Pace - Aug/Sep 2017

AUGUST/SEPTEMBER 2017 | VOL.70 NO.4 | Est. 1953

AUGUST/SEPTEMBER 2017 | VOL.70 NO.4 | Est. 1953

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INSIDE PACE

Internet of Energy

Safety

Energy Management

What is the Internet of Energy and why is it important?

How a little device helped with a big problem

kWatch: The black box with an edge

HOW ONE COMPANY SURVIVED THE AUTO DOWNTURN EXCLUSIVE: 2017 Zenith Awards: We list all of the nominees

CONTENTS

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Managing Director: John Murphy Managing Editor: Syed Shah Editor: Mike Wheeler Ph: (02) 9439 7227 mike.wheeler@primecreative.com.au

IN THIS ISSUE

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Editor’s Comment 8 News 10 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.

State of Industry 12

Bosch chairman Dr Volker Denner on AI and the expansion of the IoT Women in Industry 14

How a process engineering company survived Ford closing its automotive plant in Geelong 2017 Zenith Awards Preview 16

© Copyright Prime Creative Media, 2017

A preview of this year’s finalists for the 2017 Zenith Awards

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.

Energy Management 26

The little black box that helps companies manage their energy needs

Head Office 11-15 Buckhurst St South Melbourne VIC 3205 P: +61 3 9690 8766 enquiries@primecreative.com.au www.primecreative.com.au

Wastewater 28

Reliability of suppliers was important when a wastewater specialist took on a new projectw

Sydney Office Suite 303, 1-9 Chandos Street, Saint Leonards, NSW 2065, Australia

26

Motors and Drives 29

Scalable functionality and flexible configuration were key factors for a motor being installed at a mining site The Internet of Energy 30

Getting onboard with the Internet of Energy The Internet of Things 32

The Internet of Things can be intimidating if you don’t know where to start Promotional Feature - Safety 34

A little device solved a big problem for a mining industry supplier Artificial Intelligence 36

How well are humans and robots going to get along in the coming years as artificial intelligence takes hold in our work places?

New Products 37

All the latest new products for the process and control industry

ON THE COVER

2017 Zenith Awards

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AUGUST/SEPTEMBER 2017 | VOL.70 NO.4 | Est. 1953

INSIDE PACE

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Internet of Energy

Safety

Energy Management

What is the Internet of Energy and why is it important?

How a little device helped with a big problem

kWatch: The black box with an edge

HOW ONE COMPANY SURVIVED THE AUTO DOWNTURN EXCLUSIVE: 2017 Zenith Awards: We list all of the nominees

4 www.pacetoday.com.au AUGUST/SEPTEMBER 2017

This year’s Zenith Awards has thrown up a great crop of deserving nominees from many different areas of the industry.

A common theme with a lot of the finalists is finding innovative solutions for their clients. Luckily for their customers, one of the key attributes of those in the process and control engineering space, is that they

enjoy solving problems. And there have been plenty on display over the past 12 months ­– from the rehabilitation of a mining site in Queensland through to a liquid-state anaerobic digestion process that turns organic waste into environmentally green energy and dry bio fertiliser. Good luck to all the nominees.

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COMMENT

EDITOR’S MESSAGE

Mike Wheeler Editor

Adapt or perish

INNOVATE or go under. That is the underlying message from a story in this month’s issue about Austeng, a Geelong-based process engineering company that relied heavily on the auto industry to survive. When you’ve been in an industry for 25 years, it’s hard to take in the reality that traditional revenue streams are about to dry up and don’t look to be coming back.

However, instead of feeling sorry for itself, Austeng decided to do something about it. And what an eye-opening and positive journey it has had.

And speaking of innovation, we’re gearing up for the annual Zenith Awards. Starting in 2003, these awards highlight the latest technologies, products and projects that have occurred

over the past 12 months. Finding solutions to tricky problems is the forte of process engineers. They seem to be the first port of call when a company has an issue that needs solving, or need a product that will not only fix a problem but meet strict criteria set out by standards authorities. This year is no exception, as we have outstanding nominees in all of our various categories.

Finally, there a new is buzzword doing the rounds – the Internet of Energy. We’ve had the IoT, IIoT and Industry 4.0. Now the way we utilise energy – from production and storage to everything in between –is being touted as the IoE. At the recent Australian Energy Storage Conference

8 www.pacetoday.com.au AUGUST/SEPTEMBER 2017

in Sydney, several speakers spoke about how corporations have to get on board now whether they are generators, storage providers or users.

What is the IoE? According to Enphase managing director, Nathan Dunn, it’s all about smart energy networks, storage technologies and data-driven applications. However, it is currently a mess as there are issues surrounding standards and getting all the key players marching in the same direction. Yet, this is changing. As the same speaker said, it will be one of the disruptive factors – in a good way. He compared it to the telecommunications revolution of the 1990s/2000s where people went from using brick-type mobile phones that allowed you to talk to people, to

the smart devices we have now. He believes Australia’s energy future is in its own hands. Traditional energy generation companies will hate it, but as the blackouts in South Australia proved, traditional electricity supplies are no longer as reliable as they once were. This is not only due to generation issues, but because needs have increased due to population growth. It looks like more companies are coming on board, now they just need to agree on a way forward. Being logical and intelligent people, I have high hopes that within the next five years, the IoE will be more structured and have standards in place that will have all those involved in this important sector on the same page. PACE

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NEWS

Electricity generation set to change forever Disruptions will happen to Australia’s energy sector over the next few years – but they are necessary, says Australia’s chief scientist Alan Finkel.

Finkel believes if Australia doesn’t act now, its energy future will be less secure, more unreliable and potentially costly.

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ustralia risks being left in the dark ages if it doesn’t start taking energy reforms seriously and begin implementing strategies that will secure Australia’s energy future, according to Australia’s chief scientist Alan Finkel.

Finkel made the observation at a keynote address at the National Press Club recently where he warned that energy generators, wholesalers and retailers need to futureproof the supply.

One the back of his recently released report on the energy sector, Blueprint for the Future, he said a key to securing the supply is understanding the number of technological disruptions that need to be taken into consideration by the market as consumer demand patterns change.

“One technological disruption is that ever cheaper wind and large-scale solar, even without subsidies, are dominating investor interest,” he said. “Investors

prefer wind and solar because they are now cheaper to build than traditional generation such as hydro and coal.

Investors also like wind and solar because they can be rolled out in small steps, say 100 megawatts at a time.

“A second disruption is the nearly two million rooftop solar generators that householders have installed. The electrical load curve and the generation mix now ramp rapidly up and down during the day to the extent that it becomes difficult for slow-responding baseload generation to cope. The market into which coal generation operates has been forever changed.”

A third disruption is just beginning, he said, delivered courtesy of stunning improvements in battery capacity and cost. This is a grassroots revolution. It’s driven by billions of people wanting their smart phones and laptop computers to last longer between charges.

10 www.pacetoday.com.au AUGUST/SEPTEMBER 2017

“To meet that market pull, global manufacturers have invested massively to improve the performance and lower the price of rechargeable batteries,” he said. “Re-purposing these batteries has enabled manufacturers to configure grid scale batteries. These are now being installed internationally at a level and cost that were unimaginable five years ago.”

A fourth technological disruption results from the fast evolving digital technologies that dominate peoples’ lives. Digital technologies are poised to enhance the electricity system, allowing it to flexibly accommodate millions of distributed rooftop solar generators, two-way current flows and the connection of microgrids.

“The final disruption is that homeowners are becoming market participants,” said Finkel.

“Empowered by friendly software, they are keeping tabs on their own power generation, storage, demand management and electric heatpump heating.”

While Finkel was at pains to point out the system is not broken, the energy sector – along with both state and local governments – need to start thinking ahead about the country’s energy needs, and not keep their heads buried in the sand that it will be business as usual over the next decade. “[Our energy needs] are at a critical turning point,” he said. “We must improve on what we have.

Globally, policy makers and market bodies understand that the key driver of that change – technology – cannot be reversed.

“When we met our counterparts overseas, the thing that made the biggest impact on me was the long-term policy certainty in other countries, which enables them to efficiently plan for the energy transition.

“It is clear they are ahead of us.

For example, Ireland has a multiyear program, Delivering a Secure, Sustainable Electricity System, to actively integrate renewables into the power system. The United States has the Quadrennial Energy Review, to enable the modernisation and transformation of the electricity system. And New York has the Reforming the Energy Vision strategy, which establishes targets for emissions reductions, renewable generation and energy efficiency in buildings. These examples illustrate the need for us to adopt a more proactive approach in Australia.”

The review not only stipulated that the market had to think outside traditional spheres of generation, it also said fossils fuels were not to be taken out of the mix.

“Reliability, security, lowest cost, and reduced atmospheric emissions are the critically important outcomes,” said Finkel.

“The generation mix is an input.

The exact mix of coal, gas, solar, wind and hydro is not important as long as the outcomes are met. To minimise future price increases we will need a diverse energy mix, including fossil fuels.”

Finkel believes if Australia doesn’t act now, its energy future will be less secure, more unreliable and potentially costly. He reiterated the point by stating that even though scientists use the term business as usual when modelling in a specific way, there is actually no such thing because the system is dynamically evolving.

“The past is gone,” he said. “To preserve a stable system at lowest cost we need to embrace that future.

Embrace. Not race. Move too slowly and we will miss out on what the future offers. Move too quickly and we put at risk the stability and affordability of our electricity system.” PACE

NEWS

Apricus Australia pens distribution deal with Ice Energy After a steady increase in inquiries, US-based energy storage specialist Ice Energy has signed a deal with Apricus Australia.

Apricus will sell to all market segments including commercial and industrial.

A

pricus Australia has signed a deal with U.S. thermal energy storage specialist Ice Energy to become the exclusive distributor of all Ice Energy products in the country.

Apricus will market and sell to all market segments, including utilities, commercial and industrial, and residential, and will be responsible for installation and service. Initially, the products will be imported from

the U.S., but the parties plan for Apricus to manufacture locally as sales increase, which will offer several benefits not only to local customers but to the local economy, too.

“We’re delighted to be partnering with Apricus in this new market for Ice Energy,” said Mike Hopkins, CEO of Ice Energy.

“Over the past 12 months we’ve had a steadily growing number of inquiries from Australia about our

products. This is not surprising when looking at the needs of the country’s electricity grid, the importance of their cooling load, and the ability of our products to turn that load into a cost-effective and reliable storage resource capable of flattening peak demand and eliminating solar overgeneration.”

“We share Ice Energy’s enthusiasm about our partnership, as well as about the Australian market for Ice

Energy products,” said Chris Taylor, director of Apricus Australia.

“There are terrific applications for the whole product line, but the hybrid AC/energy storage system, with its ability to provide cooling 24/7, make ice with excess solar generation and cool for four hours without needing electricity to create the cooling for that period, is a truly disruptive product tailor-made for Australia.” PACE

The new deal will give Australia direct access to Ice Energy products.

AUGUST/SEPTEMBER 2017 www.pacetoday.com.au 11

STATE OF INDUSTRY

AI and the expansion of the IoT Dr Volker Denner, chairman of the board of management of Bosch, recently outlined a future where cars drive themselves, artificial intelligence (AI) is king, and where innovations will be able to predict the behaviour of other road users.

Many issues need addressing, such as how the technology can guarantee passengers will arrive at the correct destintation.

