devices will reportedly be installed across the utility’s

waterpipe network. Melbourne Water’s Russell Riding said that the devices will be fitted inside existing corrosion protection stations positioned alongside the Devices will be fitted inside existing corrosion protection stations.

10 www.pacetoday.com.au FEBRUARY/ MARCH 2020

utility’s main transfer. “This system will alert our asset managers if any issues with the operation of the corrosion protection systems occur,” Riding said.

“This will allow us to get to the affected site quickly and make the necessary repairs sooner, removing hundreds of time-consuming manual inspections we currently perform across our network.” EPA air quality scientist Gavin Fisher said the project would explore new ways of collecting air quality data and information on the impact of pollutionin Melbourne. “Before this innovation we’ve been limited in the ways and places we can collect air quality information,” Fishersaid. “This is an exciting and unique collaboration with Melbourne Water. We’ve obviously partnered on water issues before but not on-air issues.” PACE

NEWS

World’s largest battery to be expanded

elbourne Water has developed a pipe protection and air monitoring device to help protect its infrastructure network and provide information on air quality. The Australian Renewable Energy Agency (ARENA) has announced $8 million in funding to Neoen Australia for an expansion of the Tesla-built Hornsdale Power Reserve battery in South Australia. The $71 million project will see the current battery, which is already the largest in the world, expanded to demonstrate the ability for grid-scale batteries to provide inertia services and fast frequency responses to the grid. In what would be a first for the National Electricity Market, the project will provide an evidence base for further reform and innovation in grid management, including working with the Australian Energy Market Operator (AEMO) to test and demonstrate the capability of battery control systems to provide digital inertia replacing the mechanical inertia traditionally provided by synchronous generators. The tests could help to reduce current curtailment of solar PV and wind generation in South Australia. Neoen will also work with AEMO to provide an evidence base to support an update of the current Market Ancillary Services Specifications to increase the permissible level of Frequency Control Ancillary Services (FCAS) registration for all providers, enabling large-scale batteries to provide this service to their full extent and unlock revenue streams to provide a commercial pathway for other large-scale batteries. The Hornsdale battery extension could also allow for an increased power flow limit to the Heywood interconnector, resulting in an improvement in spot prices when importing energy from Victoria. Tesla, who built the original battery in less than nine months in 2017, will deliver the project on a full

ARENA has now supported five grid-scale batteries. turnkey construction basis. The project will also receive $15m over five years from the South Australian Government’s Grid Scale Storage Fund to address grid reliability and security in the state. The project will also be supported by the Clean Energy Finance Corporation. The total project cost includes financing and development costs in addition to capex. As South Australia continues to increase the share of renewable energy generation, large-scale storage such as grid-scale batteries will help address challenges facing South Australia’s power system including reliability and inertia. ARENA CEO Darren Miller said large-scale batteries will play a key role in ensuring reliability of supply and support for power system security, as Australia transitions

to renewable energy. “Large-scale batteries are playing an important role in providing short term, large-scale energy storage to help firm and balance the grid. The Hornsdale battery is a groundbreaking project that has proven what batteries can do for our electricity system, and this expansion will now show that it is capable of much more by demonstrating inertia, expanded FCAS functionality and extended support for the Heywood interconnector. Along with providing essential services to the South Australian grid, this will help to inform the regulatory changes required to value these services and create additional revenue markets for other batteries to enter the market on a commercial basis,” he said. “We hope this project will not only demonstrate the versatility of batteries

in providing a range of grid services but also help pave the way for market reform.” ARENA has now supported five grid-scale batteries including the ESCRI and Lake Bonney batteries in South Australia and two in Victoria at Ballarat and Gannawarra. “With this expansion, the Hornsdale Power Reserve will continue to break new ground in providing and proving up the benefits of inertial response from inverter technologies,” said South Australian Minister for Energy and Mining, Dan van Holst Pellekaan. “By providing an additional 50 MW of fast ramping market capacity it is designed to reduce spot price volatility and protect the grid from network disturbances, resulting in more affordable, reliable, and secure power for all South Australians.” PACE

FEBRUARY/ MARCH 2020 www.pacetoday.com.au 11

NEWS

Badgingarra solar farm opens in Western Australia

PA Group’s new Badgingarra solar farm in Hill River has now officially opened 200 kilometres north of Perth. The $40 million solar farm consists of almost 62,000 solar panels, installed across 40 hectares of land, and has a capacity of 19.25 MW. This is APA’s fourth facility in its renewables precinct, which is co-located with the Badgingarra wind farm, the Emu Downs Wind Farm and Emu Downs solar farm. The total combined capacity of the precinct, which includes 85 wind turbines and nearly 140,000 solar panels, is approximately 250 MW. The Badgingarra solar farm utilises

WA committed to helping secure highvalue, fast growing energy technology opportunities in the state.

a solar tracker system, so the panels can follow the path of the sun from east-to-west as the earth rotates. Western Australian energy minister Bill Johnston said that the government was committed to helping secure high-value, fast growing energy technology opportunities in the state. “I’d like to congratulate the APA Group and everyone else involved with the construction of the Badgingarra solar farm,” Johnston said. “Projects such as the Badgingarra solar farm demonstrate that we can create regional opportunities built around cleaner and cheaper energy sources that supports increased power reliability in the regions.” PACE

CSIRO releases hydrogen industry report

report from CSIRO has mapped the critical research steps Australia must take to realise the potentials of the emerging hydrogen industry. According to the report, Hydrogen Research Development & Demonstration (RD&D): Priorities and Opportunities for Australia, the hydrogen industry in Australia could create 7600 jobs and be worth $11 billion a year by 2050. The report stated that investing in research could solve industry challenges to create five key national opportunities: hydrogen exports; integration of hydrogen into gas networks; transport; electricity systems; and industrial processes. CSIRO research director, Dr

The hydrogen industry in Australia could create 7,600 jobs by 2050.

Patrick Hartley, said CSIRO is seeking to bring together industry, government and other research organisations to fast-track emerging hydrogen technologies. “This isn’t limited to the domestic

12 www.pacetoday.com.au FEBRUARY/ MARCH 2020

industry development – we’ll link Australian expertise with international projects,” Hartley said. “The overall focus will be on enabling Australia’s domestic and export hydrogen industries.

“Importantly, solving the challenges identified can have a multiplier effect that boosts demand for hydrogen – particularly in large scale industrial settings – and encourages further hydrogen supply cost reductions through improvements in efficiency and economies of scale.” The report was developed out of interviews with representatives from 35 industry and government organisations, over 80 interviews with researchers from 23 institutions, and an extensive literature review. The report was sponsored by the Department of Innovation, Industry and Science, the Victorian Government, Woodside, BHP, ARENA and Origin. PACE

NEWS

Space Agency signs agreement with Thales

he Australian Space Agency and Thales have signed an agreement that sets out plans for cooperation in investment, research, development and commercial opportunities in the space sector. Thales is a French company operating and investing in the Australian space and defence sectors, delivering satellite-based systems. Minister for Industry, Science and Technology Karen Andrews said this Statement of Strategic Intent and Cooperation was an important step in the Morrison Government’s plan to create opportunities for Australian industry and new local jobs. “Engaging with big international players like Thales will allow Australian businesses, including our advanced

manufacturers, to carve out a place in the international space supply chain,” Andrews said. “Space is very much an international game and for Australia to succeed we need to play to our strengths and have our businesses and researchers working cooperatively.” CEO of Thales Australia, Chris Jenkins, said the company was looking forward to working with the Space Agency and harnessing the strength of its global expertise in the space sector to build Australia’s sovereign capabilities. “Thales has been a long-term investor in Australia’s advanced technology sector, through comprehensive technology transfer and close collaboration with research agencies and specialised Australian

Australia is getting increasingly involved in the international space race. SMEs,” Jenkins said. “Together, Thales and the Australian Space Agency can build and develop the Australian workforce and SME sector to meet the future needs of the growing space economy.” The Australian Space Agency has also this week signed a Statement of Strategic Intent and Cooperation with

EOS Space Systems. EOS specialises in the design, manufacture, delivery and operation of technology for Space Situational Awareness. It will establish further laser ranging sensors across Australia to increase the volume of space objects they track from 10,000 to 100,000 each week. PACE

Swinburne cyber security project receives $450,000 in ARC funding

Swinburne University of Technology cyber security project that aims to enable full lifecycle privacy protection on the cloud has been funded by a $450,000 Australian

Current privacy protection approaches mainly focus on a specific case at a certain stage.

Research Council (ARC) Linkage Project grant. Deputy director of Swinburne’s Data Science Research Institute, Professor JinJun Chen, who leads the project, said that privacy protection

for user data hosted in cloud environments is at risk throughout all stages of the user information lifecycle. “Current approaches mainly focus on a specific case at a certain stage. This project aims to investigate those challenges systematically and establish innovative solutions to enable full lifecycle privacy protection on the cloud,” Chen said. The federal government has recently released a discussion paper on cybersecurity, Australia’s 2020 Cyber Security Strategy: A call for views, which states that $2.3 billion was stolen by cyber criminals from Australian consumers in 2017, while there were 53,474 reports of

cybercrime in the 2017-18 financial year and another 64,528 in 2018-19. More than 960 data breach notifications were also made from April 2018 to March 2019, 60 per cent of which were malicious or criminal attacks. “Current data auditing approaches for verifying data integrity lack sufficient efficiency and security, and hence cannot provide timely warning for removing potential data loss threats,” Chen said. “Our project aims to lead to timely warning and significantly reduce or avoid data loss incidents. In turn, this will bring significant economic, commercial and social benefits to the Australian community.” PACE

FEBRUARY/ MARCH 2020 www.pacetoday.com.au 13

NEWS

RMIT researchers explore use of ultrasound in 3D printing

study by RMIT University researchers has shown that sound vibrations can be used to improve the microstructure of 3D printed alloys. The researchers found that high frequency sound waves can have a significant impact on the inner microstructure of 3D printed alloys, making them more consistent and stronger than those printed conventionally. Carmelo Todaro, the study’s lead author and a PhD candidate from RMIT University’s School of Engineering, said that the results could inspire new forms of additive manufacturing. “If you look at the microscopic structure of 3D printed alloys, they’re often made up of large and elongated crystals,” said Todaro.

