A&D Apr-May 2017 by publish-industry India

VOL 10 | APR-MAY 2017 | ` 100 www.industr.com

A U TO M AT I O N & D R I V E S

GOING DIGITAL & CONNECTED

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Industry

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microScan3: A NEW GENERATION OF SAFETY LASER SCANNERS.

What happens when SICK, the market leader for safety sensors, brings together its comprehensive knowledge, extensive experience, and cumulative innovative strength in a new safety laser scanner? The answer is easy: the microScan3 – setting a new standard for the safety and productivity of your applications. Every single detail has been carefully thought out to provide the best possible solution for your requirements where the protection of machines and systems is concerned. Innovative scan technology, rugged design, intelligent connectivity, and intuitive operation are characteristics that can't fail to impress at ﬁrst glance and will keep on inspiring you time and time again. We think that’s intelligent. www.sick.com/microScan3

E D I TO R I A L

The way ahead! Manufacturing may be facing some headwinds, but it’s undeniably in the midst of a technological renaissance that is transforming the look, systems, and processes of the modern factory. Manufacturers, big or small, today, can’t afford to ignore the technology advances. They have no choice but to embrace technological advances to improve plant productivity, ensure product quality, compete against rivals, and maintain an edge with customers. With this, manufacturing executives will have these critical questions: Which technology investments will have positive influence on my business? What breakthrough equipment, ideas, and processes will have the greatest impact on factory environments? What is the value potential, return on investment, and risk of investing in these technologies? We interacted with a few industry leaders, to understand the major technology advances in manufacturing, concerns on data security, and readiness of Indian factories to adapt to new technology concepts such as IIoT, Industry 4.0, etc. Most of the people are of the opinion that the major latest technologies will emerge from digitisation of the existing infrastructure, with connected systems. There will be a convergence of automation and IT, and end-to-end energy management as well as data management will be a need of the day. Although the emergence of IIoT and Industry 4.0 is expected to ensure prominent growth in the Indian industry, the progress would be comparatively slow. The industry still lacks the right understanding of the concepts. Check out the Cover Story for interesting and varied views from industry leaders & experts on adoption of advanced technology and the way ahead. I am happy to inform you that, with this issue, A&D India is entering into its 9th year of operation. We would like to thank the members of our editorial advisory board, our contributors, associates and the advertisers, who supported us in our success route. Best wishes!

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EDITORIAL ADVISORY BOARD

Shekhar Jitkar Publisher & Chief Editor shekhar.jitkar@publish-industry.net P V Sivaram MD – B&R Automation President – AIA (Automation Industry Association)

Ravi Agarwal Director, Pepperl+Fuchs (Factory Automation) Vice President – AIA

Raj Singh Rathee Anup Wadhwa Managing Director Director – AIA Kuka Robotics India (Automation Industry Association) Jasbir Singh Vice President – Electrical Ganapathiraman G & Instrument Vice President & GM Essar Project Management (South and South-East Asia) Consultants ARC Advisory Group Anant Maheshwari President Honeywell India

Dr KLS Sharma Advisor Automation Education & Training Mandar Phadke CEO, Abhisam Software Former Head – Process Control Lanxess India Pvt Ltd Arcot Rajabahadur Automation Consultant Thampy Mathew Chairman, Fieldbus Foundation India Regional Sales Director, Pepperl+Fuchs (Process Automation)

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A & D I n d i a | A p r- M a y 2 0 1 7

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CONTENTS

Market

Management

Cover Story

NEWS 16

“ENERGY EFFICIENCY AS A BUSINESS MODEL”

Interview with Ajay Bhargava, Managing Director, Rittal India

Chemical & Process Industry

GOING DIGITAL & CONNECTED

The cover story feature discusses viewpoints from industry stalwarts on the advanced techonology trends & impact of digitalisation in the global and Indian contexts

Introducing www.industr.com - a new website, designed with a fresh new look and user-friendly navigation, updated with the latest information on the manufacturing technology world Available on all digital devices globally, www.industr.com is an umbrella portal that integrates content of our two magazines – EM (Efficient Manufacturing) and A&D India (Automation & Drives). Click and be a part of our online community!