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world where there are no car accidents, congestion is a thing of the past, and artificial intelligence (AI) and Internet of Things drive the future are no longer wishful thinking. It’s a reality that German-based companies like Bosch is pushing and could be happening in as little as five years.

At Bosch’s annual press conference held earlier this year, Dr Volker Denner, chairman of the board of management for Bosch, outlined the company’s future strategic plans for automated cars and the impact AI and the IoT will have on many things in the not-toodistant future.

How serious is the company in pressing innovation in this space? This year the company added 500 more engineers to work on its automated driving projects, which means it has more than 3000 specialists working in this arena.

Collaboration is a key ingredient and necessary to make these concepts a part of the automotive and manufacturing landscapes. To

highlight the point, Denner spoke of some of the partnerships Bosch has undertaken in recent times to reinforce its commitment to the automated car industry.

“We are entering into a development partnership with Daimler in order to enable automated driving in cities – in other words in highly complex driving situations,” said Denner. “Success in this first decisive step will bring us closer to a revolution in personal mobility.

“Second, together with Nvidia we are building the ‘AI onboard computer’ the very brain of self-driving cars. With the help of artificial intelligence, we are making cars clever enough to interpret and predict the behavior of other road users.”

The company also has highly automated driving activities in Australia with the launch of a trial and demonstration vehicle at the Intelligent Transport Systems (ITS) World Congress in Melbourne last October.

Many issues need addressing, such as how the technology can guarantee that passengers will arrive at the correct

12 www.pacetoday.com.au AUGUST/SEPTEMBER 2017

destination. This is an issue that Denner’s company has been working on for some time, and is something he is confident will be solved.

“Before this decade is out we will have managed to create an essential prerequisite for automated driving – an ultra accurate map that also contains the readings from our radar sensors,” he said. “We are working on this together with TomTom, as well as with Chinese providers AutoNavi, Baidu, and NavInfo. This radar signature will enable self-driving cars to determine their location with precision.”

Bosch is also ramping up its investment in the IoT and the connectivity required for automated cars. The company sees it as an essential growth area with the market predicted to increase well into double digit percentage points every year up to 2020.

Bosch will be releasing a cloud service that is designed to take advantage of what the IoT will offer.

“By the start of the next decade, the market for connected mobility will grow by almost 25 percent each year; by 2020, it is expected that 250 million vehicles will be part of the Internet of Things,” said Denner. “That is why we will be launching the Bosch Automotive Cloud Suite next year. It is a software platform that can be understood as the

heart of connected mobility. The suite will enable both us and our customers to establish new mobility services, whether it’s predictive diagnostics or online parking.”

Expanding into new technologies, Denner also outlined how Bosch is drawing a line in the sand as to how AI will impact on its business. Denner predicts that every new product rolled out by the company will either be produced or developed by AI, or will have AI integrated into it. Bosch also wants to use AI to make connectivity an emotive experience for car drivers and end-users in general.

“We sold 27 million web-enabled products in 2016 and it is our stated aim to make every new electronic product connected and develop related services,” said Denner. “The one relates to the other: artificial intelligence makes connectivity a personal, even emotive experience. It enables us to create technologies that support people in their everyday lives, that learn from data, and that relieve their users of the burden of daily chores.”

And how is Bosch measuring the impact of the IoT and AI? Dollars and cents, as well as peripheral factors.

“We estimate that the worldwide market for the IoT will grow by 35 percent each year until 2020, reaching

Bosch has employed 500 more engineers to work on its automated driving projects.

STATE OF INDUSTRY

a value of US$250 billion (AUS$330 billion),” said Denner. “The global semiconductor market offers another clear indication. Chips for the IoT are the strongest drivers of growth, even ahead of mobile telephony and automotive applications. Not least, the number of digital assistants will triple to over 1.5 billion by the start of the next decade.”

As with its Cloud Suite being set up to help fast track advancements in mobility offerings, Bosch recently set up the Bosch Center for Artificial Intelligence (BCAI) as a place where the interplay between connectivity and AI meet.

“The BCAI is spread across sites in Renningen, Palo Alto, and Bengaluru,” says Denner. “We can build on a solid base of expertise here, for instance in image analysis, as used for video surveillance in our security systems. The BCAI will initially focus above all on supporting the development of automated driving and connected manufacturing. We are also Projekt2 25.07.17 09:39 Seite 1 strengthening our 3 S’s for connectivity

– sensors, software, and services.”

By strengthening, Denner is also referring to engaging with more collaborative partnerships with those who seek similar goals and aims, and realise that the IoT is bigger than any one company.

“Our motto here is openness – we want to collaborate and enter into partnerships,” said Denner. “For example, we offer microservices from our Bosch IoT Suite software platform not only on our own cloud but also through Amazon Web Services and IBM Bluemix. The logic of the connected world points to partnerships like the ones we have entered into with GE, SAP, and Software AG.” Then there is the elephant in the room. The end game. Does this mean, as some fear, that automation is the beginning of the end? Does all the innovation in AI, IoT and automated cars mean massive job losses in the processing and manufacturing industries? No, said Denner.

“We want humans and machines to work together in intelligent teams and

By 2020 it is expected that 250 million vehicles will be part of the IoT.

we have taken this as the organising principle for our apprenticeships, which are available in 30 countries around the world,” he said.

“In Germany, for instance, we provide robotics training to all our technical apprentices at our Blaichach plant, while in Homburg we have set up a learning island on sensor- and software-based maintenance.”

Nobody can predict to any certainty

on how these technological advances will impact on the process and manufacturing landscape. However, as Denner said at the press conference, “on the one hand, we must further develop our existing and very successful businesses. On the other, we need to be quick to seek out new businesses, so we can stay ahead of possible disruptions”.

Leading those disruptions will be AI and the IoT. PACE

AUGUST/SEPTEMBER 2017 www.pacetoday.com.au 13

How opportunities arose after the auto industry left town Geelong’s engineering and manufacturing sectors have had nothing but bad news over the past five years. Auto plant closures, chain suppliers cutting back and businesses closing down because industry has moved on.

Instead of giving up, one company decided that sitting around waiting for things to happen was not an option.

Mike Wheeler explains.

F

After 25 years in business, Austeng director Lyn George and her husband Ross knew that they had to diversify if they were going to survive.

14 www.pacetoday.com.au AUGUST/SEPTEMBER 2017

ord closing its car assembly plant in Geelong was the death knell for many small businesses in the tight community south-west of Melbourne.

Despite both state and federal government promises, unions getting militant and locals crossing their fingers, toes – just about everything – hoping that the Australian car industry could survive, the doors closed on the plant in October 2016. A high Australian dollar, less government regulation in overseas markets, plus cheap labour in those same markets all contributed to the plant’s demise.

However, not everybody that relied on the automotive industry to make a living banged their heads against the cinder wall of abandoned warehouses and deserted assembly lines.

Many had been in the industry for years, if not decades. They had a lot invested in Geelong. Not just in nuts and bolts, lathes, sensors, conveyors and production lines but more prominant things – family, the community, the local footie team.

Small engineering enterprise, Austeng, was a typical example of a company that relied heavily on the big players in the market. A family concern that had been run for 25 years by husband and wife team Lyn and Ross George – he the engineer, she a commercial litigator – they knew that adjustments were essential. But what changes? And how? Closing up wasn’t an option, but both Lyn and Ross knew a business plan was needed if they were going to survive. For a company that was inducted into the Tool Manufacturing Hall of Fame in 2009 it seemed there might be some tough times ahead.

Speaking at the recent Women in Industry Conference held in Melbourne in June, Lyn George admitted that initially things were not looking great for their little engineering enterprise.

“We were very much involved in the automotive industry,” said George. “Our biggest client was Ford.

Geelong has been badly hit by the closure of a number of automotive clients and their spin-off suppliers’ chain clients and we’d had other challenges. But with disruption comes opportunities. So the question was ‘how do we transition our company?’”

George was uncomfortable talking about sea change buzz words like Unique Value Proposition (UVP), but soon got on board when Austeng connected with business analysts who said that the best way forward was to try and create a niche for themselves.

Then there were the little factors they needed to initiate. Things that a process engineering company wouldn’t usually think of doing — including publicising its wins such as awards via press releases and presentations.

Austeng also had to think differently when it came to redefining its core business and had to get its staff on-board and get them outside of their comfort zone. This was especially true of her husband, Ross, who baulked at the thought of having to start networking.

“I made the suggestion to my husband that we had to [network] and he was horrified,” she said. “He always had the thought that if you had a good product, then customers would come to you. It had worked like that up until now. He also did not like the idea of networking – getting out there. He thought he had to stay at

WOMEN IN INDUSTRY

Graphene is one atom thick and is incredibly light, and strong and it is electrically and thermally conductive.

work and work hard. That was the way to success. I really had to show the way and start networking in a very male-dominated industry.”

George believes most people think that networking is another word for trying to schmooze clients. She sees it differently. To her, it’s more about engaging with people and being curious about what they are doing. Where those conversations can lead is surprising, she said.

Also, it is advisable to join local industry associations.

“I really would strongly suggest you do that,” she said. “In our case it was the Geelong Manufacturing Council and Engineering Network.

And also be aware of what is going on with other companies. Make contact with various government bodies.

Let them know what you are doing.

Also be aware of what grant options were available.”

George also found that universities were great partners – not just due to the financial incentives that can be extricated through government and private grants, but also due to the ideas that can be thrashed around by both parties.

Once this was all taken into account, Austeng got to work. One of the first projects was helping deliver a nano-fibre production machine. At the time there was grant money floating around left

over from the automotive sector’s skills and development program. In order to benefit from the $500,000, local businesses, universities and technologies had to be involved.

“Three companies, including us and Cytomatrix, put in a joint application that we would produce commercial production equipment that we could produce nano-fibres on a commercial scale,” said George. “It was tested at Deakin University for about six months. That really involved our engineers talking to the scientists and getting the background on how it all worked out of their heads and converting that into engineering scale of equipment. Before we’d even finished the machine, a Swiss company found out about it and came in and invested in our partner Cytomatrix.”

It was exciting times, yet once it was all over there was an important lesson to be learned. While they were pleased to be involved in the project, and it expanded their horizons, they missed out when it came to investment opportunities in the new business. Maybe it was because they got too caught up in an exhilarating new field, or just didn’t think beyond getting a working model up and running. They wouldn’t be so naïve next time around. But there were positives, too.

“We received an excellence award

for R and D innovation,” said George.

“So we sat back on that and looked at it and said ‘that was great’. We had $250,000 worth of equipment that we provided. We were hoping for manufacturing rights and maybe investing in the company but it happened all so fast that we were left high and dry. That did influence us as to what our business model would be in the future.”

With her legal background in tow, George realised that some companies that might have a patent don’t have a lot of money. So they thought they could help those companies to the next stage by providing them with free legal and engineering advice.

In return, Austeng would ask for manufacturing rights and/or equity depending on how it worked out. She saw it is a key ingredient to securing a long-term future for Austeng.

That future involved graphene, a substance that is one atom thick and is put together in a lattice-type arrangement. It is incredibly light, and strong and it is electrically and thermally conductive. Austeng was approached by a Sydney-based company called Imagine Intelligent Materials (Imagine IM). While Austeng had missed investment opportunities with the nano-fibre venture, it was the company’s work on that project that encouraged Deakin University to recommend them to Imagine IM.

Imagine IM was creating graphene in a particular way and they needed to scale it up for commercial applications.