“This can make them less acceptable for engineering applications due to their lower mechanical performance and increased tendency to crack during printing.” “But the microscopic structure of the alloys we applied ultrasound to during printing looked markedly different. The alloy crystals were very fine and fully equiaxed, meaning they had formed equally in all directions throughout the entire printed metal part.” Tests found that these parts had a 12 per cent improvement in tensile strength and yield stress compared to those made through conventional additive manufacturing. The research team’s ultrasound approach was demonstrated using two major commercial grade alloys,

a titanium alloy commonly used for aircraft parts and biomechanical implants, known as Ti-6Al-4V, and a nickel-based superalloy often used in marine and petroleum industries called Inconel 625. By switching the ultrasonic generator on and off during printing, the team also showed how specific parts of a 3D printed object can be made with different microscopic structures and compositions, useful for what’s known as functional grading. RMIT’s Distinguished Professor Ma Qian, study co-author and project supervisor, said he hoped the results would increase ultrasound devices designed for metal 3D printing. “Although we used a titanium alloy and a nickel-based superalloy, we expect

High-frequency sound waves can have a significant impact on the inner micro-structure of 3D printed alloys.

that the method can be applicable to other commercial metals, such as stainless steels, aluminium alloys and cobalt alloys,” Qian said. “We anticipate this technique can be scaled up to enable 3D printing of most industrially relevant metal alloys for higher-performance structural parts or structurally graded alloys.” PACE

$13m infrastructure upgrade underway at Tarong Substation

reliminary work is underway on a $13 million electrical infrastructure upgrade at the Tarong Substation to ensure a continued reliable

supply of electricity to the South Burnett region. Queensland’s acting energy minister Mark Ryan said Powerlink’s the work was delivering critical

Crews are expected to start on-ground removal and installation works at the substation this year. 14 www.pacetoday.com.au FEBRUARY/ MARCH 2020

upgrades to the 38-year-old substation. “Tarong Substation is a major injection point in Powerlink’s transmission network, connecting the Tarong and Tarong North Power Stations to the grid,” Ryan said. “A team of highly-skilled experts will replace the substation’s ageing secondary systems equipment over the next two years. “This project will underpin the long-term safe, reliable and cost-effective performance of the transmission network in the South Burnett.” Secondary systems are the control, protection and communications equipment that operate the transmission network and prevent

damage to physical plant in the substation such as transformers. The new secondary system control panels are currently undergoing factory acceptance testing at Powerlink’s Virginia site on Brisbane’s northside. Crews are expected to start on-ground removal and installation works at the substation in April 2020 and continue until late 2021. Powerlink interim chief executive, Kevin Kehl, said replacing the secondary systems at Tarong Substation as necessary to maintain Powerlink’s capability to respond to any unexpected network issues. “This project upgrades the systems that are critical to monitoring and operating our assets,” Kehl said. PACE

NEWS

Australian sewer management technology taken up by Envirosuite

new partnership will see a modelling tool that detects sewer pipe corrosion developed by University of Queensland researchers embedded with environmental management technology company Envirosuite’s range of wastewater solutions. Sewex, an advanced mathematical modelling tool, was developed by researchers at the University of Queensland’s Advanced Water Management Centre (AWMC) following a request from the City of Gold Coast to investigate corrosion problems in its sewer pipes. The tool describes the physical, chemical and biological processes in sewers, and has reportedly saved the council $30 million in capital costs and

reduced the incidence of complaints about odour from the public. The new partnership will mean that SeweX will be available in Envirosuite products early this year. Envirosuite Chief Scientist Robin Ormerod said SeweX would help wastewater operators better manage the performance and environmental impact of their sewer systems. “Sewer corrosion is not something most people think about, but it is critically important to public health and wellbeing, and is a hugely expensive problem,” Ormerod said. “Innovations like SeweX are critically important as they help identify issues before they arise, extending the lives of sewer systems, more efficiently managing corrosion control systems, and reducing

the chances of offensive odours wafting around our streets. “Bringing tools like SeweX, which have sprung from some of the greatest academic minds in the water industry, together with our strength in technology and focus on digitising wastewater management, is hugely powerful.” AWMC director Professor Zhiguo Yuan said SeweX helps address problems that are most often caused by sulphatereducing bacteria in sewer biofilms that produce hydrogen sulphide. “Hydrogen sulphide is released into the atmosphere above the wastewater, causing odour problems, and is converted by sulphide-oxidising bacteria into sulphuric acid, which is corrosive to concrete sewer pipes,” he said. “Sewer networks can include

many kilometres of sewer pipes and various topographical elements, such as rising mains, gravity mains, pumping stations and manholes. It is practically difficult to physically inspect all these structures to identify corrosion issues, making modelling a more efficient and cost-effective alternative.” PACE Managing sewer corrosion is important to public health and wellbeing.

Battery graphite facility to be built in WA

cograf, a producer of high purity graphite, has signed a letter of intent with GR Engineering for a battery graphite facility to be built in Kwinana, Western Australia. The two parties are completing pre-development activities for the project, while Ecograf finalises arrangements with the state government’s land development agency over the proposed 6.7ha site for the manufacturing facility. GR Engineering will deliver engineering, procurement and construction services for the 20,000tpa site. The company expects commercial production to begin after 11 months, at an initial rate of 5,000tpa.

The company says it uses an eco-friendly process to sell directly to lithium-ion battery manufacturers. Ecograf expects global demand for battery graphite to increase by over 700 per cent as Europe continues to transition towards clean, renewable energy for vehicle and industrial applications. The company says it will expand its battery production base to include additional facilities in Europe and North America to support the global transition to renewable energy in the coming decade. Ecograf has completed two years of pilot test work completed in Germany to optimise its processes. The company says the

flake graphite supplies sourced from Africa, Asia, Europe and the Americas. PACE

study confirmed the successful application of its non-hydrofluoric acid purification process to natural Global demand for battery graphite is to increase by over 700 per cent.

FEBRUARY/ MARCH 2020 www.pacetoday.com.au 15

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AUTOMATION

Automation systems are rapidly modernising.

Getting the edge in industrial automation Over the last two years, APS Industrial has been the master distributor of Siemens industrial low-voltage electrical and automation products in Australia. PACE speaks with Justin Farrell from Siemens and Simon Kearney from APS Industrial to discuss the recent trends in industrial automation technology.

oming under the broad umbrella of “Industry 4.0”, recent trends in automation technology have the potential to be gamechangers in the industrial sector, pushing forward productivity and efficiency and making processes more flexible and adaptable in real-time. Many decades ago, automation systems were built as standalone packages for specific applications, designed to function with proprietary software, and they had little to no ability to communicate with other systems. However, over the last 20-30 years, these traditional barriers have been gradually breaking down. Industrial networks, for example, have allowed highly disparate systems to be connected together, although this can be in a limited fashion. According to Justin Farrell, general manager of factory automation at Siemens Australia, a major change

in the automation space is the increasing “openness” of more recent technologies and systems. “While over the last 20 years, communication barriers have been broken down and some data transfer between machines of different vendors has already been happening, it has until fairly recently been somewhat limited to simple commands, such as ‘stop/ go’ and emergency safety functions or has required significant effort to build bespoke overarching systems that can be difficult to maintain.” explained Farrell. “Quite recently, however, new communication platforms and techniques are coming out that are really open. It means that, for example, a German-built machine and an American-built machine could be brought together with an Australian built machine in Australia and communicate with each other

18 www.pacetoday.com.au FEBRUARY/ MARCH 2020

using an open, vendor-agnostic communications platform.” This is enabling detailed, highspeed communication. Effective communication in an industrial plant is, after all, now not just about being able to send information, but it is also about having close to real-time communication so that operational characteristics can be synchronised. Transparent and relatively easy to maintain these types of systems can evolve with an organisations requirements, they have the flexibility and scalability to ensure initial investment is not lost as things change. “These are the changes that are happening right now,” said Farrell. “We now have much more open standards and the ability for different machines to effectively communicate together in a way that allows the operational characteristics of each individual plant to be optimised.”

Cloud-based systems are now coming to the fore. Siemens’ MindSphere is among them. “Three years ago, MindSphere was at beginning stage, and over that threeyear journey we have seen it go from what it could do to what it can do – the real-world applications of what industrial cloud is able to achieve for industry,” said Farrell.

Edge computing

Putting data in the cloud or sending things to the cloud means companies can have easier decentralised sharing of data and global sharing of information. However, while there is much talk today around so-called “big data”, it is necessary for companies to be able to transmit data that is useful and valuable where and when it is needed. This is where “edge” computing comes in. Edge computing enables data storage and analysis closer to the

AUTOMATION

devices and even on machines where it being gathered, lessening the potential for communication and connectivity problems and reducing the need to process data in centralised cloud locations. Farrell explained edge computing by drawing on the analogy of smartphones. While smartphones are built with the primary purpose of being mobile phones, they also have the ability to access a sever and download apps that change the function of the device while retaining the original function at the same time. Over time, the phone’s connectivity makes it more useful as people develop new ideas about what it could be used for. Siemens is translating this idea into the industrial world with edge computing, releasing devices such as a human-machine interface (HMI), which in the past meant an operator console, a visualisation of data about the machine. Now the company is building edge functionality into HMIs so that what companies buy today can be upgraded to something different or new or more advanced in the future as new functions are developed. It will become a standard to build edge into all new automation products. “Also, edge devices are able to work and make decisions with machine control systems, but they don’t necessarily have to be connected to a cloud or the internet to have proper functionality,” said Farrell. “This is because they have a local computing functionality as well as an ability to take information that has been analysed up to a cloud or a local server that is on the premises.” The value that can be gained from Industrial cloud systems is often dependent on the speed of the cloud and where it is located. Farrell explained that edge devices allow the user to control what data is being sent in an effective way and, also, connect to any number of clouds. This also enables for updates to systems and machinery to be carried out remotely in a safe and secure way. “A machine builder based in Australia who sends a machine to India, for example, may not have service engineers based in the latter. With edge devices, you could have

Machine learning is based on a defined programmable system that uses operation data. that secure ability to connect and upgrade and update your machine functions from Australia without having to have anybody on the ground in India. And that is a real advantage,” Farrell explained. “Wholesale programming changes are usually difficult to do remotely without having a confident person onsite because if there is an error it could cause an unwanted result. With edge devices, you could have an app that you are working on that you can test locally, do all your testing in house with an app, and just add an enhancement to a machine via an app that is much more condensed and controlled than downloading, for example, a PLC program.”