Focus

ADOPTING ENERGY EFFICIENCY IN PROCESS INDUSTRIES

The feature explores the ways in which energy efficiency can be ensured in three key sectors in manufacturing

CONTENTS

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Technology

Gears & Motors 48

FORMS OF CLOSED LOOP STEPPER CONTROL

The article explains how the various shortcomings of stepper motors can be overcome by leveraging the method of closed loop stepper control 52

Software & Engineering Tools 58

CONTAINERS USING SIMULATION

The article highlights the challenges faced in making light weight bottles and how the use of multi-disciplinary simulation has revolutionised the bottle-making process

DRIVING LESS POWER CONSUMPTION

An application story on the usage of servo motor by the manufacturer of precision camera gimbal systems that consumes less power compared with other motors, allowing the unmanned aerial vehicle to stay airborne for longer

Control & Communication 62

mapp technology; Data logger; Data communication protocols; Smart measurement systems;

Decentralised drive solutions; PCB connectors; Gripping modules Laser sensors

Energy chains; 3D measurement system; Condition monitoring system;

MAKING FLEXIBLE CONTROL SYSTEM

Manufacturing IT

TWO SIDES OF THE SAME COIN

The feature briefs on the holistic approach required to ensure flexibility and availability in the smart factory

New Products

The article discusses how a flexible control system can be attained with the help of a remote I/O solution

Safety & Security 54

DESIGNING STRONGER, LIGHTER GLASS

REALISING ENHANCED PRODUCTION EFFICIENCY

The feature illustrates how a fastmoving consumer goods company uses NX software products to reduce product development time, thereby, optimising the manufacturing process 66

TOWARDS SMART & SUSTAINABLE MANUFACTURING

A read on the need for manufacturers to adopt advanced, smart manufacturing technologies and integrate advanced automation & cloud technologies in their operations

Columns 05 06 72 72

Editorial Contents Highlights - Next Issue Company Index

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MARKET | NEWS

Joint initiative to develop next generation of 3D printing

New electronic centre from RS in Bengaluru

Premium Aerotec recently announced a joint project with experienced partners – EOS, the leading technology supplier for industrial 3D printing, and Daimler, the renowned automotive manufacturer. Together, they will develop the next generation of Additive Manufacturing (AM) in their NextGenAM project. Through this cooperation, the companies are laying Joint development of a production system for the foundations for the serial additive manufacturing has been planned implementation of this by Premium Aerotec, EOS and Daimler technology in large-scale serial manufacturing. The objective of the project is to progress the automation of the entire industrial 3D printing process. Speaking on this initiative, Dr Thomas Ehm, CEO, Premium Aerotec, said, “We need to continue developing this technology extensively in order to expand its application spectrum significantly. Together with our partners, we can thus ensure state-ofthe-art technology for our industry.” Also elaborating on the partnership was Dr Hans J Langer, Founder & CEO, EOS Group, who stated, “We are proud to be part of such a forward-looking project alongside Premium Aerotec and Daimler.”

RS Components, a distributor of electronics and maintenance products, recently announced the opening of their innovation hub, a new ‘Electronic Centre’ in Bengaluru. The high service level supplier of electronic components and tools plans to invest close to $15 million over the next two to five years at this innovation hub in Bengaluru. Speaking at the launch of this new The new Electronic Centre was recently Electronic Centre, Keith inaugurated in Bengaluru Rice, Head – Emerging Markets, RS Components Worldwide, said, “Our electronic centre at Bengaluru is a great opportunity to bespeak RS Components’ strong value proposition for our customers in the light of our technical expertise and tailor made solutions that create a huge difference in the day-to-day life of a design engineer.” Also sharing his insight on the new centre was Shiv Bhambri, CEO, RS Components India, who added, “The electronic centre at Bengaluru is a reflection of the strong Indian ESDM market and the continued growth of the Indian operations of RS Components, which has been a significant part of the electronics design and manufacturing story in India for the past 20 years.”