They already had a client in the geo textiles field, Geofrabrics Australasia, which had various applications for its products. This included putting a layer of geo textiles on the bottom of dams to stop toxic leeching into the substrate.

“We managed to build a pilot plant facility which produces 10 tonnes of graphene a year,” said George.

As with the nano-fibre project, once the momentum began, things started to happen quickly. A second plant was built in North Geelong and the orders from America started coming in. And unlike the first project, they invested in the company pretty quickly.

All these innovations came about because Austeng was willing to sit down, work out a plan, play to its strengths and get help from different sectors – not just industrial, but universities and government bodies.

“Our niche is a one-stop shop and three words encapsulated or UVP - visualise, engineer deliver,” said George. “We’re also vertically integrated so we have engineers, draughtsmen and tradespeople. So if we are given a concept, we can come up with a concept to engineer it, design it, draught it and then build it.” PACE

AUGUST/SEPTEMBER 2017 www.pacetoday.com.au 15

ZENITH AWARDS

2017 Zenith Awards Preview

S

ince 2003, the Zenith Awards have been presented to those companies whose products, services and projects have proved innovative, exceptional and meet the demands of an ever-changing industry. This year is no exception.

The hard work and dedication shown by those in the process and control engineering sector shows no sign of abating.

Problem solving is a big part of this space, and the finalists in this year’s awards show that with a little forward planning, troubleshooting and inventive, cutting-edge products, any problem can be solved. There is a plethora of examples this year – whether it be an energy management software solution or wastewater issue that needs resolving – where those at the coalface get the job done.

And without sponsors there would be no awards night, so I would like to thank our commercial partners, some who have been with us for many years and are listed on this page.

Finally, I would like to say good luck to all those who have products, services and projects up for awards.

It is your hard work and dedication that keeps Australia at the forefront of this industry.

Mike Wheeler, Editor

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The Zenith Awards reward innovation, problem solving and thinking outside the square.

2017 ZENITH PREVIEW

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Manufacturing Traceability – Matthews Australasia Exporting baby formula to China is not open to any foreign manufacturer. Importing

manufacturers must provide the Certification and Accreditation Administration of China (CNCA), plus meet a series of strict traceability requirements.

Matthews looked at how the information about product authenticity could be safely provided. Matthews developed the solution using a cloud-based platform that provides advanced cryptographic code-generation and fraud-tracking algorithms,

as well as a consumer interface to track where the product is scanned. The solution also used a Matthews’ Solaris laser to mark each tin with a unique, serialised QR code, generated by the cloudbased provider.

Using smartphones, consumers in China can scan the QR codes, via social network WeChat, on individual formula tins to identify and authenticate that individual product and see its history.

Best PLC, HMI and Sensor Product The TX500 HMIs can be run as field devices for both Modbus TCP and RTU master.

VegaPuls 69 – Vega Australia

The VegaPuls 69 is a radar sensor for continuous level measurement of bulk solids in small up to large vessel heights. It is a sensor for continuous measurement of bulk solids under different process conditions. It has been designed for level measurement in very high silos, large bunkers and segmented vessels.

Its signal focusing means it is simple to setup. It can be equipped with an encapsulated plastic antenna or a lens antenna integrated in the metal flange. This enables the optimum adaption to different application areas.

TX500 HMI PLCs – Turck The TX500 HMI PLCs are for use in small- to medium-size food machines whose processes have to be

controlled, displayed and operated locally. Each unit is equipped with a Profinet master and EtherNet/IP scanner, as well as a Modbus TCP and Modbus RTU master.

The HMIs can also be run as field devices for both Modbus protocols.

Coesys 3 allows the lean and simple programming of the PLC and visualisation functions. The latest processor technology of the units enables the smooth handling of computing-intensive processes such as moving image visualisations.

The high-resolution TFT display with 64,000 colours also supports high-performance display of graphics and animations.

Project Flex – SAGE Automation

Arnott’s wanted to be able to run any product in any line with ease. ‘Project Flex’ was their answer. Part of the solution was in updating the outdated

oven conveyor PLC hardware and HMI. An updated HMI system would improve the way operators could load new production orders, including a feature that allows different recipes to be stored, selected and produced on the same line.

A Recipe Management Page would enable each oven to store recipes with pre-programmed conveyor path, line speed set points and variables – thus allowing faster changeover and reduced margin for human error.

Arnott’s contracted SAGE Automation to deliver the project, which included removing obsolete PLC hardware; as well as programming, designing and installing the HMI according to Arnott’s specifications.

In addition, SAGE installed two new cooling systems for the conveyors and consolidated the existing system, which included reprogramming of the PLC and HMI.

FC6A MicroSmart – IDEC Corporation IDEC Corporation’s FC6A MicroSmart is a powerful PLC with up to 520 I/O. The MicroSmart PLC provides the power of a PAC (programmable automation controller) in a controller with a small form factor. It is designed for industries that require control of standalone machines, process skids, vehicles and small-scale systems. It comes in several form factors and up to 12 expansion modules can

be added to the 16 I/O model, and up to 15 expansion modules can be added to the 24 and 40 I/O models.

These modules can be of any type with no restrictions as to the number of analogue and specialty modules.

MTL GECMA HMI Workstations – Eaton Eaton MTL GECMA HMI workstations – the Thin Client (TC) and Personal Computer (PC) – offer features that include reducing operation costs, optimising productivity and increasing plant safety.

These next generation HMIs feature state-of-the-art technology and are approved to global hazardous certification for Zone 1 environments.

As a result, they offer safe handling on site and high reliability in hazardous EX zone areas in chemical, pharmaceutical, refinery plus the oil and gas industries worldwide. The TC version is designed for virtualisation applications, for example batch control. The workstation works with a client server in the safe room across a LAN. This saves space in the cabinet as users do not need a dedicated PC and they can control up to 255 HMIs from a single server. The PC version is stand-alone working across the LAN.

Intelligent Photoelectric Sensors– SICK

SICK’s photoelectric sensors come with a range of characteristics and

AUGUST/SEPTEMBER 2017 www.pacetoday.com.au 17

are available for object detection and can provide at least one suitable solution for virtually any application. This is made possible

by SICK’s SIRIC opto-electronic ASIC technology.

Photoelectric sensors with SIRIC offer maximum optical durability to LED illumination, ambient light, and emitted light from other sensors, as well as supporting both extended sensing and scanning distances and enhanced operating reserves. SIRIC photoelectric proximity sensors also have good background suppression.

The integrated chip technology makes it possible to reduce the size of the components without impairing detection performance. By applying the auto-collimation principle, the photoelectric sensors can be relied upon to detect objects even through small gaps and openings, and avoid blind zones at close range.

Nemo Radio Transceiver – Control Logic

The Nemo radio transceiver is a configurable, intelligent bi-directional radio link that exchanges information

while adapting to the radio environment. An internal SIM card contains all the transceiver and operator module parameters, and when linked to the application it allows for rapid replacement of a transceiver if necessary.

One of its main features is the ability to communicate over many communication protocols including Modbus RTU, CANopen, DeviceNet, PROFIBUS, PROFINET, EtherCAT, Modbus TCP/IP, EtherNet/IP, or Ethernet Powerlink.

FX3 series – Mitsubishi Electric

The FX3 series compact controller has a configurable design that permits open communication, large I/O handling, as well as precise positioning and analogue control, creating systems that mould to customer requirements.

A high performance-to-cost ratio is said to make economical design solutions for a diverse range of applications a reality.

It is said to meet a variety of

user applications including serial communication, networking, positioning, high-speed control, analogue control and visualisation.

EcoStruxure – Schneider Electric

EcoStruxure is Schneider Electric’s open, interoperable, IoT-enabled system architecture and platform.

It enables smart sensing, embedded computing, IP networking and edge analytics. These capabilities allow the discovery of onboarding of connected products, configuration and messaging with devices, collection and storage of device data, the ability to perform local analytics and easy configuration, and upgrades at a device level.

Then there is the interoperatable foundation for Smart Operations, which serves as a building block for control, management, automation and optimisation of an operation on premises or in the cloud. This suite of hardware agnostic connectivity functionality, drivers, tool kits and templates enable customers to aggregate not only process information

but also manufacturing and equipment data. By putting this data into context, the Smart Operations aspect of EcoStruxure opens a new level of analysis, models and data visualisation functionality.

SmartPlant Enterprise – Intergraph

SmartPlant Enterprise is a product suite designed to improve project execution, handover, and plant operational efficiency. It offers a portfolio of applications that can be deployed individually or as a flexible, integrated enterprise solution.

This modular architecture provides scalability, enabling clients to start small and later grow.

SmartPlant Enterprise leverages project information and knowledge to improve and automate work processes, from the early project phases through operations and maintenance up to decommissioning. By tackling this major “pain point,” SmartPlant Enterprise helps the industry to gain multiple hidden benefits – for example, it improves engineering efficiency by up to 30 per cent.

Manufacturing Control Advanced Scheduler – Ailytic

The Ailytic Advanced Scheduler simplifies the complex task of importing, creating, optimising and choosing the best sequence of orders for your production environment.

It models and manages complex operational constraints to ensure what a user schedules is what will happen in the real world. It is designed to configure operations, plant floor and equipment hierarchy, BOMs and routes to accurately reflect the physical and operational environment.

It can also be configured to show model shifts, calendarised resource and machine rates, scheduled maintenance, seasonality and other attributes for true capacity calculation across the entire site.

The OneSteel Whyalla Steelworks’ Risk Control Project was instigated to lessen the risk of outages.

18 www.pacetoday.com.au AUGUST/SEPTEMBER 2017

Control System Risk project – Alliance Automation

The OneSteel Whyalla steelworks is located at Whyalla, South

Australia. The Control System Risk project was aimed at mitigating the risk of extended production outages at the steelworks due to issues with the support and spares availability of obsolete control and drive systems.

Alliance Automation conducted a detailed task analysis of the operations from the control room, and with the assistance of SCADA users, developed solutions that fully satisfied operational requirements. Improvements were also made to how information was displayed so that operators could have a better understanding of the overall status of the plant.

Improved SCADA operability greatly enhanced the ability of the plant operations team to achieve high productivity and quality targets. It also improved operational safety as the operator was given the information required to manage situations

2017 ZENITH PREVIEW

when the plant deviated from optimum control parameters.

Egg-packaging integrated inspection – Matthews Australasia Egg-packing is a fast-paced environment with numerous

different production lines, running any one of 30+ SKUs on each production line. Each line may be running a different brand or another egg size (or similar variation) simultaneously. All these egg cartons need to go into specific shipper cartons, or ‘outers’,

for transportation.

Since multiple products are running at the same time, there is a possibility that the inner and outer don’t match.

To avoid any quality issues, Matthews installed an integrated inspection solution where a camera-

based vision inspection solution looked into the shippers before they were closed, checking if they matched the barcode on the inner with the barcode on the shipper, to verify if the right cartons/ consumer units were in the right shipping boxes.

HMPS5000 Wraparound Case Packer - HMPS

with an output speed of 10 to 30 cartons per minute.

The machine was designed to place boxes of dry food into larger cartons, ready for palletising and shipping, and was required to be easy to maintain, clean and operate.

It was required to do multiple functions and had to be easy to set up for various product lines.

The HMPS5000 Wraparound Case Packer solution delivered an expected lifespan of at least 10 years.

Machine Builder AI Assistant – IBM and ABB

Working with ABB, IBM has developed a new AI assistant to help manufacturers detect defects on the production line.