Machine learning and AI

Two other major recent trends in automation technology are machine learning and artificial intelligence. Farrell said that while these terms are often conflated, they refer to distinct technologies that need to be distinguished. Machine learning is based on

a defined programmable system that utilises and learns from data produced in the course of operation. This data is fed back into the system, enabling it to adjust itself on the basis of a defined set of parameters. The benefit of machine learning is process optimisation. By contrast, artificial intelligence (AI) comes to the fore when the number of parameters or variables in a process is too vast to be programmable. “A simple example of that is a conveyer belt where a random part is placed in random location in a random orientation on a conveyer belt, and you want to pick it up with a robot,” said Farrell. Traditionally, robots are programmed to be able to carry out a procedure in a defined number of ways. If a task falls outside of the set parameters, the robot will be unable to successfully perform the action or task. “With AI, robots are able to look at the parts and pick it up no matter what the orientation is – it is not

limited by programmability, and that is a step beyond machine learning,” Farrell explained. An example of where this could be extremely effective is baggage handling at airports, where today baggage handling is done manually. “Because every bag is different – the orientation of each bag is different, some bags will be on top of each other, some are hard, some are soft – there are so many variables in the baggage coming off an aircraft that it requires a human worker to unload it. Further, large airports the large number of bags coming through every hour is a constraint on how much throughput the airport can have,” said Farrell. “AI-enabled robots would be able to handle those bags in all their different combinations, variations and permutations quickly and efficiently. This could be a real benefit for occupation health and safety, alleviating the manual handling risk of heavy and or awkward to lift bags whilst also allowing for increased baggage through put.”

FEBRUARY/ MARCH 2020 www.pacetoday.com.au 19

AUTOMATION

Adapting for the future

According to Farrell, the effective adoption of the Industry 4.0 technologies will require a change of mindset. This is a point echoed by Simon Kearney, APS Industrial director of sales. “It is a really big shift in mindset for the industry – and it can a bit of a nervous step if you are taking the first one,” Kearney said. Indeed, the partnership between APS Industrial and Siemens is focused on helping Australian companies adapt to the shifts in automation technology. “One of the points we try to get across is that you don’t have to be an expert to get on board with these developments. Siemens is leading the way with Industry 4.0 – they are walking the walk,” said Kearney. “You don’t have to be an expert to take advantage of all of this because Siemens will guide you through that journey. As a business, as long as you expressed a want or desire to get on this journey and make a start, you just need to engage with the experts that can help you get your business on the path.” Farrell said that the goal of addressing the particular needs of companies in Australia by drawing on local knowledge and expertise was one of the driving forces in the collaboration between Siemens and APS Industrial. “The only way that we can address the needs of the different industrial markets is to work with partners that have expertise in these areas. There is a whole lot of great expertise available in Australia to help companies achieve what they need to achieve,” Farrell said. “It is through partnerships, like the one we have with APS, through that network of expertise, that we can solve the problems and achieve the solutions for our customers. It is a real community.” Farrell said that newer automation technologies, while complex, can be made simple, accessible and usable for non-specialists. “Machine learning, for instance, is rapidly becoming quite simple. There is extremely complex programming behind the scenes, but this same programming allows for simplicity when it is configurable by an easy-

APS Industrial and Siemens signed a master distribution deal back in 2018.

to-use interface in the front end that can be used by people without highly specialised skills and knowledge,” he said. And the introduction of edge computing doesn’t have to be difficult either. In fact, Siemens is releasing products that have edge capability already built in. All of Siemens’ HMI panels, for example, will have edge capability as standard straight out of the factory. They can carry out all the normal functions of an HMI panel, but they are also future-ready. “That takes the risk away, as it lowers the risk of investment – you are already making that further investment in the future – and if you want to use it in the future, it is available,” said Farrell. According to Kearney, it is now easier than ever before for Australian

20 www.pacetoday.com.au FEBRUARY/ MARCH 2020

companies to get hold of cuttingedge industrial technology. “This is something that APS and Siemens are helping with. Our partnership is not yet two years old, but there is a real passion and energy in both companies,” Kearney said. “It is not only exciting for us, but it can only be a good thing for Australian industry as well, because the more that these technologies get adopted, the better our industry will perform.” Farrell agreed. “For Siemens, the reason why we have chosen to go with a master distribution setup is our commitment to the concept of partnering for success. We recognise that we need to partner with a business that can provide the touchpoints and reach into the market with our product portfolio. “People still want to do business

with people. Despite all the information that is available online, we need to connect physically and personally with our customer base. APS is enabling us to do that,” he said. “Digitalisation has been very challenging to many businesses, small and large. But it is happening around us and companies need to adapt and change to get on board. We are surrounded by countries and regions that are well advanced in digital technologies and digital solutions. It has been happening in Europe for quite some time, and it is now happening rapidly across Asia, especially China. Australia has a lot of great talent, a lot of great minds with extensive knowledge. But I firmly believe we need to embrace these technologies so that we can be truly competitive on the world stage.” PACE

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ENERGY MANAGEMENT

Making production sustainable and efficient Food and beverage production needs high volumes of energy and produces large amounts of waste. What are the best ways for companies to be environmentally sustainable while maintaining economic efficiency? PACE talks to Total Construction’s James Bolton and Rob Blythman.

ood and beverage processing is highly energy intensive. Producing the heat required for industrial production, for instance, consumes high volumes of gas. This comes at a price: energy usage accounts for at least 15 per cent of total operation costs for food and beverage manufacturers. Alongside energy consumption, water consumption and waste production are also high in food and beverage plants. Improving efficiency in all these areas is therefore critical for companies looking to improve their bottom line. With high power costs looking likely to remain a norm in Australia, reducing reliance on the grid and generating energy onsite is an increasingly attractive option.

Utilising renewable sources of energy can help food and beverage companies to both reduce emissions, and save on operating costs. There are a number of renewable energy technologies available that can replace traditional energy sources. However, companies need to know what approaches will suit the particular needs of their operation. According to James Bolton, national manager of Total Construction’s energy and infrastructure division, it is essential that companies weigh up the costs and benefits of the available options before rushing ahead with costly installations. “When it comes to building food and beverage manufacturing plants with renewable energy features, companies need to know what is the best fit for them, and it is not always obvious,” Bolton told PACE.

Recently, Total Construction carried out a detailed analysis for a client looking to construct food manufacturing plant that would be energy efficient and affordable. “They had a relatively high energy consumption, particularly electricity, and they also use a lot of water. We have had a pretty thorough look at how we could make this whole facility more sustainable without blowing out the cost,” said Bolton. When exploring the options for onsite power generation, Total Construction quickly established that solar panels would be greatly beneficial for the client. With ample roof space at the facility, it was determined that installing solar panels would cut back the facility’s demand on the grid during the day. “It was a no-brainer. Solar is a sustainable power source and it makes sense from an economic perspective. Its affordability is improving each and every day,” Bolton explained. Sizing the panels correctly was a key consideration. Bolton explained

that if excess power was produced, it would be exported back to the grid, thus reducing potential returns due to the low prices generally offered from the retailer. It was also found that installing battery storage would increase the proportion of renewable power used, something that would be favourable during peak usage periods. Co-generation, the generation of high-temperature heat and electricity from a single source, was another option explored. But in this particular case, Bolton explained, it wouldn’t have been especially beneficial for the client. Due to questionable reliability of co-generation supply, a back-up source would need to be invested in, making it less

Solar, a sustainable power source, is becoming increasingly affordable. 22 www.pacetoday.com.au FEBRUARY/ MARCH 2020

ENERGY MANAGEMENT

advantageous compared to the more reliable and similarly priced power from the grid. “We found that it was pretty hard to make it work for them, economically speaking, as it costs a very similar amount to what they would be paying for power from the grid, making it hard to get a good return on investment,” said Bolton. “One thing that has changed in the last five years, and what has made co-generation less attractive, is gas prices – the price of gas has gone through the roof.” Total Construction also explored the gas requirements of the plant. Solar-powered hot water was deemed a viable alternative with minimal cost impact. Alternative methods of gas supply, such as onsite biogas generation via anaerobic digestion and hydrogen generation by solar-powered electrolysis, were considered. However, while these methods have great environmental benefits, the costs were too high. “Because the food manufacturing plant would create a lot of food waste, there is the potential to produce gas from it using anaerobic digestion,” said Bolton. “But it is quite an expensive process to build a plant that is able to do that. Relatively speaking, this particular factory didn’t require much gas for water heating, so it didn’t make sense for them to spend $1.5 million on a special plant for little or no return.” Rob Blythman, manager of Total Construction’s Energy Construction Group, explained that particular technologies and methods, while not always suitable for some operations, can be beneficial and sensible in others. “Each client needs to be assessed individually – on their usage of gas, their usage of power, the amount of food waste that goes out, and the amount of water that they have to recycle. It is not a case of saying that other technologies are rubbish and solar is the only way to go: you have to weigh each option to determine which suits an individual client and their particular needs,” Blythman said. “You have to do this each time for every client – you can’t just assume co-generation is a waste of time, because it might not be for some businesses. The choice needs to be bespoke for their operation.”