ABB to acquire B&R

Voith Industrial Services is now Leadec

ABB recently announced the acquisition of B&R, the largest independent provider focused on product- and software-based, open-architecture solutions for machine and factory automation worldwide. The combination will result in an unmatched, comprehensive offering for customers of industrial automation, by pairing B&R's innovative products, software and solutions for modern machine and factory automation with ABB’s world-leading offering in robotics, process automation, digitalisation and electrification. Through the acquisition, ABB expands its leadership in industrial automation and will be uniquely positioned to seize growth opportunities resulting from the fourth industrial revolution. Speaking on this acquisition, Ulrich Spiesshofer, CEO, ABB, said, “B&R is a gem in the world of machine and factory automation and this combination is a once-in-a-lifetime opportunity. This transaction marks a true milestone for ABB, as B&R will close the historic gap within ABB’s automation offering. This is a perfect fit and will make us the only industrial automation provider offering customers the entire spectrum of technology and software solutions around measurement, control, actuation, robotics, digitalisation and electrification.”

Voith Industrial Services recently announced that it will be operating under its new name – Leadec. Under its new owner, Leadec operates as an independent service company capable of aligning itself fully to the needs of the service sector and providing customised solutions. Speaking on this, Markus Glaser-Gallion, CEO, Leadec, said, “The new name serves to emphasise that we are striving for market leadership to provide our customers with a competitive edge. This is why we are going to continue to expand our core business internationally and are looking forward to exciting times ahead.” In its capacity as an affiliate of Leadec, the division of the industrial services provider that operates in the process and power plant industries will also have its own brand: Veltec. The new brands were developed to reflect the company's DNA and took account of the aspirations and values that the company represents today and would like to reinforce in the future. In India, Leadec has been operational since 2010, providing customised service solutions for the automotive industry, auto-ancillaries and manufacturing industries. With more than 1200 employees in India, Leadec is able to make a mark in Indian automotive industry, introducing various service lines and offering satisfaction to its customers.

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SINAMICS V90

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MARKET | NEWS

Honeywell introduces new IIoT offering

Manufacturing cluster in Aurangabad receives govt approval

Honeywell recently announced that it has introduced a new software-based service designed to allow refiners and petrochemical & gas processing plants to improve performance. The new Connected Performance Services (CPS) business leverages the Industrial Internet of Things to tap the company’s deep process knowledge, design expertise, and understanding of catalysis with next-generation software platforms from Honeywell Process Solutions. Speaking on this, Zak Alzein, VP, CPS, said, “This cloud-enabled service makes plants smarter and more responsive. Problems that caused plants The CPS offerings include applications to to be less efficient or less address critical challenges for refineries and productive and that went petrochemical and gas processing plants undetected for weeks or months now can be resolved quickly and proactively, and decisions that used to take days now can be made in hours. For many plants, the avoidance of downtime and suboptimal performance, and better agility can be worth millions of dollars per year.” He further stated, “The unique feature to this solution is the combination of customer operating data and UOP expertise that provides plant personnel with early-stage warnings that identify performance improvements.”

India Electronics and Semiconductor Association (IESA) has recently announced that it is assisting in setting up the first Brownfield Electronic Manufacturing Cluster (EMC) in Aurangabad. Reinstating their commitment to the Maharashtra region, IESA also stated their foray into Pune by officially announcing their Pune Chapter launch. Elaborating on this initiative, Sanjay Sethi, IAS & CEO, MIDC, said, “It is our endeavour to transform the state into a strong manufacturing-based economy and the Electronics System Design and Manufacturing (ESDM) sector IESA is forging the launch of its Pune chapter is a major thrust area for to strengthen the ESDM ecosystem us. We are elated with the government’s decision of approving the Brownfield cluster set-up (Phase-I) in Aurangabad. The EMC will not only benefit the local companies by providing them common facilities and R&D support services, but will also provide a huge boost to the electronics manufacturing in the region. The state government is committed towards the development of the ESDM sector in the state.” Additionally, IESA is forging the launch of its Pune chapter to strengthen the ESDM ecosystem in Maharashtra.