The Cognitive Visual Inspection System is connected to ABB’s industrial monitoring system, ABB Ability, and will help manufacturers improve speed, yield, and uptime.

The system works by transferring images from an ultrahigh-definition (UHD) camera

to a section of IBM’s Watson software that has been trained to detect and classify production faults in real time.

Watson is capable of inspecting parts up to five times faster than production workers, says the company, and can detect faults not visible to the human eye. It enables manufacturers to potentially inspect every product coming off the line, allowing them to reject or rework only faulty products rather than complete batches.

HMPS developed a solution to automate the end-ofline requirements for a food manufacturer that would automate the process with minimal operator involvement, while adhering to the health requirements of the food and beverage industry.

The challenge in this project was the number of variables the machines had to deal with – one machine to pack up to 12 products formats of between 180g and 260g

B E F E A T U RE D I N

Electronics componentry is an essential part of the engineering sector. By 2020 more than 21 billion devices are expected to be connected to wireless technology – all of them will have electronic componentry. The October issue of PACE talks to specialists in this field about where wireless technology is heading and where electronics fit in the landscape.

If you’re interested in taking part in the next edition of PACE, contact Nick Baker today at Nick.Baker@primecreative.com.au 02 9439 7227

AUGUST/SEPTEMBER 2017 www.pacetoday.com.au 19

Mining and Minerals Process Control The FAG Plummer Block Housing SNS is engineered to increase the life of fitted spherical roller bearings.

Metso MX – Metso

The Metso MX is based on patented multi-action crushing technology, which combines the piston and rotating bowl into a single crusher.

Designed for demanding rock conditions and with a focus on automated adjustment features, the Metso MX provides a high reduction ratio with a premium end-product shape and consistency critical in aggregate applications.

The key benefit of the multi-action technology is the easy underload setting adjustment and wear compensation without having to stop the process. Optimal cavity design, stroke direction and effectively distributed crushing action lead to the ultimate rock-

on-rock crushing motion. This combined with the innovative multi-action technology results in extended maintenance intervals and higher production.

FAG Plummer Block Housing – Schaeffler Australia

A new generation of large-size bearing housings is engineered to increase the life of fitted spherical roller bearings by up to 50 per cent compared to conventional plummer block housings.

The FAG Plummer Block Housing SNS, for shafts from 115mm-530mm diameter is a split plummer block concept that allows maintenance to be carried out more

As parrt of the rehabilitation of the CSA Mine, process underground temporary winders were used.

efficiently and quickly by providing easier access to the bearing.

The extended lifespan is made possible by the innovative housing design, which ensures optimum load distribution in the bearing.

The housing also provides a high sealing action against the ingress of contamination under extreme environmental conditions, making it suitable for use in aggressive environments commonly encountered in industry.

FAG Split Bearings – Schaeffler Australia

FAG split spherical roller bearing technologies are engineered to reduce downtime of machinery vital to industries seeking to minimise production shutdowns and process interruptions.

The latest FAG split bearing designs also increase safety by reducing the amount of heavy disassembly and assembly tasks, including applications such as conveying equipment, materials processing plant, ventilation plant, rolling and milling equipment, energy and water utility machinery and primary processing plant including timber, paper and agribusiness machinery.

The bearings simplify cutting, mounting and maintenance downtime by 50 per cent.

Niagara Scalper screening system – Haver and Boecker

Haver & Boecker’s Niagara Scalper screening system is suitable for screening and scalping coarse 20 www.pacetoday.com.au AUGUST/SEPTEMBER 2017

material, and moist and sticky material with a tendency for screen blinding and pegging. It is well suited to operations with high feed rates and those with discontinuous feed rates.

Other features include a drive system that generates a constant circular vibration with a fixed amplitude, regardless of feed material loads and conditions; distinctive four-bearing design with eccentric shaft acceleration, which is essential for loadindependent operation, ensuring screen blinding or clogging won’t occur; and counter weights on the shaft – in combination with the support buffers, the weights balance the system to dynamically minimise loads.

CSA Mine Shaft No.1 Winder Electrical and Control System – Alliance Automation

CSA Mine is an underground copper mine located in Cobar, Central Western NSW. To sustain and increase in production and meet legislative requirements, CSA Mine are undertaking a $65 million project to upgrade two mine shafts.

As part of the rehabilitation, process underground temporary winders are used to set up staging and haul people and materials associated with the rehabilitation works. The purpose of this project was to design a temporary winding system that was relocatable and that would meet all the mining safety standards.

Alliance Automation’s responsibility was for the complete electrical and control system design, software, and commissioning of the temporary winding system.

Jumboguard – YUMARR Automation

YUMARR has developed JumboGuard, a laser scanner based assistance system that protects the operating crew of mobile underground drill rigs called Jumbos.

The risk of inadvertent contact with moving booms and entanglement in rotating drill steels continues to be an

2017 ZENITH PREVIEW

industry wide problem when people are working with underground drill rigs. JumboGuard reduces the risk of human errors. YUMARR designed the system to be retrofitted to all types of underground drilling equipment such as rock and cable bolters as well as face drill rigs. As an additional layer of protection, JumboGuard integrates into existing drill infrastructure and hydraulic control.

JumboGuard observes the machine surrounding and monitors the movement of persons. If anyone enters the danger zone, JumboGuard detects the hazard and automatically stops the boom’s hydraulics, blocking the rotation of drill and movement of the boom.

As long as there is someone remaining in the danger zone, JumboGuard actively prevents the reactivation of the machine.

As part of restoring facility to full operation status, Alliance Automation was engaged to replace the existing Yokogawa DCS system across the coal handling and preparation plant, run of mine (ROM) and product coal handling systems.

The control system replacement project was aimed at providing operational staff with a familiar wash plant control experience; a current technology platform with commonality with other sister plants in the portfolio; upgraded control wiring with greater fault discrimination and conversion to extra low voltage; as well as higher reliability, improved safety and maintainability; and improved plant operation.

Rix’s Creek North CHPP Control System Replacement – Alliance Automation

The Double Bed Mining System is a strategic combination of two flat-bed mixers with tesselated surfaces under distributed network field control.

This configuration is designed to achieve crushing, assaying, mixing,

Rix Creek North is an open cut mining operation located northwest of Singleton, NSW.

concentration and overall processing with waste movement to the ‘just mined’ volume behind the machine.

The leading structure is built to cut the ore body into tiny tetrahedrals and octahedrals using high water pressure gel grit computer-controlled jetting that pushes the ore elements into the main space between the two flat beds.

The whole system moves forward with four upper and lower friction crawlers.

The system is connected to the distant control centre with three main cables that include a high water pressure feed, grit feed, two-way management and guidance electronics, extraction of the concentrated metals and movement of a small amount of waste materials away from the system.

The main waste materials are packed into the ‘just mined’ area to reduce the majority handling of tailings that need to be pumped away.

The Rix Creek North control system replacement project included providing operational staff with a familiar wash plant control experience.

Double Bed Mining System – Columbus Group

New possibilities with Beamex workshop

AMS AMS INSTRUMENTATION & CALIBRATION PTY LTD Unit 20, 51 Kalman drive Boronia VIC 3155 AUSTRALIA Phone: +61-3-9017 8225 Fax: +61-3-9729 9604 E-mail: sales@ams-ic.com.au Internet: www.ams-ic.com.au

The Beamex MCS200 Workshop offers a controlled environment enabling very accurate calibration and ergonomic ready-to-use equipment. Beamex has recently launched the product, MC6 Workstation, an advanced panel mounted documenting calibrator and communicator. MC6 Workstation offers calibration capabilities for pressure, temperature and various electrical signals. Full fieldbus communication for HART, FOUNDATION Fieldbus and Profibus PA instruments is available. MC6 Workstation communicates with pressure controllers and temperature blocks, enabling fully automatic calibration.

www.beamex.com info@beamex.com

AUGUST/SEPTEMBER 2017 www.pacetoday.com.au 21

Power and Energy Management InfoSyte – NHP and Switch Automation NHP partnered with Switch Automation to deliver InfoSyte, an energy management software solution tailored for the Australian and New Zealand markets. InfoSyte has the ability to integrate with energy, water and gas measuring devices along with other facility systems such as building management systems (BMS) and HVAC systems.

It offers a range of features, such as in-built reporting advanced analysis and trending functionality, fault detection and diagnosis and configurable user dashboards.

Solar Battery Storage – Reposit Power

By integrating innovative software with solar battery systems, Reposit Power helps customers who invest in energy systems maximise performance, minimise power bills, and participate actively in electricity markets. In addition to encouraging solar and storage uptake, the company believes in the importance of investing in the right software to coordinate supply and demand, and ensure balance in a grid where energy consumers are also producers.

V2 Power Fence – Columbus Group

The V2 is a simple-to-use PV system that can recharge many cycle batteries. It is mounted to

VFDs vary the frequency and voltage supplied to the motor, allowing for different speeds, torque or power to be used at different times. fence tops and can be expanded by plugging in more units, without worrying about voltage and battery matching. The power takeoff is done through different ‘L-shaped’ multi-purpose mounting brackets that are manually set to define its operational priority when there is limited power available.

The output voltages (3, 5, 8 and 12V DC plus 25 V AC) are determined by different plugtogether mounting brackets with different internal electronics.

Variable Frequency Drives – Bonfiglioli

Variable Frequency Drives (VFDs) vary the frequency and voltage supplied to the motor, allowing for different speeds, torque or power to be used at different times.

Bonfiglioli ACT Active is a system drive featuring integrated PLC functions with connectivity

to most bus systems, but also commonly used on apron feeders and conveyors, where starting torque and process speeds need to be managed. Bonfiglioli’s S2U series plug and play frequency inverter is often used in applications like the packaging industry, fans, pumps, mixers and doors. Bonfiglioli Agile inverters are used in all areas of industry, but are particularly suited to food and beverage, textiles, wood, packaging, ceramics and even wind turbines.

Bonfiglioli Active Cube series is designed for extensive motor control and functionality to suit machine automation using servo drive package solutions.

Li-ion battery project – Nano-Nouvelle

Nano-Nouvelle designs nanotechnology materials that can boost the energy storage capacity

of lithium ion batteries by as much as 50 per cent. Nano-Nouvelle worked with Portland, Oregonbased Polaris Battery Labs to apply a graphite layer to its coppercoated nanomaterial, Copper Lumafoil. The trial proved graphite adheres well to Lumafoil’s porous nanostructure and that Lumafoil is strong enough to work in present battery manufacturing lines.

The graphite application trial had addressed key customer concerns. It demonstrated Lumafoil is a plug-andplay replacement for solid copper current collectors in batteries.

Green-star Factory – Kingspan Insulation

Kingspan Insulation’s new factory is said to be the first Green star-rated manufacturing facility in Australia, by aiming to support production through renewable energy. The 14,000 square metre facility was designed by architect Tone Wheeler, using sustainably sourced building materials, a 750kW solar system, a rainwater harvesting system and energy renewing ventilators.

The facility utilises Kingspan technology, including a smart lighting system and highperformance insulation. Kingspan places a priority on net zero energy manufacturing and aims to meet the energy needs of its 100-plus factories around the world through renewable energy by 2020.

Safety System Innovation Safety relays – Lueze Electronics

Lueze safety relays are designed for smaller safety tasks – from the monitoring of simple components, such as E-STOP or safety switches, to the integration of optoelectronic sensors or standstill monitoring of motors.