Each manufacturer needs to determine what energy and sustainability measures work for their particular operation. Bolton gave an example of a facility where co-generation and trigeneration are good options. “These approaches work well, for instance, at data centres, where the electrical load is constant 24/7 – it actually doesn’t change – and there is a lot of cooling required for the servers. That is a situation where trigeneration can work really well.” When it came to determining how the food manufacturing facility could manage its water usage, it was found that using recycled water was not a viable option. In fact, the cost of potable water was so cheap that other options couldn’t compete. “We were actually quite shocked by the results. In terms of sustainability, we thought that collecting rainwater from the roof would be a good idea. The client’s facility has quite a large roof area. But the cost of a rainwater tank, coupled with the cheap price of potable water, makes it economically inefficient in comparison,” said Bolton. Furthermore, there are few options for using recycled water in a food manufacturing plant. As per health and safety regulations, all water that comes into contact with food or items in the vicinity of food must be of high quality to avoid contamination. “When you are a food manufacturing facility, and you are

using water in your manufacturing process, you can’t use any of that rainwater unless you treat it. But the process and cost of treating it for re-use way outstrips the cost-per-megalitre that you’re paying, and it doesn’t make sense, as a business, to spend that,” said Blythman. Onsite herb and vegetable growth were considered as a potential use for the water harvested from rainwater tanks. Blythman said that can work for some clients, where they can grow their own herbs and vegetables onsite for their food production to eliminate the extra costs of having those products trucked in. “Most councils will force manufacturers to install retention tanks for rainwater. And for that water not to be used is a waste. In these cases, it makes sense to find uses for the rainwater so that it is a benefit for the manufacturer, rather than a hindrance.” When it came to the facility’s wastewater discharge, it was determined that a dissolved air flotation (DAF) plant would be the best option. A DAF dissolves air in water under high pressure then releases it at atmospheric pressure, causing solids to float to the surface with the bubbles, where they are removed. An emerging technology for the

processing of solid waste, in which micro-organisms digest the food waste into a liquid product that can be discharged into the sewer, was found to suit the needs of the plant, as it dramatically reduces waste disposal costs. “The cost of getting rid of solid food waste is usually quite expensive. This method allows you to be environmentally sensitive while also saving in operations costs,” said Blythman. Blythman said that this kind of analysis carried out by Total Construction enables businesses to make a strong business case for efficient renewable energy options at their facilities. “Doing this kind of analysis on your facility allows you to have a detailed understanding of what you need in terms of your energy generation, your water usage, and your waste management. What works for some companies won’t work for others, and you need to do the analysis to establish what suits your needs,” said Blythman. “You shouldn’t say, ‘I want to use renewable energy and I want to be environmentally friendly’, and then choose options that are totally wrong for your operation. You need to determine what works for you.” PACE

FEBRUARY/ MARCH 2020 www.pacetoday.com.au 23

SENSORS

Detecting, interpreting, communicating: smart sensors for intelligent packaging machines Marco Kaiser, strategic industry manager for consumer goods, packaging in the factory automation global industry center at SICK AG, Waldkirch, Germany talks about what sensor support can do for packaging.

Article author: Marco Kaiser, Strategic Industry Manager for Consumer Goods, Factory Automation Global Industry Center, SICK AG, Waldkirch, Germany.

mart packaging – the use of active and intelligent packaging is growth and future trend offering huge potential. The networking of the physical and digital worlds using smart packaging also has a direct impact on the machines that produce packaging and package products. This is reflected, for example, in the increasing use of intelligent sensors that can communicate in packaging machines. The portfolio of Smart Sensor Solutions from SICK is actively paving the way for increased flexibility, transparency, efficiency, quality, and availability. To achieve all of this, a wide range of real-time information is required directly from the machine. Intelligent sensors which collect data, interpret it, generate information from it, and then communicate this, are in a position to enhance this valuable data and to use it to create effective packaging machines and high-performance

packaging processes. With its Smart sensor portfolio, however, SICK goes even further and uses the intelligence of the sensors for additional Smart Task functionalities which can be used to carry out different checking and automation functions directly in the sensor. Examples include the adjustment of switching thresholds when detecting contrast marks or transparent films and containers, the automated activation of object, format, or configuration-related detection profiles, or the automated differentiation of objects, object edges, and gaps in a material flow. Logic functions integrated into the sensors for processing signals form the basis of this, building on proven sensor technologies with best-in-class detection capabilities. These make it possible to carry out defined tasks autonomously and remotely, meaning that automation systems and networks of packaging machines can be relieved effectively in the case of edge computing.

What sets smart sensors apart?

Sensors are generally the sensory organs of machines – in the context of digitised manufacturing, they are also the initial contact with and link to Industry 4.0. Whereas the aim in the past was to simply collect data and make simple decisions, today’s sensor intelligence also enables data to be prepared, further processed, and interpreted. Sensors therefore no longer just “sense”. Within the scope of digitisation, they are also starting to “think”. As a result, sensors convert data into valuable information. The intelligence of these smart sensors is supplemented on the one hand by the option to communicate this

24 www.pacetoday.com.au FEBRUARY/ MARCH 2020

information. In other words, they can exchange information with the control of a packaging machine or a cloudbased application. On the other hand, these sensors are capable of completing defined tasks autonomously – in the form of the Smart Task functionalities that have already been mentioned.

Sensor intelligence supports the commissioning and condition monitoring of packaging machines

The advantages offered by the intelligence of smart sensors and their communication capabilities are a recurring theme throughout the entire life cycle of packaging machines. Various parameter settings can be visualised, tested, and optimised from the integration and initial commissioning of the sensors in the machine – on the device as well as via the control. What’s more, various sensor parameter sets can be stored here on an order-specific or format-specific basis and loaded to the smart sensor during operation. This option enables flexible settings to be made for any number of sensors simultaneously by downloading parameters directly from the control, such as the sensing distance, hysteresis, or switching threshold. This saves time, eliminates errors, and means that the settings can be documented at any time. At the same time, this makes the packaging machine so intelligent that products, product variants, or packaging formats can be changed autonomously, quickly, and reliably. The smart sensors perform permanent condition monitoring autonomously while the packaging machines are operating. Alongside this,

they also keep an eye on the packaging process and provide information in real time on whether there is a functional impairment or whether one is to be expected, as well as on whether maintenance may be required (predictive maintenance). This enables the service intervals of the packaging machine to be optimised in line with the cycle – and therefore intelligently – for example by using scheduled machine downtime as an opportunity to carry out sensor cleaning or maintenance.

Smart sensors provide added value that packs a punch

Intelligent sensors which are able to communicate offer key properties and therefore advantages for packaging machines right from the outset. They also become smart – and that is the unique selling point of Smart Sensor Solutions from SICK – as a result of the logic functions integrated directly into the sensors for processing signals. Depending on the requirement and task, the advantages of smart sensors for packaging technology can cover up to four areas: enhanced sensing, efficient communication, diagnostics, and smart tasks. The enhanced sensing feature of the Smart Sensor Solutions provides extra detection performance if required. The contrast sensors from SICK’s KTS, KTX, and KTM product families offer dynamic adjustment of the switching threshold. This enables even faded print marks and optical markings to be detected quickly and reliably. As a result, processes such as the correct positioning of packaging material, the perforation or folding of the packaging at the right point, or the control of table

SENSORS

top inserters are becoming much more powerful and reliable – improving the productivity of the packaging machine. When producing bottles, different product variants are often conveyed in the same system. These must be reliably detected and counted in the flow of bottles to enable them to be transferred smoothly to a packaging machine, for example. The challenge for the sensor comes from the huge differences that are found in the shape and surface of the bottles – i.e., their optical appearance. Photoelectric sensors such as the WL12-G, the W4-3 Inox, or the WLG16 with ClearSens technology are Smart Sensors which are able to master tasks of this nature, as they offer the option of storing bottle-specific sensor settings as pre-defined detection profiles and retrieving them automatically to match the bottle variant. This means that the sensors always work with the optimum parameterisation, ensuring maximum detection reliability. Shiny and reflective packaging also requires particular detection capabilities as it reflects the sensor’s light back in different directions – which can lead to switching errors when using conventional sensors. In contrast, photoelectric sensors such as the W16 with their TwinEye-Technology achieve the highest levels of operational safety as detection is carried out using two logically linked receivers in the sensor. The sensor only switches to the output state when both “eyes” come to the same evaluation. Efficient communication is the second feature of smart sensors and comes into play with the digital transmission of analog values. It is based on the bidirectional IO-Link communication standard and is carried out via standard M12 cables in parallel to the usual IO communication in the packaging machine. Smart Sensors such as the WTT12L Powerprox enable individual sensor parameter sets for different packaging formats or configurations to be loaded into the control via IO-Link during commissioning and then stored there. During operation, they are then loaded via IO-Link into the sensor to match the relevant secondary packaging. As a result, the connectivity of Smart Sensors opens up intelligent and – again and again – new possibilities for enhancing the productivity of packaging machines. At the same time, the sensors deliver

Photoelectric sensors with ClearSens technology can even overcome the challenge of dealing with huge differences found in the shape and surface of bottles. important process information via the communication interface which can be used for statistical purposes, documentation, cloud applications, or visualisation on stationary and mobile devices – which is where the area of Diagnostics comes in. The diagnostics functionality of the smart sensors – which would be virtually unthinkable without its communication capability – is used first of all for the purposes of selfmonitoring. On top of this, the sensors check the quality and reliability of their signals independently. In digitised packaging processes, diagnostics functions also provide the possibility to significantly improve the availability of packaging machines through condition monitoring. A welcome “side effect” for the machine manufacturer is the fact that the sensors provide the edge data and additional function at no additional cost and enable it to be used in the machine itself as well as in the cloud – for example for big-data-based predictive maintenance applications. The smart WLG4SC-3 photoelectric sensor is also capable of monitoring itself autonomously. To do this, it evaluates its signal strength and any changes that may have occurred due to deposits forming, and uses its AutoAdapt function to adjust the switching threshold

dynamically in response to the gradual contamination of the optical surfaces of the sensor. From the perspective of the packager, this too is an intelligent machine function which significantly extends the cleaning cycles, increases availability, and reduces service costs. In addition, cleaning and maintenance work can be scheduled in such a way that it does not have any negative impact on the productivity of the packaging machine. The decentralised computing power of Smart Sensors, combined with their flexible programmability, lays the foundation for a multitude of Smart Tasks, which make the packaging machines even more flexible, dynamic, and efficient. When using the “Object and Gap Monitor” smart task, objects and gaps can be detected and measured within the sensor. The Smart Sensor only sends corresponding signals to the control if there are deviations from set target values – otherwise, there will be “radio silence” that protects the network between the sensor and the automation system. At the same time, the connectivity of the intelligent sensor offers the option to directly control an actuator using its signal delay and buffering functions and thereby to manage the removal process autonomously – without having to go via the control and the network.

These and further functions can be carried out independently by SmartTask-enabled, intelligent sensors. They are also able to network with other sensors or actuators directly to resolve partial applications relating to edge computing autonomously, quickly, efficiently, and cost-effectively without extensive PLC communication.

Smart sensors – more efficiency thanks to autonomous action

Intelligence and communication capabilities – on the one hand, the potential of smart sensors is oriented toward gradual increases in efficiency for the tasks at hand, such as downloading parameters for fast changeover, easy device replacement, formula management, and condition monitoring. Smart tasks raise the value of these sensors to a whole new level – with their remote intelligence, they are able to generate new, higher-quality detection information, network, and carry out defined Smart Tasks autonomously. All of this makes SICK’s Smart Sensor Solutions a highly forward-facing technology for the packaging industry – enabling users to overcome the challenge posed by digitised packaging processes in a technically and economically efficient manner. PACE

FEBRUARY/ MARCH 2020 www.pacetoday.com.au 25

ROBOTICS

Automating agriculture A recent presentation by Professor Hiroshi Shimizu at AgriControl 2019 in December explored the expanding potentials of robotics and advanced automation within plant factories and protected horticulture. PACE reports.