LANXESS invests EUR 100 mn in production network

Automation devices to communicate on CC-Link IE field

Lanxess recently announced that its business unit – Advanced Industrial Intermediates will be investing EUR 100 million in expanding its production facilities for chemical intermediates. Around EUR 40 million, each will be invested in the Leverkusen and Krefeld-Uerdingen sites in the federal state of North Rhine-Westphalia. The expansion project is scheduled for completion by 2020. Speaking on this, Hubert Fink, Member of Board of Management, Lanxess, said, “Organic growth is a key success factor as new Lanxess heads forward. This investment programme accompanies the dynamic development of our customers and their sectors. A high proportion of the planned new capacities is already backed by customers’ orders. At the same time, we are also strengthening our sites.” Further elaborating on accommodating growing demand on global markets, Neelanjan Banerjee, Senior Executive Director, LANXESS India & Senior VP, Business Unit, Advanced Industrial Intermediates, stated, “Benzylalcohol is one of the key products in the business unit Advanced Industrial Intermediates’ portfolio where LANXESS holds global market leadership positions. We service customer demands around the world from our production sites at Krefeld-Uerdingen in Germany and Nagda in Madhya Pradesh.”

HMS Industrial Networks recently announced that it has now extended the Anybus® CompactCom™ 40-series family with a new version, which enables any automation device to communicate on CCLink IE Field. This means that HMS now offers both embedded and stand-alone gateway solutions for any CC-Link-related HMS offers both embedded and stand-alone gateway communication solutions for any CC-Link-related communication issue issue, including CCLink IE Field. Anybus CompactCom is a range of embedded communication interfaces, which provides automation devices with connectivity to any industrial network – fieldbuses as well as Industrial Ethernet. The company now expands the Anybus CompactCom 40-series to include connectivity to the gigabit CCLink IE Field network. Speaking on this new development, Leif Malmberg, Product Manager, HMS, said, “With the new Anybus CompactCom for CCLink IE Field, HMS further strengthens the offering towards automation device manufacturers in general, and for those wishing to connect to CCLink networks.”

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MARKET | NEWS

ABB India to deliver digital substation for an IT park

Murrelektronik opens new subsidiary in India

ABB India has recently announced that it will deliver a 110 kilovolt (kV) digital substation to Technopark, the largest Information Technology (IT) park in India, based on built-up area, located in the southern state of Kerala and spanning an area of 930,000 sq m. Due to the nature of the industry, the campus is highly The technopark will be among the first dependent on reliable, digital substations in India that supports the round-the-clock power to country’s vision of smarter grids and cities serve the 350 companies employing more than 50,000 people. Speaking on this new development, Claudio Facchin, President, Power Grids Division, ABB Group, said, “This will be among the first digital substations in India that supports the country’s vision of smarter grids and cities. It highlights the increasing digitalisation of the grid, a key focus area of our next level strategy and reinforces our digital thrust based on our common ABB Ability offering.” Also elaborating on this was Pitamber Shivnani, President – Power Grids Division, ABB India, who stated, “ABB continues to pioneer technologies that support the future for India’s digital power grid and the vision of India’s National Smart Grid Mission.”

Murrelektronik recently inaugurated its new subsidiary in Bengaluru. The event was presided by Luis Rauch, Executive Board Member, Murrelektronik; Matthias Eschle Reinold, VP – Business Unit, Murrelektronik and Martin Falk, Director – Asia Pacific, Murrelektronik. “Our new office is located in Jayanagar, Bengaluru, alongside our warehouse. We will now cater to our customers & distributors directly in India Murrelektronik inaugurates its new and strengthen our market subsidiary in Bengaluru approach & commitment for the Indian market. With focus on automotive and machine tools sector, we plan to expand our reach in material handling & packaging industries too,” said Chetan TA, Managing Director, Murrelektronik India. The branch office employs a total of 13 people. The sales associates have all obtained their sales license from the company’s head office in Oppenweiler and possess a comprehensive knowledge of products and solutions. The company provides solutions that are made to measure for the applications in the field of industrial automation - from a single source.

Bentley advances Reality Modeling to extend scope

EOS & IESE to collaborate on education programme on IIoT

Bentley Systems recently announced that it has demonstrated its new ContextCapture offerings at SPAR 3D Expo & Conference (SPAR) for reality modeling that increase joint opportunities in surveying and engineering. ContextCapture capabilities now include cloud processing services, a mobile app, and photo planning for Bentley’s applications. Speaking on this initiative, Greg Bentley, CEO, Bentley Systems, Bentley technician capturing a reality mesh using said, “Reality modeling has the ContextCapture mobile application gone mainstream globally, supporting projects and assets of every domain and scale in ‘going digital’. Additionally, laser scanning is now fully incorporated, where available, and as needed to supplement photography—among hybrid inputs for engineering-ready reality meshes.” He further stated, “Our ContextCapture and ProjectWise ContextShare announcements at SPAR complete the reach for reality modeling’s fidelity, accessibility, scalability, and shareability. In the coming year, our priority at Bentley Systems is to help engineers and surveyors take full advantage of this breakthrough opportunity to broaden the scope and value of their work in going digital themselves.” ContextShare extends Bentley’s ProjectWise connected data environment to securely manage, share and stream reality meshes.