With 22.5mm housings, the relays have a compact design and

can be installed in the switch cabinet in a space-saving manner.

Modules with adjustable time delay and contact extensions round out the new range.

The new safe controls of the MSI 400 product family offer both 24 inputs/outputs as well as an integrated industrial Ethernet protocol such as Profibus and Ethernet IP in a compact design

22 www.pacetoday.com.au AUGUST/SEPTEMBER 2017

of 45mm. The safety controls are suitable for the safe monitoring of simple safety functions as well as for performing more complex safety tasks.

FAG SmartQB - Schaeffler Australia

FAG SmartQB is a ready-to-use monitoring solution for electric motors, pumps, and fans that

is easy to install and does not require any knowledge about vibration diagnosis, including for common installations such as vibratory, grinding and rolling processes.

The automatically generated plain text messages on the seven-inch display are a genuine innovation on the condition monitoring market.

2017 ZENITH PREVIEW

The early warning system FAG SmartQB comprises a FAG SmartQB sensor unit (a variant of the existing FAG SmartCheck), a cubic housing with a touch panel, and a cable for power and data transmission.

The system was developed for detecting irregularities in electric motors, pumps, fans, and their rolling bearings.

zone. The sensor skin makes it possible for man and machine to collaborate directly and contact-free without the need for further precautions. The specially designed sensor skin covers the robot arm of the APAS assistant and reacts, as soon as somebody approaches.

APAS Assistant – Bosch

This is a personal protection safety system that uses the power of a ZigBee network umbrella to automatically identify a worker when he or she comes on site.

By wearing their AS2200 boots or shoes onto site, workers are automatically logged in and monitored as to their position in 3D at any time, checked on a regular basis. The system tells them if they are coming close to hazards that pose a safety threat.

There is a feedback system from the central autonomous control centre that signals through the bottom of the wearer’s feet to

The APAS assistant is a versatile automatic assistance system. As an intelligent and intrinsically safe robot system, the APAS assistant allows direct collaboration with people without expensive safety fences.

It is suited to supporting the worker in tasks that are potentially unsafe, overly simple and monotonous or ergonomically challenging. Before there is any contact between human and robot, the assistant stops and only continues its work when the person is out of the danger

FAG SmartQB was developed for detecting irregularities in electric motors, pumps and fans.

Personal Protection Safety System – Columbus Group

warn of dangers and which way to move to protect themselves. It works hands-free in bright sun or in the dark of night. There are no visual displays or units clipped

onto belts. There is also a way of hands-free signaling the central control if there are pending concerns, through touching either heal and toe together.

AUGUST/SEPTEMBER 2017 www.pacetoday.com.au 23

Water and Wastewater Control locally available industrial waste products. Filtration was powered by gravity, solar or by hand pump.

Lower South Creek Project – Aqseptence

Part of the Luggage Point WWTP upgrade included having to reverse engineer the existing system.

RAPTOR – CST Wastewater Solutions

Rapid Transformation of Organic Residues (RAPTOR) is a liquid-state anaerobic digestion process that consists of enhanced pre-treatment followed by multi-step biological fermentation. RAPTOR is suited to both industrial and municipal applications in Australasia. It has been used successfully in several projects around the world. One example is an organic-waste-toenergy project in Connecticut USA, which moved into production late last year.

It converted up to 40,000 tons of organic waste annually into environmentally green energy and dry bio fertiliser. The plant also avoided the need to dump the waste into landfill, from where organic wastes can seep into water tables of surrounding urban and rural development. Biogas extracted from the refuse replaces fossil and other fuels typically used to generate electricity for the nearby town of Southington

Malabar WWTP Project – 4Malabar

Malabar is Sydney Water’s largest wastewater treatment plant. It has an average daily discharge of almost 500 ML. As part of an upgrade the plant’s aging compressed air system needed replacing. Compressed air is used for a number of plant site services across Malabar WWTP including valving, pneumatic actuation and sparging. A reliable and efficient supply of quality compressed air is critical to deliver

these site services and was therefore key criteria in selecting the new system. Three Kaeser CSDX series rotary screw compressors, along with a Sigma Air Manager 4.0 (SAM 4.0) compressed air management system were selected to meet the requirements. Every screw compressor was equipped with a low-speed and highly efficient screw compressor block featuring the high performance and flow-optimised Sigma Profile rotors.

An in-house centralised control system, SAM 4.0 enables compressor performance to be precisely matched to actual air demand thereby allowing energy savings.

Removing pollutants from groundwater – UTS Faculty of Engineering and IT

A low-cost project to remove arsenic and deliver safe and clean drinking water was developed by UTS’s Professor Saravanamuth Vigneswaran and Dr Tien Vinh Nguyen. They wanted to remove pollutants from the Red River Delta in Vietnam — a densely populated area that is beset with serious public health issues caused by high levels of arsenic in the groundwater. Systems in place were neither cost-effective nor efficient at removing arsenic.

The UTS team deployed the technology to provide a model for clean water that can be adopted worldwide to improve water quality in the region. There were three key components to this system: an organic membrane, a tank/drum in which the membrane is inserted, and an absorptive cartridge made from

24 www.pacetoday.com.au AUGUST/SEPTEMBER 2017

The Lower South Creek Program will construct three new treatment plant upgrades at Riverstone, Quakers Hill and St Marys and is set to cost $300 million.

Supplied equipment will include Aqseptence Group’s Centre-Flo with honeycomb panel, which has greater than 30 per cent improved hydraulic capacity and 5 per cent greater screen capture rate – based on 5mm apertures – over a conventional perforated plate screen panel. The improved hydraulic capacity allows existing inlets works to increase hydraulic throughput without civil modifications while providing cost savings for new sites through smaller mechanical and civil footprints.

4D processing, pump, filter and valve systems – Columbus Group

The Columbus Group R&D team has had a long-term commitment to the group of tetrahedrals (four-sided shapes) and octahedrals (eight-sided shapes) that can come together to make continuous solid shapes.

By bringing together tetrahedrals and octahedrals in a mixed matrix of combinations, variable hardness, and drive mechanics, it is possible to undertake a range of water and wastewater outcomes.

Acting as a valve, by holding a maze of octahedrals, it is easy to shuffle the tetrahedrals and they act as valves to allow the passing of fluid, and restrict back flow. The suffling process can also ‘suck’ fluid into the capture volumes. Acting as a filter, the tetrahedral shapes can also be an extra soft capturing shape that secures large segments and waste water unwanted elements to restrict ongoing flow. The filter action can be reversed if needed by reverse flow.

The assembly of many hundreds of tetrahedrals and octahedrals into a filtering structure performs the task.

Pressure Sensor – Vega Austalia

The Vegapuls WL S 61 is a sensor designed for all typical applications in water and wastewater. It is particularly suitable for level measurement in water processing, pump stations and overflow basins.

The flood-proof IP 68 housing ensures a maintenance-free continuous operation. It comes with an integrated Bluetooth module for wireless communication via smartphone, tablet or PC. It offers exact measuring results independent of product, process and ambient conditions, is wear and maintenance-free, has maintenancefree operation through non-contact measuring principle, and it offers simple sensor adjustment.

Queensland Urban Utilities’ Luggage Point WWTP – Alliance Automation

Queensland Urban Utilities’ Luggage Point WWTP contains an existing microfiltration/reverse osmosis (MFRO) plant for the treatment of effluent water.

The plant was originally commissioned in 2000 and had become unreliable both electrically and from a control system and process perspective. This made the plant difficult to maintain and operate. Alliance Automation was engaged to perform a full process, electrical, mechanical and control system software upgrade of the plant. The existing plant control system was undocumented.

Before any improvements could be determined, the company was required to reverse engineer the existing system implementation. A site audit of the existing electrical installation was required.

The fully supported control system and process improvements allowed MFRO plant to operate fully automated with a high level of efficiency, minimising operator intervention and increasing reliability, which helped ensure that operational, safety and environmental compliance objectives were achieved.

2017 ZENITH PREVIEW

Young Achiever of the Year at the company he has risen from a graduate engineer to performing a technical lead role on some of the company’s biggest projects like the Sydney Harbour Bridge ELCS Southern Toll Gantry Removal for Roads and Maritime Services.

One of his first projects was a documentation job for a major gas client in Queensland. What was meant to be two weeks turned into four months out onsite – and Angus’ determination and success on this project stood out and paved the way for subsequent opportunities and challenges.

SAGE systems engineer Angus Heyworth

Bhavna Pandian - Eaton Angus Heyworth – SAGE Automation

Heyworth is a systems engineer with SAGE Automation. In his four years

Pandian is an associate engineer who initially started with Eaton as a Customer Service Representative.

This role was quite technical, and made extensive use of her engineering knowledge and

subsequent degree.

One of her major achievements has been overseeing the development of a quoting tool for Eaton’s power quality division, Bid Manager. This is an uninterrupted power supply (UPS) product configurator tool that allows the customer or sales person to input technical specifications, then receive a customised UPS solution in under 10 minutes. This tool aims to increase productivity of the sales team as manual calculations could previously take up to one hour. Currently, it is available for Eaton staff, with a wider customer launch planned in the near future.

Michaela Craft – BOC Limited

Craft joined BOC in 2014 as a remote operations engineer. This

role involved responsibility for starting up, shutting down and optimising 40 different tonnage and merchant plants across the South Pacific.

In early 2016, Craft was promoted to Energy Coordinator.

In this role, Craft works with an end-to-end approach for the strategic procurement of electricity, natural gas and Renewable Energy Certificates (RECs) for 287 BOC and Elgas sites across Australia and New Zealand, totalling over $100 million per annum.

Craft’s promotion to Energy Coordinator coincided with the departure of a senior staff member, which meant she was required to oversee numerous additional senior responsibilities, including optimisation projects and supplier contract negotiation.

Minimise costs when connecting Modbus-TCP networks/devices to ControlLogix® or CompactLogix® controllers with an Ethernet/IP interface.

Save between 40-70% compared to an in-chassis PLC communication module.

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EtherNet/IP to Modbus TCP Linking Device

See what you can do with Anybus Linking Device! visit www.anybus.com.au

Ph: +61 3 9338 8189 www.globalM2M.com.au

AUGUST/SEPTEMBER 2017 www.pacetoday.com.au 25

ENERGY MANAGEMENT

kWatch – the little black box with an edge Mike Wheeler talks to Flow Power managing director Matthew van der Linden on how a little black box gives control of a customer’s energy supply back to them, as well as offering all the information they need on their consumption.

The kWatch Intelligent Controller has got advanced capabilities to make complex decisions.

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iving commercial consumers access to wholesale energy prices was at the heart of why Matthew van der Linden started Flow Power, a company that does exactly that – take out the middle man in the energy stakes.

Managing director van der Linden felt that for too long many of the electricity retailers had things their own way and that maybe it was time for a new player in the market. They all offered similar pricing and services, and therefore there was no real competition. Van der Linden saw an

opportunity for a fourth player.

Van der Linden knew that setting up an electricity retailer was no small thing. There were many facets that needed to be brought on-board.

Questions included: • How can we pass on savings to consumers?

• What length do our contracts need to be to secure energy from suppliers?

• How do we work with customers to give them access to the wholesale market?

• How do we help consumers monitor their power usage in real

26 www.pacetoday.com.au AUGUST/SEPTEMBER 2017

time and manage their load more efficiently?