With increasing demand for food due to expanding populations, there is a need for the improvement in agricultural productivity.

ith the continued expansion of the global population, the demand for readily available food is increasingly at a rapid rate. However, as arable land is depleted and as populations continue to move away from rural areas to urban centres, agriculture is undergoing a period of change. How can robotics and automation technology ensure stable food production into the future? The 2019 AgriControl conference, held in Sydney in December, featured the cutting edge of

research on agricultural automation technology. One of the highlights of the event on the second day was a presentation by Professor Hiroshi Shimizu from the Graduate School of Agriculture at Kyoto University, Japan, on recent global trends in automation and robotisation in protected horticulture and plant factories. With increasing demand for food due to expanding populations, agricultural productivity needs to be improved. However, according to Professor Shimizu, fewer people are entering the agricultural sector, with

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workforce ageing and skill shortages on the increase in many countries. One area that shows signs of fruitful technological developments in protected horticulture. With a relatively more controllable and stable environment than outdoor cultivation, protected horticulture is ripe for intensive automation. Research on the potentials of automation and robotisation in this area has been actively researched for some time. Recent advances in artificial intelligence (AI) technology are beginning to make this a practical reality.

Growing potential

Shimizu began by giving an overview of the status of plant factories with artificial light (PFALs) around the world. In Japan, plant factories have been in operation since the 1980s. From the second half of the 1990s, fluorescent lamps were used to grow vegetables, allowing for multistage cultivation. Today, LEDs are used. There are approximately 200 PFAL facilities in operation in Japan, not including those in universities and research institutes. The capability of these factories has been expanding. “While the number of facilities

ROBOTICS

has not expanded greatly in the last few years, smaller plant factories have been replaced by larger factories newly in operation,” Shimizu said. “The size of production carried out by plant factories today is 10 times that carried out 10 years ago.” Taiwan, where currently only 60 plant factories are in operation, is considered a key area for future growth, as manufacturers of plant factories – including those developing parts such as lost-cost, high performance LED lighting – looking to expand the market. In Korea, too, plant factory operations are expected to grow, due partly to the support of the Korean government. “The Korean government announced a plan to invest in large scale farms to expand the area of smart agriculture using ICT from 4,000 hectares to 7,500 hectares,” Shimizu said. “It seems that this has stimulated the Korean domestic market in response to the rapid increase in the plant factory ventures accelerating with the global market.” China is currently investing

heavily in the development of plant factories and battery automated farming systems to feed its growing population, which is expected to reach 1.5 billion by 2030. “The demand for food is increasing and particularly from the affluent middle class. Furthermore, the urban population is demanding pesticide free, clean, fresh food,” explained Shimizu. And China’s agricultural workforce is rapidly ageing, with 60 per cent of farmers over 50 years old. “For these reasons, battery automated indoor farming systems and plant factory systems are essential.” Outside of Asia, the United States as seen an increase in plant factories since 2010, particularly in mid-size and large-scale operations. Shimizu said that part of the impetus was the need to close the distance between production locations and markets. “The sales destinations of the harvest are natural organic supermarkets, restaurants, and farmer’s markets,” Shimizu said. “Buying local is of growing importance as many people begin to consider the impact of their

carbon footprint on the environment. According to the US Department of Agriculture, the local food market share of the whole market is small but growing.” In Europe too, where there is demand for increased production through winter months, plant factory operations have increased. “The use of plant factories is increasingly all over the world, and the scale of plant factories is expanding – this means there is an increasing number of facilities with tens of thousands of vegetables in production per day,” said Shimizu.

New developments

As the scale of these plant factories becomes larger, the number and height of cultivation shelves where plants are grown is increasing. Plant factory workers are therefore increasingly working at high levels above the ground using lifts, which opens up potential safety hazards. The introduction of automation and robotics into plant factories can not only lower the risk of worker injury, it can also significantly boost

productivity and efficiency. Shimizu gave the example of a plant factory in Kyoto, Japan, where the number of cultivation layers is 14, and where production numbers 30,000 lettuces per day. “In this plant factory, automatic harvesting robots have been introduced to protect workers from dangerous work in high places,” he said. The harvesting robot can harvest two cultivation trays at the same time, before transporting them to the collection station, where they are then transported to the next room by a conveyer. The robot operates from 8:30am in the morning to 7:30pm in the evening. Shimizu said that with the introduction of this robot, the number of workers has been reduced from 60 to 30 – a 50 per cent reduction in the labour required for operation. Shimizu then detailed some of the trends in tomato harvesting robots. One robot, developed in the US, is a self-driving robot that uses sensors and cameras. It also features

The use of plant factories is increasing all over the world to meet expanding demand. FEBRUARY/ MARCH 2020 www.pacetoday.com.au 27

ROBOTICS

lights to navigate large commercial greenhouses both day and night. The robot is able to detect which tomatoes are ripe for harvest. Shimizu said that the company is able to write new AI software and add additional sensors and grippers so that the robot can handle different crops too. “This robot has been tested at commercial greenhouses in the US and Canada. The company is expected to develop software that enables it to pick other high-valued crops.” An Israeli company has developed a tomato ripeness detector featuring a 3D vision system which is able to detect ripe fruits and measure their location in space. Deep learning technology, utilising the data of thousands of images, is able to locate the fruit and measure variable ripeness. The collected data is also analysed to provide mapping of forecasts for projected ripening of the crop, enabling optimum planning of the robot’s picking schedules. Another robot system is designed to locate the tomato stem and to cut and catch the fruit in a single operation. It is able to clear away obstacles and harvest fruit without causing damage. “The system is designed for simple operation and smooth integration into the existing greenhouse infrastructure

and practice,” said Shimizu. “When harvesting in the greenhouse, this system is generating the data about the crop. The system can inform the grower on the forecast and therefore help create work plans. Automated reports improve the control a grower has on their crops and gives valuable information on the yearly distribution. Altogether, this system can save up to 50 per cent in labour costs.” A Wageningen University & Research team has developed a sweet pepper harvesting robot. This robot is assembled on an autonomous mobile platform with robot arms effective for harvesting. During operation, the robot moves around the greenhouse and stops every one metre. First, this robot uses a laser sensor to determine three-dimensional coordinates of the sweet pepper. Next, it moves up to sweet peppers from various angles and then judges fruit maturity based on colour. It carefully checks whether the sweet pepper is ripe, then moves its head so that the small saw on its forehead is on the stem and the small tray on its chin is under the fruit. It then cuts the fruit off the stem and drops it on the tray and then carries it into the collection basket. “This process takes 24 seconds to complete. The human worker

In Japan, there are robots specially designed for strawberry harvesting. 28 www.pacetoday.com.au FEBRUARY/ MARCH 2020

Cobots are being used in commercial greenhouses in the US and Canada. can do the same thing in three to four seconds,” said Shimizu. “It may then be said that the robot harvester is slow – but humans cannot work 24 hours a day.” Shimizu gave further examples of cutting-edge robots in development for fruit harvesting. Strawberries, a major greenhouse crop, have particular requirements due to their soft skins. A robot developed by the National Agricultural Institute in Japan is specialised for strawberry harvesting. Mounted on a mobile platform, the robot can autonomously move around the greenhouse, smoothly harvesting strawberries. The robot discriminates the colour grade of the fruit via image processing, and then the robot is able to grip the fruit, cut and pick it without causing damage. The processing time per fruit is nine seconds. “The development team is not aiming for 100 per cent harvest to be carried out by the robot. The idea is that 60-70 per cent of the strawberries will be harvested by the robot at night and the rest harvested by the human workers during the day,” Shimizu explained. A company in Belgium has developed an autonomous robot aimed at improving production efficiency in strawberry harvesting. This robot moves with autonomous vehicle technology and detects the strawberries using 3D vision sensors, determining the ripeness and optimum harvest time via various sensors. The robot arm automatically

picks the strawberries with a gripper that gently grabs the fruit, removes it from the stem and places it in the collection container. The machine takes only three seconds to harvest a strawberry, maintaining the quality, speed and accuracy of human workers. Another robot for strawberry harvesting has been developed in Spain. Featuring 24 manipulators, the robot can harvest multiple strawberries simultaneously. The robot uses a 3D sensing scanner with short range integrated camera, and an infra-red depth sensor to capture details and identify fruit ready for picking. The robotic arms grip the strawberries from the stem, meaning the robot doesn’t contact the fruit itself, and places them into a container. With these and other harvesting robots either in development or in operation within plant factories, it is apparent that automation presents the potential to unleash greater productivity and efficiency while combatting a trend of growing skill shortages. While research on automation and robot technologies in plant farming and protected horticulture has been carried out since the 1980s, the capabilities of the computer technology meant that practical commercial realisation was difficult. Shimizu’s presentation indicates that now, following dramatic improvements in computer processing power, and the recent leap forward in AI technology, has brought advanced automation in commercial settings closer than ever before. PACE

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INDUSTRIAL CABLES

Energy chains versus motor cable drums Exploring the advantages and disadvantages of two industrial energy supply systems with Treotham Automation.

henever design engineers have to guide hoses and power and data cables in moving applications with long travels (more than 100 metres), the question arises of which energy supply system is the most efficient, especially considering such factors as reliability, maintainability, and future security. A motor cable drum? Or an energy chain? The advantages and disadvantages of the two systems are explored below.

Candidate 1: The motor cable drum

prepared surface on the ground and is rolled back up on a drum mounted on one of the supports. There are several variants for retracting the cable. In addition to motorised drums, there are designs for shorter travels that work with spring force: the rolling action is normally either cylindrical or spiral rolling. In the cylindrical form, also called broad rolling, the cable first rolls up from left to right along the drum body. Then it rolls up vertically, layer by layer. Spiral rolling works differently. The cable is stacked immediately after the first rotation. The market for cable drums is

The motor cable drum is a proven energy supply that has been in use for decades – in applications such as cranes, transfer carriages, and the bulk material industry. The principle is simple. It is, in its simplest form, like a garden hose reel. When a gantry crane, for example, moves back and forth on its four supports, the cable is deposited on a

The energy chain first made its way into the market in 1953.