EOS, a technology and quality leader for high-end Additive Manufacturing (AM) solutions, recently announced that it will cooperate with IESE, one of the world’s leading business schools. The core of the collaboration is the executive education programme on ‘Industry 4.0: The Future of Manufacturing’. The manufacturing sector is currently facing a significant transition, with senior management facing new challenges. IESE and EOS combine their expertise in the fields of IESE and EOS combine management knowledge and technology know-how their expertise in the fields of management knowledge and technology know-how, introducing executives to new business models and opportunities focusing on the future of manufacturing. Speaking on this initiative, Marc Sachon, Professor – Technology & Operations Management, IESE Business School, said, “Remaining competitive requires future-focused leaders. The Industry 4.0 executive education programme takes a dynamic, interactive approach to developing participant skills through interactive discussions, lectures and workshops, and direct engagement with manufacturing businesses already on the transitional journey to Industry 4.0. We have the perfect partner to conduct this executive education programme.”

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NOW LOCATED IN INDIA FOR YOU

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Connectors

Automation

Power

MARKET | INTERVIEW

“Energy efficiency as a business model” Ajay Bhargava, Managing Director, Rittal India, discusses his company’s innovation of bringing value to its customers in this interaction with Maria Jerin, while highlighting Rittal’s journey towards Industry 4.0 transformation. Interview excerpts… How has been the performance of Rittal so far in India? How do you see the challenges and opportunities in the industry? Rittal started its operations in India in 1997 with a factory in Bengaluru. We started with the manufacturing of enclosures, and later entered into power distribution, IT infrastructure and software & services. We have multiple business segments and we supply products across different verticals, such as energy, pulp & paper, petrochemical, infrastructure, etc. Over the last five years, our growth rate is around 12-15% in the Indian market. Though we are facing challenges from the local manufacturers in India, we want the best quality product to be available in the market. Our innovation lies in bringing value to our customers—providing energyefficient solution is one such example. As such, our business model includes continuously educating our customers and end users to understand the benefits of our products in the long-term and from an environmental perspective. Tell us about your participation at IMTEX 2017? What were the new launches demonstrated by Rittal? At IMTEX, we focussed on our industrial cooling solutions. The machines that are used in the shop floor are inbuilt with high-end electronics, which generates a lot of heat during its functioning. So, these machines need cooling systems to run at an optimum temperature. For this, we displayed our latest innovative cooling solution called ‘Blue e+’ that provides 70% to 80% energy efficiency, compared to other products that are available in India and globally. As the global industry is moving towards the next wave of industrial revolution, what are the initiatives from Rittal towards Industry 4.0 transformation? We see Industry 4.0 as a digital transformation of manufacturing industry. Within our group, we have another company called EPLAN that is specialised in engineering and software solutions. We have also acquired Kiesling (Now called as Rittal Automation) that provides seamless integration and automation solutions. So, Rittal together with these companies

provides an edge to customers with the complete solution of Industry 4.0. In India, Industry 4.0 is in its early stage of adoption, mainly because the volume of production is not big enough in India, and the labour cost is cheap as compared to the European countries. Taking the case of our factory, we are witnessing the evolution of automation and connectivity from engineering to manufacturing; however, the final assembly is done with the help of manual labour. Therefore, we are continuously evaluating the Indian market, and once the market is ready, we will be launching Industry 4.0 services for our customers. What are the major challenges faced in the shop floor and how are your cooling systems helping them to overcome those challenges? In the shop floor environment, if you take the example of conventional cooling unit, the condensation happens that results in the leakage of water from the cooling system. We have an in-built evaporator mechanism within our cooling units that makes the system completely condensation free. We also give 3 to 5 years warranty for the compressors used in the cooling system, thus, offering zero-maintenance with highly energy-efficient solution. Also, we are launching new cooling units that are integrated with the cloud, thereby, monitoring it remotely from PC or mobile. Thus, we are making digital transformation in our cooling solutions, which provides huge benefits to customers. Going forward, what are your future plans for the Indian market in short, medium and long term? For us, investment is not a one-time phenomenon. Almost 80% of our investment happens in the machine itself for expansion, productivity improvement and upgrading the machines. We have to change the machines, which are 15 years old. We have to renew the machines with energy efficiency and more productivity. The strategy is that we are continuously expanding our output to serve our customers. In the long-term, we are evaluating a second plant when the market becomes stable and growth in consistent. ☐