It was the last question that gave Flow Power a point of difference – giving consumers an easy-to-use device to monitor their power consumption in real time and manage their use efficiently. The answer was the kWatch Intelligent Controller, a proprietary black box that has a huge range of features under its hood.

Designed in-house by Flow Power, the controller is a nifty little device that is designed to record data and transmit it live back to monitoring systems that can be accessed online.

Designing the device was no easy task. It took a while for the boffins at Flow Power to come up with a unit that would meet a range of end-users’ needs.

“It is designed around a Windows IoT OS, which is a little unique in the market,” said van der Linden.

“It’s got advanced capabilities so that it can make complex decisions.

It was developed to interact with advanced control systems. It’s designed to be onsite and be a reliable communication tool to the cloud.

However, it can also make decisions without being connected to the

ENERGY MANAGEMENT

Your job just got easier TransPort® PT900 Portable Flow Meter Fast-response transmitter with health indicator LEDs to ensure it’s always ready to use cloud. It’s also designed to deal with networks that might be unreliable or have connectivity issues. This includes tracking power loads and helping with troubleshooting.”

Problems with power supplies are nothing new in the energy sector. It is rife with examples of when loads have been mismanaged, blackouts have occurred, or problems have arisen between retailers and their customers because monitoring the system has been inadequate. This little gadget was designed more out of necessity.

“We needed a device that solved certain problems including the ability to control load in response to price fluctuations,” said van der Linden. “We tried to go off the shelf but couldn’t find anything that specifically met that need. For about five years we tried to roll something out that did the job and finally we came up with the controller, which we’ll be rolling out this year.”

Inventors of similar devices might think it would have been an easy build – after all, most energy companies have similar products that monitor energy use and build up. But Flow Power wanted to take it one step further. The end result being for the consumer to control loads over multiple sites – important if one site is under pressure when shedding load.

“Imagine we have a large customer that has 30 sites across Victoria and they’re on wholesale,”

said van der Linden. “When you are on wholesale you need to be able to control those 30 sites in a co-ordinated fashion in order to achieve a certain demand reduction across many different sites. You might have a load of 20 megawatts in Victoria and you might buy a wholesale hedge of 10 megawatts.

What that means is that during a high price event you need to bridge all your sites across the state to 10 megawatts. The kWatch Intelligent Controller is designed to achieve that goal.”

For Flow Power customers without the controller, information is sent via SMS, which has problems. “[SMSing] is arbitrary and it’s hard to get specific information,” said van der Linden. “When we developed our wholesale pricing system we knew we needed the black box solution to make it scalable. The concept of doing this manually works but it’s a hassle. Over time people would get tired of doing it this way.

Our controller solution makes it simple for everyone.”

Although the kWatch Intelligent Controller was not designed to be sold as a standalone device (it is paired with Flow Power’s Freedom Power Plan sells), it does give customers a solid solution to help manage their energy needs.

For a company trying to make it with the big players, Flow Power needs every little advantage it can get. PACE

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1497854994 2017 www.pacetoday.com.au 27

WASTEWATER

The keys to wastewater treatment success Wastewater is a by-product of a huge range of industrial processes. When wastewater specialist Waterwerx developed a new system for the industry it needed to make sure it had reliable partners onboard that could meet its ongoing needs.

W

astewater specialist Waterwerx developed a state-of-the-art system designed for the wastewater industry called Streamwise. Streamwise is an all-encompassing solution that includes robust hardware and intuitive software. It is an automated system for optimising the chemistry of industrial wastewater solid-liquid separators, such as dissolved air flotation units, induced air flotation units and clarifiers.

Streamwise is a highly sophisticated system that incorporates advanced artificial intelligence to assess the incoming water quality. It does this via built-in intelligence that determines the best possible chemical dosage to ensure the treated water quality meets regulations. Streamwise helps maximise the efficiency of the operation while reducing the cost, too.

Waterwerx also knew that it needed reliable partners when it came to building and developing the system.

“In developing the Streamwise solution, we recognised the importance of establishing global partnerships with our key international suppliers,” says Waterwerx chemical and applications engineer Sharmen Rajendran. One such partner was automation specialist Beckhoff.

“Ruggedness, reliability, performance, compatibility, expandability and longterm availability are key elements when deciding on products that meet our specifications,” said Rajendran.

“Beckhoff met our requirement to operate powerful software, control complex applications and electrical systems with speed, efficiency and reliability.”

A key element in working with wastewater is making sure plant

Streamwise is a sophisticated system incorporating advanced artificial intelligence to assess the incoming water quality.

and devices have the ruggedness and reliability to survive in harsh environments.

A key product was Beckhoff’s EtherCAT offering, which had to meet strict criteria if Waterwerx was to incorporate into Streamwise.

“EtherCAT is an open source communications protocol that offers a high degree of efficiency and functionality for fieldbus

28 www.pacetoday.com.au AUGUST/SEPTEMBER 2017

communication,” said Rajendran.

“The integration with the TwinCAT development environment is very programmer friendly and allows robust installation of EtherCAT communication.”

Waterwerx also looked at what future offerings Beckhoff might have, which solidified their relationship.

“They are staying up to date with technology as they continue to

produce innovative products such as the Power over EtherCAT modules and cables as well as expanding into other fields such as web-based Human Machine Interface development software,” said Rajendran. “[What helps] is that they provide a sizeable range of products that integrate into their EtherCAT systems, which are currently utilised by Waterwerx.” PACE

MOTORS AND DRIVES

A rugged solution for hostile environments Nord’s IEC motors with a decentralised frequency inverter were an ideal solution for the harsh mining environment.

I

SMC Australia | New Zealand

ron ore mining can dish up harsh environments, which means a plant has to be up to standards that can withstand constant unforgiving surrounds. These surrounds can include extreme temperatures, dust, as well as wet conditions. Breakdowns can cost millions, so reliability is of utmost importance That is why customers look for products that can not only withstand the harsh environment but continue to operate without fail.

Nord’s IEC motors with decentralised frequency inverter in ranges from 5.5 kW to 7.5 kW were selected for a pump application at a mining site.

Energy usage can be reduced by close to 50 per cent with the use of variable

speed drive’s (VSD) to control motors in these applications.

It supplied an IP66 motor and VSD as an integrated solution. For this new project, the customer wanted to avoid installing a new centralised switchroom.

Increasingly, customers are looking for solutions where there is no need for cabinet mounting to avoid the additional cost and labour as a result of more cabling and wiring, according to Martin Broglia, managing director Nord Drivesystems Australia. Broglia says his company’s solution whereby the electronic control is mounted on top of the motor, is becoming more popular among customers.

The Nordac Flex SK200E came fitted with an internal EtherCAT card,

which connects to a B17 plug. The communication network was important in this application as it assists with the full control and status of the motor.

“We were able to offer a quick supply solution according to the customer’s specifications because all of these components are assembled locally” said Boglia.

The decentralised frequency inverters were supplied in a 7.5 kW with IP66 rating as specified by the customer.

The Nordac Flex SK 200E offers many installation possibilities. Scalable functionality and flexible configuration makes for simple installation and easy maintenance through the plug in capability and parameter transfer via EEPROM memory. This variable speed

drive comes in power range up to 22kW, is suitable for wall or motor installation and comes in variants of IP55 and IP66.

Nord supplied the customer in the required power range and with the B17 plug needed to suit the new installation.

The company supplied 11 units for a pilot run with more potentially on order.

“What made this installation unique was the development of a plug adaption to suit the customer requirement,” said Broglia. “We had to fit a new B17 plug. The beauty of this plug is that it provides power and communication in one cable allowing for a quick connection to the master PLC. We were able to provide the customer with a plug and play solution.” PACE

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AUGUST/SEPTEMBER 2017 www.pacetoday.com.au 29

INTERNET OF ENERGY

Getting to grips with the Internet of Energy PACE attended the Australian Energy Storage Conference and Exhibition and found out why the coming disruption is going to be a good thing.

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ustralia must soon get on board with the Internet of Energy (IoE) if it wants to be at the forefront of the coming energy revolution. That was the message from Enphase managing director, APAC, Nathan Dunn.

At the recent Australian Energy Storage Conference and Exhibition, the term was rolled out as Dunn addressed the changes that are coming to the energy market over the next 5 to 10 years – and he added that he believed the IoE will be the key for the Australian energy sector moving forward.

Like its cousin, the Internet of Things and all its permutations, the IoE is all about smart energy networks, storage technologies and data-driven applications. Talking at a seminar entitled, Global Energy Storage Markets, Opportunities for Australia,

Dunn said disruption is the key. “[Enphase] sees that technology is a key criterion for the evolution of the energy sector and will be one of the disruptive factors in the energy market as we roll through and develop the internet of energy,” said Dunn.

It’s disruption in a good way.

What Enphase, and companies like it, are trying to do is empower businesses and individuals to take care of their own energy needs. It’s giving traditional energy companies a run for their money.

Dunn compares the oncoming energy revolution to the telecommunications evolution of the late 1990s and early 2000s.

“As we know, early on in the telecommunications industry they were talking about fixed lines,” said Dunn. “You had a box on

30 www.pacetoday.com.au AUGUST/SEPTEMBER 2017

your desk and you picked up the phone and you dialed a number and you were connected to somebody else. As that technology evolved so did the relationship between the consumers and the hardware. With the telecommunications industry we moved away from being stuck to a fixed line. We started using pagers, then bulky mobile phones.

Finally, it developed into phones that everybody’s carrying today. That sort of disruption or transition from a technology perspective and growing consumer sentiment are going to drive the internet of energy and the transformation of the energy market.”

But there is a problem. It’s solvable but does need addressing.

Dunn asked the audience what they thought the IoE looked like at the moment. He then put up a picture of balls of wool all entangled

to illustrate that it is a mess. This is due to different organisations, government bodies and companies having differing agendas – whether it’s the utilisation of hardware, software applications, standards, or even something as complicated at data sovereignty.

“As this disruptive factor emerges, and the industry itself transforms, we’ll start to pull together the interactions between energy storage and software and data and the applications that can be applied,” he said. “Over time, and hopeful not a long amount of time – probably as quick as the internet of things picked up – we’ll start to see the internet of energy look more streamlined than it does now.”

Dunn says his company has a founding set of principles that he believes will not only be a driver of

INTERNET OF ENERGY

Helping to put you in Control

Electronic compass with RS-485

“We’ll eventually be in a position where you can essentially get notifications remotely where someone has left the fridge door open at home, or you might eventually get a notification that your AC system is struggling”

the IoE, but is something any company serious about the direction of the energy sector needs to take on board if they are going to succeed. Giving consumers autonomy is the starting point.

“To win in the energy space you had to take a decentralised view to the architecture,” he said. “That decentralised architecture takes a lot of work but it’s more intelligent and it essentially pushes the [energy] generation into the network. However, in utilising that aspect of the business, the points at which generation happen become deeper embedded into the network and for that you need a whole heap of smarts. You need a bucket load of semiconductor technology, you need a lot of work to go on in the background in the development of that product to ensure it is connected and working to the best of its ability. An example of this is our standard micro inverter of which we’ve sold more than 14 million units.”

Next, Enphase believes that something has to be part of a system and believes integration starts with component manufacturers like itself. Dunn says that it is not good enough to make a one-off product and hope that other designers and creators of energy

componentry will make a device or widget that will compliment that product.

“Everything has to be part of a system,” he said.