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growing. A key region is North America, and one reason for this is that the demand for cranes in the northern US is rising. Another booming region is the Asia-Pacific, especially China and Japan. Among the reasons for this is urbanisation and a flourishing construction industry. According to Persistence Market Research, a market research institute, the global market volume will be more than $3.4 billion in 2026.

Candidate 2: The energy chain

An alternative for guiding cables on cranes, handling portals, or stackers/

Motor cable drums have been in use for a long time. reclaimers is the so-called energy chain. This option is a mobile protective cage. It consists of parallel side links that are connected with crossbars along the top and bottom of the carrier. When the system moves, the chain folds, and the upper run glides on the lower run. No motor is required; the chain is attached to the crane’s boom, for example, and moves with the movement of the crane. Like the cable reel, the energy chain has been well-tried. Inventor Gilbert Waninger launched the chain in 1953. At the time, it was entirely made of steel, but today’s manufacturers are more flexible. Since 1969, companies have developed high-performance plastics that can be used under a wide variety of environmental conditions – constant contact with salt water and heat in metal works, for example.

Energy chain versus motor cable drum – Round 1: Installation space and weight

Energy chains generally have weight advantages for long travels. If the chain folds, the upper and lower run reach a height of around 800mm, depending on filling and chain series. This makes them compact. Motorised cable drums operate differently. They do not require guide troughs, saving space on the user’s travel path. But in many applications, their drums have diameters of 6,000mm or more. If this space is not available, the cable drum cannot be used as a solution. Another disadvantage of drums is that they are relatively heavy. This makes systems heavier and lowers their energy efficiency. The crane’s structure must also be designed for this additional load. Sample calculation: for a travel of 400 metres in length and a cable weight of 10kg/m, the additional

INDUSTRIAL CABLES

weight of the rolled-up cable is about 4t. Then there is the weight of the drum, the steel structure, and the drive technology. Energy chains made of high-performance polymers, on the other hand, are much lighter and contribute to energy savings. No additional load must be calculated on the crane.

Round 2: Assembly

Motor cable drums may have an advantage in this round, since their functionality is very simple. It is just as easy and fast to assemble the drums. Energy chains are also relatively quick to assemble, especially when users order the system with cables and plug-in connectors so that it is ready to connect. However, only qualified technicians should carry out the assembly. For long travels, a guide trough is obligatory for gliding applications (when the upper run lies on the lower run), and an energy chain riser guard or an enclosure that protects the system from weather may be recommended as necessary. This allows safe operation under any weather conditions.

Round 3: Cable protection

the slip ring body are the elements that are especially affected by corrosion and wear. At worst, this can cause long, expensive system downtime. Then there is occasional maintenance work for guide elements, clamp connections, and motor and switch deflectors. This means that operating motor cable drums involves time and expenditure. Energy chains operate differently. High-performance polymer variants are resistant to chemicals, saltwater, and UV radiation. The result is that, in some applications, energy chains can be operated for almost ten years with hardly any maintenance.

Round 5: Combinability and extendibility Transmitting energy and data via motor cable drums requires either different drums or expensive special cables. If additional fibre optic cables or hoses for supplying air, water, or oil must be moved, additional drums and components are indispensable. Energy chains, on the other hand, accommodate the use of a wide variety of cables and hoses in a single system from the very beginning. In order to react flexibly to technological trends,

they allow easy addition of other cables if reserve space is set aside from the beginning of operation. This is not true of motor cable drums: it is very difficult to add hoses or cables later on. To do so, the operator needs either a special design or additional drums.

Round 6: Compatibility with Industry 4.0 In the Industry 4.0 era, more and more users are integrating machines and systems into the Internet of Things in order to digitise processes. This enables systems to autonomously call attention to a problem. Energy chains come out ahead here. Manufacturers have begun equipping energy chains with break detection systems and push/pull force systems. Anomalies in set parameters, such as those caused by breakage in a chain link or blockage in the energy chain run, can activate emergency stop systems or trigger maintenance missions in good time. Before there is expensive system failure.

Round 7: Operation and speed

Today, industry everywhere requires faster turnaround times, which

necessitates faster and faster travel speeds for moving equipment. A system with motor cable drums can achieve average travel speeds of up to 120 m/min (up to 300m/min with limitations). An energy chain system with integrated rollers in the chain link can reach travel speeds of 600m/min. And that speed is constant across the entire distance. Systems with motor cable drums must brake when they reach or pass infeed points so that the cable can be properly rolled up or deflected.

Conclusion

Energy chain or motor cable drum: which energy supply system comes out ahead? There is no blanket answer because, in the industrial world, no two applications have exactly the same conditions. Different elements are weighted differently. Some points favour the motor cable drum – among these are its simple assembly. Others, such as cable protection, largely maintenancefree operation, and theextendibility, favour the energy chain. Treotham offers a large range of lubrication free igus energy chains for a variety of applications and industries. PACE

The task of motor cable drums and energy chains is to protect moving cables and hoses from mechanical loads. The chain comes out ahead here, since it guides cables and hoses safely through the interior separation and relieves strain at the fixed and moving ends. They are subjected to neither tensile forces nor high mechanical loads during movement. Moreover, some high-performance polymers have vibration-damping properties. The cables and hoses are protected from wear along their entire length. Motorised cable drums operate differently. There is a constant tensile force during rolling and unrolling so that the cable experiences a greater load, reducing its service life.

Round 4: Wear and maintenance

Motor cable drum manufacturers now have corrosion largely under control. But in extreme environments, such as offshore facilities, rust can force operators to intensively maintain or replace their motorised drums over the course of the years. Bearings and

Energy chains accomodate the use of a wide variety of cables and hoses in a single system from the beginning. FEBRUARY/ MARCH 2020 www.pacetoday.com.au 31

DIGITAL CONNECTIVITY

Getting the best I/O performance for high-performance machines Guido Beckmann and Thomas Rettig from Beckhoff Automation explain how the latest Ethernet technology can improve communication speed and efficiency. The current EtherCAT G product portfolio includes the EK1400 Coupler, the CU1403 and CU1418 branch controllers with 3 or 8 ports, the CU1423 EtherCAT G junction and, for evaluation by developers, the FB1400 EtherCAT G and FB1450 EtherCAT G10 piggyback controller board.

therCAT reaches the next performance level with the EtherCAT G technology extension through its capability to superimpose itself on Gigabit Ethernet for particularly data-intensive applications. Compatibility with the globally established standard EtherCAT, which uses 100 Mbit/s, and the same familiar ease of use are both guaranteed. In addition, the efficient operation of parallel network segments is possible with the branch concept introduced for EtherCAT G. EtherCAT G uses the 1 Gbit/s data transmission rate of standard Ethernet, while the EtherCAT G10 variant, recently presented as a proofof-concept technology study, even achieves data rates of up to 10 Gbit/s. The considerable increase in data rates compared with standard 100 Mbit/s EtherCAT significantly increases the possible data throughput. In conjunction with the newly introduced branch concept, EtherCAT G (1 Gbit/s) enables a 2 to 7-fold increase in performance in relation to communication times and up to 10 times the bandwidth, depending on the application. One hundred

times the bandwidth is even possible with EtherCAT G10.

EtherCAT G as a fully compatible technology extension

With EtherCAT G, the proven success principle of EtherCAT can be used to leverage the high Ethernet data transmission rates that are technologically available today – without any changes to the EtherCAT protocol itself. The telegram sent by the EtherCAT master thus continues to pass through all network devices. Every EtherCAT slave reads the output data addressed to it on the fly and places its input data in the forwarded frame, but now with data rates of 1 to 10 Gbit/s. As before, the last device in a segment (or branch) will detect an unused port and send the telegram back to the master. The full-duplex property of the Ethernet physics is utilised for this capability. All other EtherCAT properties are also fully retained. Devices with three or four ports (junctions) make extremely flexible topologies possible that can be individually adapted to the respective machine architecture. Optional

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machine modules can be plugged in or out by Hot Connect as required. A comprehensive internal network diagnostic function helps to minimise machine or plant downtimes and thus to increase availability with familiar efficiency. The integrated distributed clocks concept also remains available and enables synchronisation accuracies of better than 100 ns between devices. Conformity with the Ethernet standard IEEE 802.3 is also guaranteed.

Rollout of EtherCAT G made easy

Exceptional performance and ease of use have always been the hallmarks of EtherCAT communication. The same applies to EtherCAT G. Not only the protocol, but also the fundamental mechanisms and the configuration options remain the same. Only the function blocks necessary for physical access to the communication cables have been replaced by corresponding Gbit/s variants. The master therefore requires no new software, just one Gbit/s port – which usually exists in any case. The existing familiar cable types can also continue to be used: Cat.5e cables

for EtherCAT G or Cat.6 cables for EtherCAT G10. Consequently, EtherCAT G slaves can be operated on an existing EtherCAT master, provided it has the aforementioned Gbit/s port. Several special protocol extensions for EtherCAT G are currently being prepared that will allow for even higher-performance use. However, the extensions required for this on the master side will not be mandatory for the network to be operational.

Branch concept for mixed operation with maximum efficiency

EtherCAT and EtherCAT G can be operated within the same network, i.e. EtherCAT G slaves will work in a 100 Mbit/s EtherCAT network and vice versa. However, all EtherCAT G devices will switch back to the 100 Mbit/s mode in such a mixed network. In order to prevent this, the new branch concept makes EtherCAT branches possible, which enable the parallel operation of 100 Mbit/s segments in a 1 or 10 Gbit/s network through appropriate speed implementations. In this way, a branch

DIGITAL CONNECTIVITY

of an EtherCAT G segment can be implemented on a 100 Mbit/s network, for example, using the new EK1400 EtherCAT G Coupler, thus allowing the extremely wide range of standard EtherCAT Terminals to be used within the EtherCAT G network environment. The 1 Gbit/s speed of EtherCAT G communication segment is retained. Moreover, the EtherCAT G branch concept offers another crucial efficiency benefit: minimised propagation times. The CU14xx multi-port branch controllers are designed for this purpose and enable the interconnection of several EtherCAT and EtherCAT G segments. The individual branches are addressed with a single telegram from the master, which will then be processed simultaneously. This makes much shorter signal propagation times possible and therefore shorter communication and cycle times, because the telegram of a segment travels directly from the branch controller back to the master and not through all other connected segments as well. In most applications, the parallel operation of network segments results in a significantly higher performance increase than a mere increase in the transmission bandwidth would render possible.