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C O V E R S TO R Y | M A N A G E M E N T

GOING DIGITAL & CONNECTED

Unleashing added value...!

With the recent emphasis on digitalisation in the manufacturing sector, the need for creating a manufacturing ecosystem that allows linkage of multiple digital solutions across various platforms and in-plant connectivity is of paramount importance. Considering this approach will open up avenues for manufacturers to adopt IIoT technologies for better productivity and quality and in turn creating value to businesses. The cover story features a series of interviews from industry stalwarts who share their insights on the advanced technology trends in the age of integrated industry and the impact of digitalisation in the global as well as Indian contexts. Team A&D India 16

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M A N A G E M E N T | C O V E R S TO R Y

“Adoption of robotic automation increasing in India” “Digitalisation requires the integration of multiple technology developments with traditional control systems, including cloud computing and smart devices” G Ganapathiraman Country Manager ARC Advisory Group India

What are the major technological advancements that are witnessed globally, given that the factories and energy systems are representing Integrated Industry? We can go a step beyond ‘Integrated Industry’ and call it an ‘integrated world’. The technologies driving this transformative wave are once again connected via IoT and digitalisation. The IoT architecture builds upon current and emerging technologies, such as mobile and intelligent devices, wired and wireless networks, cloud computing, Big Data, analytics, and visualisation simulation tools. There are four main parts to this — intelligent assets with sensors, processors, memory, and communications capability; data communications and infrastructure; software and analytics; and people and business entities that use the technologies for better decision making and improved business processes and models. It is also observed that the machines will recognise faults even before they appear, which is also termed as ‘Predictive Maintenance’. How is such an approach beneficial in your industry or application areas? A sound predictive maintenance strategy can improve workforce and financial performance. With a combined view of asset availability and other operational constraints, workers can make information-driven decisions. Predictive maintenance solutions help users in industrial plants quantitatively evaluate equipment condition relative to an established baseline or standard; its value is in its diagnostic capabilities, which greatly aid users in the maintenance decision-making process. Industrial plants must investigate predictive maintenance solutions and adopt those that support core enterprise objectives. What is your opinion on the growing concern over the transmission and storage of data in a secured manner? How does the overall industry address such challenges? Digitalisation requires the integration of multiple technology developments with traditional control systems, including cloud

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computing and smart devices. Each of these developments represents new challenges for plant cyber-security teams. Many organisations recognise the limitations of strategies that rely solely upon strengthening internal cyber-security resources. Outsourcing responsibilities to external resources is already growing and the future will be more focused on suppliers assuming responsibility for sustaining security of all devices and systems. Current security processes will require review and adaptation for the broader scope of tomorrow’s industrial cybersecurity. They will have to incorporate Security-by-Design, more comprehensive authorisation, broader risk analysis and remote management of devices. With the evolution of cobots, today, humans and robots are working hand-in-hand in a safe and efficient manner. What is your opinion about the future of such technologies in countries like India? The global trend towards adoption of robotic automation is increasing in India, but is still in the early stages. For India’s push into manufacturing to be successful, we need to prepare for manufacturing as it will be five years from now. Robotic automation is, thus, clearly an integral part of the kind of manufacturing that we in India, hope to do. Although we have the available manpower, technology skills for robotic automation are lacking. This challenge can be overcome with an industryacademia partnership. How is the progress of Industry 4.0 globally and in India? How ready is Indian industry to adopt this new technology? The progress of IIoT in a connected world has been rapid. Data is freely available in India or US. Hence with IIoT, the applications & services will readily span across both corporate and national boundaries. Agility and flexibility will be key. Cloud-based solutions can offer an easier solution for connecting disparate technologies across boundaries. This can enable industrial companies to adapt faster to address changing business needs. ☐