“So you cannot have a standalone product and hope others create a product that makes yours great. At Enphase we develop a complete system that includes hardware, bidirectional communications and then cloud-based applications software that allows users to see what energy their system is generating. They can also see what energy is being stored and understand the relationship between generation and utilisation.”

And every piece of hardware that the company creates has to be software defined, too.

Which means what, exactly? Dunn revisits the telecommunications analogy.

“A phone is a classic example,” he said. “It can be a piece of communication technology where you can talk to people. You can also bring up a GPS system.

That is a software defined piece of hardware.”

Dunn says the endgame for streamlining energy needs is that everything will work together. This isn’t pie-in-the-sky wishful thinking, but something that will have myriad effects – cheaper electricity, processes and controls in place to make sure equipment is being maximised to the best of its ability, and a much reduced carbon footprint on the landscape. It will even lead to simple things, like notifications that can help businesses and residential consumers save money.

“We’ll eventually be in a position where you can essentially get notifications remotely where someone has left the fridge door open at home or you might eventually get a notification that your AC system is struggling,” he said. “It gives people the opportunity to think about their investments and their position about how to best utilise their energy and then how to best utilise the funds they have available to ensure they have a good solid energy future.”

What about the future? If the IoE stops being a mess of random woolly threads all mixed together, Dunn says, that the energy future is not only bright, but exciting, too.

“It means you can finally get to a point where you are using AI to manage some of that data too,” he said. “So instead of having a physical reaction and the consumer making a choice, the AI programs that could be applied will enable people to work on their own and operate independently. The consumer will have the benefit of knowing that the system is running optimally without any human intervention.” PACE

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AUGUST/SEPTEMBER 2017 www.pacetoday.com.au 31

INDUSTRIAL INTERNET OF THINGS

The Industrial Internet of Things – where to start Industrial network specialists Moxa sheds some light on how plant and process managers need a good starting point on IIoT to make the most of a plant’s capabilities.

T

he Industrial Internet of Things (IIoT), Industry 4.0, the Internet of (IoT) Things and now the Internet of Energy – all these terms relate to how industries are adapting to the synergy between the connectivity of the internet and business. Whether it is manufacturing, processing or related industries, having device-todevice or people-to-device connectivity is a must, thus plant manufacturers and software developers now have to work hand-in-hand when developing products and services for industries, as well as smart factories.

While a large number of industries and industrial companies are tech savvy, there are those that, while they may have the smarts in their own particular field in the manufacturing and process industries, leave the IIoT in the ‘too hard’ basket. This kind of thinking is going to be detrimental to any industrial business that wants to keep up with the latest innovations, especially those who are setting up automated, or smart factories.

A stumbling block for some is not the intricacies of the internet and how it relates to the interconnectivity of devices within the business, but more where to start. It can be an overwhelming experience, especially if your current business has many different facets that need to be updated and adapted to the IIoT. However, there are steps that can be taken that can be seen as at least a starting point. These steps will not address all the needs necessary for a business, but are designed to help it get underway in what will be a complicated, but ultimately rewarding innovation.

First it is important to identify the operational goal. It is recommended that when contacting a supplier or

system integrator they are given a goal that is simple so that technical conversations on connectivity and network architecture start at the ground level.

An obvious starting point is to find out where the operational pain points are in a business. These could be environmental or technical causes, or they could be processes that need improving, or demands made by the management team. These pain points could be as specific as converting one legacy portion of an operation to the Ethernet, or they could be as broad as lowering company-wide manufacturing costs by 10 per cent within the next five years. If a provider knows up front what a business’ end goals are, they can tailor a solution taking these points into consideration.

An example would be a recently acquired company trying to integrate its existing computer integrated manufacturing (CIM) system into the new company’s systems including its manufacturing execution system (MES). Replacing an entire CIM would not be practical but the facility must be made more efficient and interoperable with the new company’s operational processes. The operations manager needs a brownfield solution that offers smart I/O condition monitoring that can help optimise their existing CIM and connect to the new MES. Once the pain points have been identified and addressed, the next step is to develop and prioritise the operational goals. Having operational goals is good, however, if they are not prioritised in order of importance then it could be a pointless exercise.

The objective here is to identify mission-critical solutions and/or improvements from those that would be considered benefits.

32 www.pacetoday.com.au AUGUST/SEPTEMBER 2017

A stumbling block when starting to get into the IoT is knowing where to start.

Additionally, prioritising these goals will allow the company, the integrator and the supplier to select the most scalable solution possible. This should ensure the operational goals will be met at the point of project completion, and long-term operational and maintenance costs will be considered as well if there is a need to scale up or down in the future.

Once priorities are set, the next step is to understand the interoperability status of key processes. A main consideration to take into account when achieving a connected smart factory is protocol division. Sometimes numerous disparate and proprietary fieldbus automation protocols may be encountered that must be connected to achieve operational goals. It is important to work with internal resources and integration teams to record and organise all devices, end nodes and equipment that exist within the company’s solution space. It is important to then register their corresponding protocols, physical interfaces, plant

locations and operational purposes.

It is also important to include any specific limitations or details relevant to the technology, device or piece of equipment that could be integral for a networking supplier or system integrator to know.

Finally, and probably the most important aspect is to make sure you choose the right devices when getting connected.

Uncovering potential hidden costs and savings of a connected, smart factory solution investment requires identification of explicit, as well as projected, operational costs and savings. In addition, by carefully formulating savings projections, combined with a payback timeline on the initial investment, a strong operational prospectus can be calculated. Getting started on the IIoT is not easy if a company is technophobic, or has no starting point. Once a company has scoped its priorities and made a definitive decision of its needs, then the rest of the puzzle will fall into place. PACE

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–SAFETY

How a little device solved a big problem Safety in mining opreations is a big concern for operators. Pilz shows how a reliable PLC is the perfect solution for safety issues.

S

afety is paramount in mining because it is a volatile industry where any slip in standards can see an increase in visits to the coroner’s court to explain mishaps and misadventures that should never have happened.

It is an industry governed by strict guidelines – from how a mine is opened, through to the life of its active working, and finally, rehabilitation. It’s a serious business run by serious people.

Winder Controls Australia specialises in machinery for the mining industry. When one of its clients needed a safety solution for its mine winders, only a reliable, adaptable PLC would suffice.

A programmable logic controller (PLC) is a controller that can be programmed to do a job. They come in all shapes, sizes and configurations, and have varying programming abilities depending on the job at hand.

In the case of Winder Controls Australia, it had a project that required a safety PLC that would monitor the mine shaft cage that transported miners up and down a mine shaft, in a safe manner.

“In the old days we used to have a mechanical device that would follow the speed/distance profile of the cage, or skip winder,” said Krishnan Nair, general manager Automation and Drive technology for Winder Controls Australia.

“It made sure that at every point in the shaft the cage was travelling at the correct speed and did not exceed its maximum travel limits. If anything went wrong, you could have a catastrophic situation.”

Because mining technology has evolved, companies have moved away from the mechanical version and are now using electronic PLCs, which is where Pilz’s Programmable Safety

Pilz offered a safety PLC that would monitor the winder of a mine shaft cage that transported workers up and down the mine.

System (PSS 4000) came into play.

In the not-too-distant past, a cage going up and down a shaft at the wrong speed caused a lot of accidents and even deaths — something that is avoidable today.

“We were evaluating a number of products and came across the Pilz PSS 4000,” said Nair. “Back in the dim dark ages they never had devices like this and they used to have lots of accidents in the shaft because there is a possibility of something failing.

For example, if a cage was coming up the shaft, and then for some reason the electronics failed, and it didn’t slow down and went past its normal

34 www.pacetoday.com.au AUGUST/SEPTEMBER 2017

stopping place, it could go up further and crash into the headframe.”

Nair was at pains to point out that the safety aspect was the key ingredient, therefore reliability and failsafe behaviour were the cruicial aspects of the solution.

“The important thing is that as safety is so paramount, we needed a totally reliable safety PLC that could shadow the cage anywhere in the shaft and make sure the winder kept to it limits,” he said. “The minute it exceeds or breaches any of its limits, it puts out a signal and trips the safety circuits, which in turn applies the brakes and brings the conveyance to a stop. And of course

we need to be able to identify why the system has come to a stop, so a simple visualisation of the system is important, along with detailed diagnostics.”

Pilz’s scope of the project was the turnkey supply of the safety PLC cabinet that includes the design, supply, installation and testing of all safety PLC components. The components were selected to be Safety Integrity Level 3 capable and included PSS 4000 hardware, Pilz’s Safe Encoders (PSENenc) and Pilz’s latest visualisation software (PASvisu). With PASvisu the user can track the winder every step of the way as well as quickly and easily identify any faults when and if they

occur. While the winder is still at the commissioning stage, Winder Controls has put the system through its paces and is happy with the outcomes.

“We built a prototype, thoroughly tested it and it passed with flying colours,” said Nair. “We did everything in house. We bought the device from Pilz and then programmed it, got it working and commissioned the first one. We’ve not gone into operation just yet but in the next couple of months we will.

“We have simulated the wind at the top and bottom so you can count by the number of drum revolutions where you are in the shaft. This is what we call Commissioning Without Ropes and that has been very successful.”

As with any type of new application, there were a few minor problems but nothing that held the project up from going forward. This is where the support that was by Pilz was critical.

“I’ve been in contact with them over the journey, said Pilz technical support manager Adam Hallinan. “There were some little teething problems at the start that included working out the exact functions for the application. We had to do a little bit of back and forth between them and Germany to fine tune everything to do exactly what they needed it to do.”

So why a Pilz Safety PLC? There are plenty of others out there, but as Nair points out, “it’s horses for courses. The PSS 4000 had the features necessary to complete the task.

“When it comes to safety, the Pilz PSS 4000 has a number of features that are very useful,” said Nair. “It is in that regard that we picked this Safety PLC. The company has been very helpful.

Because this is the first time we are using a Pilz Safety PLC in this application, we had a few teething problems and they came over straight away to help us. Although we wrote the software ourselves, there was a lot of help from them on how to optimise the software.

We put it through its paces and initiated all kinds of faults to see how it pulls up the winder. It was all good.”

The next stage is putting the system in place into the mine shaft. As far as the safety aspects go, Nair is happy that the Pilz System will do its job after the rigorous testing and has no issues moving forward with finishing the job.

“When it came to the speed distance protection and safety, the PSS 4000 fit the bill very well.”

Coupled with the PASvisu visualisation software it works well and, most importantly, solved a big problem - the winder is now safe. PACE

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ARTIFICIAL INTELLIGENCE

The future of human labour and AI Self-learning machines and smart robots are the basis for future technologies in many industries says Hager Unternehmensberatun’s Andreas Wartenberg.

E

xtensive progress has been made with artificial intelligence (AI) over the past few years – Watson, Siri, and Deep Learning are just a few examples that show how AI systems can now perform services that can be classified as intelligent and creative.

Companies that want to optimise their business or save costs will hardly be able to dispense with AI. A computer, much like a human, saves knowledge gleaned from experiences and can then independently derive solutions – based on algorithms – to new and unknown problems. To do this, a computer program analyses samples and, using self-learning algorithms, tries to recognise certain patterns and regularities in the data.

The world is becoming more complex, meaning that a well thought-out and wise use of our human resources is required. This is where high-quality computer systems can help. It also applies to applications that require intelligence. The downside of AI is that the possibility of intelligent machines is something that scares many people who argue that intelligence is something unique, something that sets humans apart from machines.

Economists expect that this technology will increase prosperity.