Disclosure and availability

In the coming months, the FB1400 EtherCAT G piggyback controller board will be available for the EL9820 EtherCAT evaluation kit. The FB1400 will have an FPGA with a fixed configuration as an EtherCAT G slave controller (ESC). If necessary, customers can then also create and use their own ESC configurations with the planned IP core for EtherCAT G. This will give EtherCAT users as well as master and slave manufacturers ample opportunity to evaluate the new technology. Availability of the EK1400 EtherCAT G Bus Coupler is scheduled for the second half of 2019. It will offer branch controller functionality and enables direct connection of all Beckhoff EtherCAT Terminals as well as all other EtherCAT products in EtherCAT G networks. Further products will follow, such as 3-port and 8-port branch controllers (CU1403, CU1418), an EtherCAT G junction (CU1423), an EtherCAT G10 branch controller (CU1468) and an EtherCAT G10 piggyback controller board (FB1450). A disclosure and introduction of

communication through all devices, taking into account hardware progagation delay times and telegram lengths, a communication time of 237 µs will result. If the standard EtherCAT devices are now replaced by EtherCAT G devices, the communication time can be reduced to 150 µs just on account of the shortened frame length due to the higher data rate. If in addition the branch concept is used and the complete network is divided into eight EtherCAT G segments with 16 servo drives each, a communication time of only 34 µs can be achieved – i.e. communication is now 7 times faster.

Using the bandwidth advantage: scanning 200 analog inputs with 100 ksamples/s

With the branch concept, the mixed operation of EtherCAT, EtherCAT G and EtherCAT G10 segments is possible in one network, resulting in the bestpossible overall communication efficiency for the complete system. the EtherCAT G/G10 protocol by the EtherCAT Technology Group (ETG) is planned for this autumn. As with EtherCAT more than 15 years ago, all ETG member companies will be able to use the extension and benefit from it.

Areas of application and performance examples

For most present-day applications the high performance of standard EtherCAT is fully adequate. Accordingly, EtherCAT G communication was developed with extremely large-scale applications and many devices in mind as well as the increasing use of particularly data-intensive devices such as vision cameras, complex motion systems or measurement applications with high sampling rates. Machine vision, condition monitoring or the innovative transport systems XTS and XPlanar require transmission of several hundred bytes of process data per cycle for each device. In conjunction with short cycle times of less than a millisecond, the high transmission bandwidths provided by EtherCAT G are called for in this context. The first practical EtherCAT G

application is the XPlanar transport system, which was shown for the first time at the SPS IPC Drives 2018. This planar motor system enables motion control and highly precise positioning of passive free-floating movers with six degrees of freedom. Due to the continuous position feedback required for the unique new system, extremely large data quantities are produced that have to be transmitted within a few microseconds. This would hardly be possible without the high performance of EtherCAT G. The following two sample calculations illustrate the boost in performance or the savings in data transmission time that can be achieved with EtherCAT G and the branch concept.

Accelerating communication times: 128 servo axes in 34 µs

A machine network with 128 servo axes was selected as the initial application. A “standard data width” of 8 bytes in and out per device results in this case in a total of 1024 bytes in and out per cycle. With classic EtherCAT

The following is an existing measurement application – Condition Monitoring – where a 10 km-long conveyor belt is monitored. The application consists of 200 analog channels (±10 V) with 100,000 samples/s (10 µs measurement interval) per channel, which have to be scanned with a cycle time of 1 ms. The present-day solution consists of four independent 100 Mbit/s EtherCAT networks, each with 26 two-channel analog input terminals with oversampling function (EL3702). Eight telegrams with 1313 bytes each are required in every EtherCAT network, resulting in a required bandwidth of 322 Mbit/s. Thus, each of the four networks utilises 88 per cent of the available bandwidth. If the four EtherCAT networks are now replaced by an EtherCAT G network and the EK1100 Bus Couplers by EK1400 EtherCAT G Bus Couplers (branch controllers), it is possible to continue to use existing standard EtherCAT Terminals. With the same cycle time (1 ms), however, a bandwidth utilisation of only 350 Mbit/s results in just one EtherCAT G network. The remaining bandwidth of 650 Mbit/s enables an extension of the channels and the support of even higher analog sampling rates. Further cost advantages are the extremely reduced cabling requirements (one network instead of four) and the reduction in the number of the ports required in the master from four to one. PACE

FEBRUARY/ MARCH 2020 www.pacetoday.com.au 33

WASTEWATER

Building customer confidence across the wastewater sector The risk of environmental damage in the wastewater industry means experience, expertise, and sensitivity to customer needs is a must. PACE speaks to Wayne D’Douza, BSC national accounts manager, about the importance of getting it right.

n the water and wastewater segment, operations tend to be risk adverse. This is because there is little, if any, room for mistakes, said BSC National Accounts Manager Wayne D’Souza. “It’s a segment where all eyes are on it. A mistake could mean the pollution of rivers, or oceans. Or it could mean that the supply of water is cut off from residential areas. The ramifications of a shutdown or a mistake can be catastrophic,” D’Souza explained. “Which is why the industry is cautious when it comes to the equipment they are using and how they maintain it. If there is a process in place that works, the general attitude is not to change it, even if it is not the most efficient process.” Having said that, D’Souza said that BSC have seen a significant spike in the number of customers requesting their engineering services. “In this segment we are getting a lot of requests for site surveys and asset management. As a whole, we’re seeing a lack of asset records among our customers. Once our engineering team has been assigned to a project, they will go onto a site, assess the machinery and components, and then make recommendations as to how the customer can improve their process.” Importantly, BSC can draw from an entire country’s worth of customer experience.

“We’ve identified a number of ‘problem solver’ products based on our existing network of customers. So, when we go to a site and figure out where the process can be improved, we’re not just going by a book or a brochure. We’ve actually identified applications in the water and wastewater space where we know these solutions will work.” To illustrate some of the success that BSC has seen in this segment, D’Souza had some of the BSC team discuss real customer experiences.

the Timken Spherical Roller Bearing Solid-Block Housed Units,” said BSC’s Nick Girdlestone. “It is important to develop a relationship with the customer. With this particular wastewater treatment plant, if there is a problem, they call us in, and we have a look at what has gone wrong. If we can, we see if we can come up with something that is more efficient and saves them time and money.”

Gold Coast City Council

At another wastewater treatment plant in Victoria’s east, BSC services have been involved with providing products to enhance safety. Several years ago, a worker at the plant was taking samples of effluent out of the tanks. Having no harnessing, the man fell into the tank and drowned. When the tank was drained to retrieve the body, grating was found at the bottom of the tank. This was followed by a call to action to ensure that gratings are securely anchored, which led to the development of the BSC product Gratesafe, which provides a mechanical fixing to keep the grate in place. Gratesafe is a 120mm round disk featuring yellow anti-slip coating. It has gone through several iterations to further enhance the safety of grates,

A wastewater treatment run by a city council on Queensland’s Gold Coast, called upon BSC’s services due to a problem with their press mats. The bearing products that the plant was using for the press mats had become weakened by contaminants in the effluent and were beginning to fail. BSC suggested a trial of the Timken Spherical Roller Bearing Solid-Block Housed Units (formerly known as Blue Brute), which was carried out for 12 months. Meanwhile, several of the old bearings still in use had failures during that same interval. “The Timken bearing trial was going smoothly, so we were able to prove to the client that these would better suit their needs. They decided to go with us, and we changed the first press mat, which required 35 of

Eastern Treatment Plant, Victoria

preventing them from moving from side-to-side or backwards and forwards. Further designs were developed to provide shapes that can secure grates in varying situations. BSC’s Dean Molloy said the product significantly improved the safety of the treatment plant. “We have several variations of the product now, and we offer these to clients depending on their application,” Molloy said. “Over a whole site, there could be three or four acres of grating, and all of that has to be held down to make it safe for those who are working at the plant.”

365 days, 24/7 Engineering Availability

Another one of BSC’s key strength’s is their ability to provide customers with round the clock services. This is critical to the water and wastewater segment where there can be huge public health or environmental impacts if equipment fails. D’Souza reiterates the importance of having a team that can provide a 24/7 operation. “The bottom line is our customers need to feel secure in our service capabilities. We give them that confidence. If a customer rings in the middle of the night with an equipment failure, they know we’ll have someone on call to resolve the problem.” PACE

There is little or no room for error in wastewater management. 34 www.pacetoday.com.au FEBRUARY/ MARCH 2020

B E F E A TURED IN

Quality education and training is critical in maintaining and expanding a skilled workforce capable of guiding Australiaâ&#x20AC;&#x2122;s industrial sectors through the challenges associated with Industry 4.0 and the Industrial Internet of Things (IIoT). Staying ahead of the curve in new developments such as robotics, digital technology, and artificial intelligence will require the knowledge, innovation and know-how of trained engineers. Skill shortages in engineering and other STEM professions and how they can be overcome will be the focus of the April-May feature of PACE magazine.