C O V E R S TO R Y | M A N A G E M E N T

“Digitisation prioritises security and safety” “In India, we are on the course to successful implementation of IIoT at several locations in plastics, packaging and automotive industries” PV Sivaram Managing Director B&R India

What are the major technological advancements that are witnessed globally, given that the factories and energy systems are representing Integrated Industry? Digitisation is the first step towards digitalisation. Connecting all the data in real-time to a central system gives possibilities for more advanced analytics and higher benefits for manufacturing plants. Increased availability of intelligent things, and more robust and flexible means to connect them drives this effort of digitalisation strongly. In future, it’s possible to imagine devices intelligent enough to configure themselves automatically, develop alternate routes to communicate to the central facility, etc. With a view to providing Integrated Industry solutions, standardisation on open source protocols for efficient machine-to-machine communication is coming into centre stage. It is also observed that the machines will recognise faults even before they appear, which is also termed as ‘Predictive Maintenance’. How is such an approach beneficial in your industry or application areas? The latest trends in automation attempts at optimising maintenance costs by replacing fixed maintenance intervals with condition-based preventive maintenance. This enables in taking up maintenance activities only when needed, and at the same time, avoids risking system failure due to neglected maintenance. Condition monitoring makes this balancing act easily achievable. Condition dependent, predictive maintenance is the best way to optimise machine availability to maintenance costs. With B&R, customers are able to use a single system for process data acquisition, energy monitoring & condition monitoring and that too using standard component. What is your opinion on the growing concern over the transmission and storage of data in a secured manner? How does the overall industry address such challenges? With digitisation, security and safety have the highest priority. Transmission of data needs to be Ethernet based, real-time, hack-

proof and safe. The industry is fast adopting established open standards in the field of automation. OPC UA TSN (time sensitive networking) has all necessary security mechanisms as required by IIoT – encryption, user authorisation and certificate exchange. Simultaneously, open source Ethernet field networks such as Ethernet POWERLINK already have companion specifications implemented to facilitate secure & seamless connectivity right to the sensors. With the evolution of cobots, today, humans and robots are working hand-in-hand in a safe and efficient manner. What is your opinion about the future of such technologies in countries like India? The industry has moved to a human-robot collaboration approach, which reduces line stoppages and losses, while at the same time maintains and further enhances the human safety standards. There has been, and still is considerable anxiety regarding robots making humans redundant. If automated robots will take over the menial, repetitive hazardous tasks from humans, it is not a bad thing. We now need to make use of the increasing penetration of broadband to provide quality education & skills to make our manpower ‘I4.0-fit’. How is the progress of Industry 4.0 globally and in India? How ready is Indian industry to adopt this new technology? Globally, Industry 4.0 and IIoT are seeing tremendous investments and early adopters. The Indian industry, as seen, is not hurrying into implementations, but are evaluating, discussing with vendors on the available solutions and then preparing implementation cases, based on ROI. In India, we are on course to successful implementation at several locations in plastics, packaging and automotive industries. Intelligent machines, which can self-diagnose incipient faults and report autonomously, are no longer in realm of science fiction. This could even lead to machines, which then reconfigure themselves to avoid or reduce production loss. ☐

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C O V E R S TO R Y | M A N A G E M E N T

“Information is the key to business success” “Indian manufacturers need to review their present approach in a manner that increases efficiencies of their manufacturing plants & overcomes present competitive challenges using the Industry4.0 concept” Jitendra Kumar Kataria Managing Director Beckhoff Automation