Previous studies have been restricted to investigating the impact of intelligent automation. An example is when machines in networked factories communicate with each other or when autonomous vehicles, transport goods or people without drivers. This view, however, neglects other growthstimulating effects of intelligent systems — artificial intelligence will support people in their work and make them more productive.

Another consideration is that machine learning is becoming more mainstream. While self-learning programs were only to be found in universities, research institutions, and some technology companies up until a few years ago, nowadays they are finding their way into ordinary products

The world is becoming more complex, meaning that a well thought-out and wise use of our human resources is required. and solutions. Our everyday life and business lives are increasingly being determined by intelligent programs that learn from data and extrapolate from what they have learnt.

Speech recognition on mobile phones, for example, is essentially controlled by machine-learning algorithms – much like the spam filters in PCs and notebooks or face detection in the management of photos. We are often in contact with learning systems without being aware of it.

Although robots can take over communications, computing, and thinking, there will be limits even here. There will still be the need for highly qualified professionals, such as engineers, architects, or judges. Also tasks, whose dexterity remains beyond that of robot fingers, will remain for the foreseeable future.

Machines cannot replace the emotional intelligence of a person.

Occupations that require social skills or creativity or represent a high-quality personal service cannot be substituted

by AI.

36 www.pacetoday.com.au AUGUST/SEPTEMBER 2017

Certainly, some professions will disappear completely and, in many areas, the requirements will change greatly. However, there is no need to panic just yet.

Tech companies such as Apple and Microsoft want to automate as many working processes as possible with learning machines.

The employees of tomorrow must be more flexible, because in the future man will have to adapt to the computer and not vice versa.

Employees will have to adjust to more flexible working practices — a fixation on permanent locations and times is often no longer required.

This implies more flexibility and freedom on the one hand, but on the other hand, that work and personal time will intermingle. In addition to the technical expertise, specialist and managerial staff must bring a more in-depth process knowledge and have a higher willingness to undergo independent and ongoing training in the appropriate technologies.

According to Bernhard Rohleder,

managing director of German digitial association, Bitkom, new, exciting and challenging jobs will be created.

However, they require a good education and offer much creative freedom and responsibility.

The number of workers with low-grade qualifications will fall, but staff with correspondingly high, mainly digital skills, are now already increasingly in demand. The number of employees in the IT industry has been increasing continuously for years, as do the number of vacancies in this sector that are difficult to fill.

And there’s more. Even if artificial intelligence means that we are talking about machine learning, a harmonious combination of machine and human intelligence working as a single unit is required to develop theories and to confront challenges.

Working on the basis of the existing data, it is possible to develop company-specific business ideas, whether in the form of products, processes, or new data-based business models. PACE

NEW PRODUCTS

High power packed in a compact housing THE new Automation PC 2100 from B&R unites the PC world with hard real-time applications. If needed, Automation Runtime and Windows can run at the same time thanks to powerful Intel Atom multi-core processing technology, allowing the unit to be used simultaneously as a high-performance industrial controller as well as a PC for things like sophisticated HMI applications.

Available with single-, dual- or quad-core processors, the computing power of the Automation PC 2100 is fully scalable. At the upper range of performance, it is said to exceed the performance of many Core i-series processors. Regardless of the variant, the absence of fans or other rotating components means that no maintenance is required. Other features include two Gigabit Ethernet interfaces as well as one USB 2.0 and one USB 3.0 interface. Fieldbus connections such as Powerlink or CAN can be individually configured, and compact MLC-based CFast cards with 60GB or more are available to meet memory needs.

The graphics engine used by Intel Atom processors is derived from Core i technology and provides powerful processing all the way up to Full

HD. This is also the first time that support for DirectX 11 is provided in this segment, opening up even more possibilities for enhanced graphic capabilities in SCADA and other HMI systems.

Daanet 1300 322 638 www.br-automation.com

Oil-free, low-noise compressor technology THE PureAir Ultima compressor is a water-cooled, oil-free unit that is part of Gardner Denver’s CompAir range of products. Ultima is available in models from 75kW to 160kW and is designed to be the perfect compressed air solution.

CompAir has developed the U-Drive unit, a variable speed permanent magnet synchronous motor that is capable of speeds up to 22,000 rpm.

“U-Drive is a true, next-generation motor and the result of three years’ development,” said Ulrich Thomes, senior technical engineer and leader of the engineering team responsible for Ultima’s design. “We believe that this is one of the most advanced compressor drive technologies available to customers today and ideal for a pioneering product such as Ultima.”

Ultima utilises two motors simultaneously, each powered by its own inverter.

Forgoing the single motor and gearbox design, Ultima runs each dry screw air end directly for enhanced performance and

lower levels of friction. An intelligent digital gearbox links the two U-Drive units, adjusting their speeds continuously. The ability to run both air ends at different rates, depending on demand, means Ultima can perfectly match the delivery ratio for optimum efficiency.

Around 94 per cent of compressor energy is converted to heat energy that can be easily wasted. Ultima aims to prevent this. Offering up to 12 per cent better heat recovery than a standard two-stage, oil-free compressor, Ultima features a closed-loop, water-cooling system that takes heat from all major components. This water can then be piped out of the machine to be used elsewhere.

For maximum performance, the air entering a compressor should be as cool and dense as possible, so the Ultima is designed to vent no warm air into the compressor room. Instead, warm air is processed and cooled within the unit, where it is re-circulated around the compressor via the base frame. This design ensures minimal waste, eliminates the need for external ducting, and prevents dust and particles from entering the compressor.

Its bespoke construction means that a 160kW compressor runs at 69 dB(A) noise level.

Gardner Denver Industries 03 9212 5823 www.gardnerdenver.com/industrials

New push-in device needs no tools for connection Phoenix Contact is offering a new range of products that feature push-in connection technology with the release of its M12 connector. The new product complements the existing M12 connector portfolio, which includes Quickon, Crimp, Screw and Piercecon connection technology. Designed for easy assembly whether on-site or out in the field, the connector is a suitable connection technology for the transmission of data, signals and power.

The direct plug-in capability of the device means installation can occur quickly and efficiently. Whether working with solid conductors or conductors with ferrules, the Push-in M12 connector lets technicians connect directly to the terminal point, making the process simple. The new device does not require the use of tools. The technician lifts the coloured lever on the terminal point to connect or release the corresponding colour-coded conductor.

As no soldering is required to connect conductors to the device, the opportunity to damage the connector, or for human error to occur, is reduced.

Shock and vibration resistant, the Push-in M12 connector features a springcage connection to secure the conductor to the M12 even under harsh conditions. Plus, the SPEEDCON fast locking system provides maximum contact reliability.

Phoenix Contact 1300 723 399 www.phoenixcontact.com/online/portal/au

AUGUST/SEPTEMBER 2017 www.pacetoday.com.au 37

NEW PRODUCTS

Hygienic design meets high-performance machine technology SMC’s hygienic guide cylinders (HYG ) cylinder uses guided rod cylinders and is designed for use in machine applications where hygiene needs to be considered. This series has many features including high lateral load resistance, as well as smooth surfaces to enable easy cleaning.

The improved water resistance is achieved by new socket, seal and scraper

options, optional NBR or FKM seals/scrapers on guide, and piston rods.

They can also operate with a choice of lubrication grease – standard grease for normal environments without spray water, and food safe grease for environments with water and chemicals A coating applied to the piston rod guide (PAT), and with its cleverly designed air relief ports on the guide, the released air is outside of the spray water environment. Due to the design of the HYG cylinder, mounting is possible in three positions: from the top, side or from underneath. Plug bolts are used to close the mounting holes not used.

SMC Australia | New Zealand 1800 763 862 www.smcworld.com/en/

Elbow flow conditioner for accurate wastewater flow measurement PROCESS and plant engineers who can’t find room for the recommended straight pipe run required by liquid flow meters in their municipal water treatment plant retrofit projects will find the Vortab elbow flow conditioner eliminates the problem by removing swirl and asymmetric profiles caused by pumps, valves and other equipment placed too close to the meter.

To provide accurate and repeatable flow measurement, electromagnetic and other types of flow metering technologies used in municipal plants for drinking water require a specific amount of straight pipe to be run upstream and downstream from the installed location of the meter.

The straight pipe runs create a swirl-free and symmetric velocity profile in the pipe that can be measured accurately over and over again.

When flow meters are moved or added during retrofit projects at municipal water treatment plants to accommodate new equipment, such as pumps, valves or other devices, problems can occur. Often there isn’t enough available plant real estate left to support the new equipment.

The elbow flow conditioner nearly eliminates the flow meter upstream piping requirements by conditioning the flow stream into a flow regime, mimicking adequate straight run.

In addition to conditioning the flow stream, the 90-degree angle tab-type elbow flow conditioner eliminates the pipe cost and technician labour for the five to 10 upstream and three to five downstream pipe diameters required by many types of flow metering technologies.

The device isolates the flow irregularities and conditions the flow stream into a swirl-free and symmetrical velocity profile.

Swirl reduction and velocity profile correction occur naturally in long lengths of straight pipe due to diffusion and turbulent mixing.

Vortab’s anti-swirl and inclined vortex generating profile correction tabs, projecting from the inside pipe surface, generate vortices that accelerate these natural pipe effects to create a uniform, non-swirling, symmetrical flow profile in a much shorter section of pipe.

The elbow flow conditioners can be made from carbon steel, 316L stainless steel or Hastelloy C-276. A variety of process connections are also available– ANSI flanges, male NPT threads, butt-welded preps or retaining wafers.

AMS Instrumentation & Calibration Pty Ltd 03 9017 8225 www.ams-ic.com.au

Award-winning ultra-rugged scanner ZEBRA Technologies has announced that its DS3600 series Ultra-Rugged Scanner has won an Outstanding Product Innovation award from Good Design.

Good Design Australia is an institution that celebrates design and innovation.

According to Good Design, the scanner was one of the submissions that met and exceeded the criteria of the jury. The jury consisted of 35 international design experts and assessed 244 shortlisted entries from all around the world. “[The scanner series has] beautifully detailed design with solid ergonomics and fit for purpose functionality – the designers have done a remarkable job in designing for use in harsh environments,” said a member of the jury.

“The jury commends the clever positioning of the main user interface at the top of the unit to enhance the overall functionality and ease of use of the scanner.”

The scanner offers the industry’s highest drop, tumble and sealing specifications in its class and can survive an eight-foot drop to concrete, as well as being dustproof, sprayproof, and waterproof. It features an IP65-sealed cradle.

The company’s researchers and designers tested a range of end-users’ hand sizes and warehouse applications to arrive at the final design. The series features design elements that are focused on ergonomics and comfort for 38 www.pacetoday.com.au AUGUST/SEPTEMBER 2017

warehouse workers who need to hold the devices for long periods of time.

Zebra Technologies 1 800 457 439 www.zebra.com/ap/en

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RELIABILITY AND OPERATIONAL CERTAINTY Proudly supported by

Emerson and Prime Creative Media have partnered to host workshops and seminars targeting production optimisation, reliability improvements, plant safety and emissions reduction. International speakers and local experts will present Reliability & Operational Certainty case studies across multiple industries.

Monday 28 August 2017 - Brisbane Wednesday 30 August 2017 - Melbourne Friday 1 September 2017 - Perth To see the full program and to register please visit

bit.ly/EmersonConnect

For enquiries, please contact Simon Coburn 03 9690 8766 or simon.coburn@primecreative.com.au