IF YOUâ&#x20AC;&#x2122;RE INTERESTED IN TAKING PART IN THE NEXT EDITION OF PACE, contact Danilo Cortucci at Danilo.Cortucci@primecreative.com.au

NEW PRODUCTS

Operational visibility enables optimised business outcomes Available from Control Logic is Red Lion’s award-winning Crimson 3.1 family of “Data Stations” and operator touch interface panels for multi-vender cloud connectivity. With a growing list of 300 industrial built-in protocols including the newly released MQTT, SQL and OPC connectors, its user-friendly and always free platform provides companies with a smart yet economic option when deciding to transform business decisions to the cloud. Built from the ground-up and developed for over 15 years, the Crimson 3.1 configuration platform offers proven industrial reliability with simplified drag and drop development. It solves the remote firmware, configuration and version tracking problem that Linux OS boxes fail to overcome. Additionally, its compatibility with other manufacturers such as ABB, Emerson, Rockwell Automation, Schneider and Siemens, makes the Red Lion Crimson 3.1 platform a desirable option. The Crimson 3.1 platform exposes PLC and machine data beyond the operational environment, enabling enterprise business systems to a smooth transition of direct access to reliable real-time and historical operational data using MQTT. According to Red Lion, this can dramatically simplify system architectures, increase scalability and accelerate data integration initiatives with no additional hardware or expensive software customisation required. . Control Logic 1800 557 705 www.controllogic.com.au

ICP Electronics Australia presents iEi’s Mustang-F100 PCIe FPGA high-performance accelerator card ICP Australia introduces iEi’s Mustang-F100 PCIe FPGA high-performance accelerator card with Arria 10 1150GX support, DDR4 2400Hz 8GB and a PCIe Gen3 x8 interface. The Mustang-F100-A10 is a deep learning convolutional neural network acceleration card for speeding up AI inference, in a flexible and scalable way. Equipped with Intel Arria 10 FPGA, 8 GB DDR4 on board RAM, the MustangF100-A10 PCIe card can be used with the existing system, enabling highperformance computing without additional integration and expense. FPGAs can offer the ability to reprogram, this allows developers to implement algorithms in different applications to achieve optimal solutions. Algorithms implemented in FPGA provide deterministic timing, which achieve low latency real-time computation. Furthermore, compared to a CPU or GPU, the power consumption of FPGA is extremely efficient. Those features make the Mustang-F100-A10 suitable for edge computing. “Open Visual Inference & Neural Network Optimization (OpenVINO) toolkit” is based on convolutional neural networks (CNN), the toolkit extends workloads across Intel hardware and maximises performance. It can optimise pre-trained deep learning models such as Caffe, MXNET, Tensorflow into an IR binary file then execute the inference engine across Intel-hardware heterogeneously such as CPU, GPU, Intel Movidius Neural Compute Stick, and FPGA. Key features: • Half-height, half-length, double slot; • Power-efficiency, low-latency; • Supports OpenVINO Toolkit, AI Edge computing ready device; • FPGAs can be optimised for different deep learning tasks; • Intel FPGAs support multiple float-points and inference workloads ICP Electronics Australia 02 9457 6011 www.icp-australia.com.au 36 www.pacetoday.com.au FEBRUARY/ MARCH 2020

NEW PRODUCTS

Smart factory with IoT: igus develops smart plastics app for Fanuc FIELD system In order to be able to evaluate data from machines and systems centrally, Fanuc is now presenting its new open industrial IoT platform called “FIELD system”. The system can connect production machines of all manufacturers by means of a local network topology, enabling comprehensive data analysis of the entire process chain. In this infrastructure, apps from Fanuc and also from third-party suppliers are used. Now, igus has developed a smart plastics app for the new system. The app can be used by maintenance personnel to monitor the condition of their igus components, for example, energy chains and cables and plan all their maintenance work in good time. Networking is the current buzz word where predictive maintenance and Industry 4.0 are concerned. In addition, industrial IoT platforms are used. Automation specialist Fanuc has now developed such a platform. The Fanuc Intelligent Edge Link & Drive system (abbreviated: FIELD) was presented by the company for the first time in Europe at EMO. With the FIELD system, production machines can be networked with each other. It can work “on premise” or, in future, with a Cloud link. The system collects and analyses the machine data on site. The operating data and sensor data of the machines can therefore be gathered centrally via only one server and viewed whenever necessary. Efficiency is easy to monitor, production processes can be accelerated and maintenance work can be planned. Due to the openness of the platform, all machines can be connected to the system. Apps for the system are provided by FANUC as well as by third-party suppliers. The motion plastics specialist igus has developed an app for its smart plastics and made it available to the FIELD platform. Once the igus smart plastics app has been integrated, users can monitor the condition of their energy chains and cables at any time and can also plan maintenance work well in advance.

In the future, the condition of slewing rings, linear and plain bearings will also be monitored with the app. Connection via icom.plus in a secure environment Under the name isense, igus carries sensors of various kinds that detect the condition of igus components. They measure among other things, the wear during operation and alert the user early enough to plan repair or replacement. The icom.plus communication module provides the igus data via an integrated OPC-UA server. This data is then fed into the platform by means of the FANUC Converter. With the openness of the FIELD system, the customer can now use the data and service life statements of all igus products in a protected local network environment. The igus smart plastics app tells the maintenance technician when they should carry out the next maintenance. Hence, unscheduled machine downtime can be avoided. Treotham Automation Pty Ltd 1300 65 75 64 www.treotham.com.au

Modbus compatible thermal mass flow meters With the addition of the Modbus communication protocol to its new ST80 Series, recently enhanced ST51A/ST75A Series, and ST100 Series and multipoint MT100 Series, Fluid Components International (FCI) now provides the industry’s broadest selection of Modbus compatible thermal mass air/gas meters. For Modbus-based measurement and control systems, with air or gas flow rate components, FCI can now provide an optimal, highest value flow meter solution matched to the application. FCI thermal mass flow meters with Modbus I/O are available for line sizes from 6 mm to the largest of stacks and ducts, and every size in-between. They are designed to measure the flow of air and more than 200 different gases, including inert and hydrocarbon-based, in both pure and mixed compositions. Thermal mass air/gas flow meters are direct mass flow measuring, have no moving parts to foul or clog, and require no routine maintenance that achieve lowest installed cost and superior service life. FCI’s family of Modbus compatible thermal flow meters range from small, compact models to high feature, high performance, highaccuracy models. Models are available that carry global agency approvals for Ex installations, both Div.1/Zone1 and Div.2/Zone 2 types. Four of the series’ carry independently evaluated SIL compliance (IEC 61508) ratings for use in safety instrumented system applications. All FCI thermal flow meters are available in a vast choice of process connections to ensure compatibility with virtually any piping and installation criteria. The instruments are inherently dual function and can provide flow and temperature measurement, as well as totalised flow, outputs over the Modbus connection. The Modbus option for all five FCI model series flow meters meets the EIA/TIA-485 standard. Transmission is via RTU or ASCII with standard

MS (16 bit), standard LS (16 bit) or Daniel extensions (32 bit). They’re ideal for use with PLCs, large SCADA systems or DCS systems. In addition to Modbus, FCI’s thermal air/gas flow meters also provide 4-20 mA, analogue outputs, pulse outputs, and/or other digital bus communications of HART, Foundation Fieldbus, Profibus-PA and Profibus-DP. AMS Instrumentation & Calibration Pty Ltd 03 9017 8225 www.ams-ic.com.au

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NEW PRODUCTS

Backplane Systems Technology presents Neousys’ IGT-30 Series ARM-based industrial IoT gateway Backplane Systems Technology is proud to present Neousys’ IGT-30 Series, TI Sitara AM3352 ARM-based industrial IoT gateway with dual LAN and pre-installed Debian. Neousys’ IGT-30 Series, equipped with the AM3352 from Texas Instrument’s Sitara AM335x family, is an ARM-based Box PC designed for Industrial Internet of Things (IIoT) gateways and Industry 4.0 applications. The IGT-30 Series is supplied as a ready system preinstalled with Debian and in compliance with common industrial certifications such as CE/FCC, shock and vibration. It has a power input range of 10 to 25 VDC and a wide operating temperature from -25°C to 70°C to ensure the IGT-30 continues to function under harsh industrial conditions. The IGT-30 Series supports PoE Powered Device (PD) mode meaning it can be powered by a LAN cable from a PoE Power Sourcing Equipment (PSE), and at the same time transfer data via this cable. The IGT-30 Series has I/ Os that are applicable to a range of industrial grade sensors. It features one USB2.0 port, two 10/100M LAN ports, one configurable COM port (RS-232/422/485) and an optional CAN bus port. In addition to the ports mentioned, there are eight built-in isolated digital input channels that accept discrete signals from various sensors or buttons/ switches. There are also two built-in isolated digital output channels to control actuators and indicators. Communication wise, the IGT-30 Series has a mini PCIe slot and a USIM holder allowing it to transmit acquired data and system status via 3G, 4G or WiFi (mini PCIe WiFi module). There is an opening on top of IGT-30 Series for users to mount the SMA connector of the wireless module. In terms

of storage, the IGT-30 Series has dual microSDHC slots, one internal and one external. This design allows users to separate the system and user data which can expedite in OS deployment for mass production. The IGT-30 Series provides six LED indicators and two function buttons that can be programmed by users. The function buttons can act as controls for the IGT-30 Series and exclude the need for external input devices, such as keyboard or mouse. Key Features: • Industrial grade ARM-based system with pre-installed Debian; • AWS Device Qualification Program (DQP) certified; • F ield-ready isolated DI/O and RS-232/422/485; • 1 0 to 25V wide-range DC input and 802.3at PoE+ PD; • - 25°C to 70°C wide temperature operation. Backplane Systems Technology Pty Ltd 02 9457 6400 www.backplane.com.au

Endress+Hauser releases Liquiphant FTL51B and FTL41 point level instruments Endress+Hauser releases Liquiphant FTL51B and FTL41 vibrating fork (vibronic) level instruments. The FTL51B features Industry 4.0 and IIoT capabilities, including access via wireless Bluetooth technology, automatic proof tests and verification, and easy commissioning via a mobile device. In addition, operational clarity is provided by a highvisibility LED. The Liquiphant FTL51B can be used in storage tanks, containers, and pipes for point level detection of all types of liquids. The instrument’s vibronic sensor is not affected by changing media properties, flow, turbulence, gas bubbles, foam, vibration, or build-up. The instrument works in process temperatures of -58 to 302°F (-50 to 150°C) and pressures up to 1450 psi (100 bar). It can be used in SIL2 and SIL3 hazardous locations and has built-in automatic maintenance and verification functions. The economical, general-purpose FTL41 is similar to the FTL51B, but works at lower pressures, up to 580 psi (40 bar), and with a narrower temperature range of -40 to 302°F (-40 to 150°C). Both perform proof tests, with the FTL51B meeting SIL and WHG (Water Resources Act) requirements. The proof test can be activated remotely at a control system, or locally via a magnet or push button test. The proof test diagnoses the sensor for corrosion and build-up, and ensures the entire instrument is operating properly. Verification can be activated either manually or automatically via Endress+Hauser’s Heartbeat Technology, providing a verification report sufficient as documentation for various regulatory agencies. Access via Bluetooth technology and a mobile device – such as smartphone – allows a user to identify each device, commission it, check the status, start a proof test, and download verification documentation.

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Bluetooth has a range of 33 ft, allowing a technician to access Liquiphant instruments installed in hard-to-reach locations, such as at the top of tanks. Endress+Hauser 1300 363 707 www.au.endress.com

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