What are the major technological advancements that are witnessed globally, given that the factories and energy systems are representing Integrated Industry? Digitisation and vertical/horizontal integration of machines, systems, services, supply chains and integration of customers and vendors are at the core of Industry 4.0 implementation. The contributing technologies like OPC UA, PC-based control & automation systems, cloud computing IT solutions, networking technologies, machine learning, condition monitoring and Big Data Analytics are the basis for implementing integrated factory. It is also observed that machines will recognise faults even before they appear, which is also termed as ‘Predictive Maintenance’. How is such an approach beneficial in your industry or application areas? Failures can be predicted and machine availability can be increased by real-time data acquisition of the machine parameters, operating conditions, vibration levels, energy consumption patterns, job quality & tolerance parameters & its overall status. PC-based control with its ever-increasing high processing capability will assist further in computing the acquired data in real-time & provide the required results. With implementation of predictive maintenance, one can arrive at a right decision, which can result in reducing downtime cost, better inventory management of service parts, better inventory cost management, avoidance of costs due to emergencies and many more derived benefits. What is your opinion on the growing concern over the transmission and storage of data in a secured manner? How does the overall industry address such challenges? Today, information is the key to business success and profitability. Data security is a matter of concern & hence global industrial standards organisations like OPC Foundation have developed interoperability standard OPC-UA for the secure and reliable exchange of data in the industrial automation space and in other

industries. Security is a fundamental requirement for OPCUA and therefore, integrated in the architecture. Also, India Inc is cautiously graduating to a global level in terms of cloud computing or data sharing because of data security concerns and trust deficiency. With the evolution of cobots, today, humans and robots are working hand-in-hand in a safe and efficient manner. What is your opinion about the future of such technologies in countries like India? Because cobots are meant to work seamlessly with manual workforce, the infrastructure investments required is optimal vis-a-vis for robots. Being easy to handle, install & teach, the technology just cannot be ignored. With the ‘Make in India’ initiative, many investments are happening in India and certainly skilled manpower requirements are going to increase. Cobots working along with skilled labors can help increase productivity for such skillful tasks. How is the progress of Industry 4.0 globally and in India? How ready is Indian industry to adopt this new technology? The progress of IIoT in a connected world is enthusiastic about implementing Industry 4.0. It is indeed a global phenomenon but many industries still lack the right implementing strategy for Industry 4.0. Many are planning to initiate projects in this direction. However, most of them lack the right understanding of this concept and either set wrong benchmarks or get misled by commercially motivated proposals. Indian manufacturers need to review their present approach in a manner that increases efficiencies of their manufacturing plants & overcomes present competitive challenges using the Industry 4.0 concept. There is urgent need for Indian industries to focus on digitising, automating & interconnecting their manufacturing processes & business operations using appropriate automation technologies. IT-enabled services will play a vital role in the future of manufacturing and cannot remain isolated. ☐

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C O V E R S TO R Y | M A N A G E M E N T

“Significant demand for skilled manpower” “The skill requirement of the manpower will change and move in the direction of higher skill levels as we grow towards higher levels of productivity in the industry” Bipin Jirge Managing Director IFM Electronic India

What are the major advantages that are witnessed globally, given that the factories and energy systems are representing Integrated Industry? There are many advantages of connected or digital factories. Some of them are trend analysis and predictive maintenance, increased productivity of machines, less inventory costs, one piece lot size for production and higher safety of operations by connecting many related processes. It is also observed that the machines will recognise faults even before they appear, which is also termed as ‘Predictive Maintenance’. How is such an approach beneficial in your industry or application areas? Predictive maintenance is one of the major benefits of these technologies, which can bring down machine downtimes immediately. Also, with digitisation of machines, we can plan the spare parts order and procurement processes as well as conduct analysis online and in real time. In this context, technologies related to IO Link will revolutionise sensors and actuators. By using the IO Link technology, sensors and actuators can give a lot of data hidden inside such devices. This is a big advantage in the direction of intelligent sensors and intelligent machines. What is your opinion on the growing concern over the transmission and storage of data in a secured manner? How does the overall industry address such challenges? Security of data storage as well as communication is a major challenge whenever machines are connected to open networks like internet. Although sophisticated algorithms have been developed, which are quite secure, there will be a race against fraudulent/hacking attempts into these systems. This will be an ongoing process so as to improve security against such attacks. Earlier, it was said that robots will replace human jobs, but

with the evolution of cobots, today, humans and robots are working hand-in-hand in a safe and efficient manner. What is your opinion about the future of such technologies in countries like India where there is good manpower availability, but lack of technology skills? In countries like India, there is a significant demand for skilled manpower. Therefore, initiatives such as ‘Skill India’ are important. However, it will take time to develop and upgrade the skills of our manpower. Also, the skill requirement of the manpower will change and move in the direction of higher skill levels as we grow towards higher levels of productivity in the industry. Hence, if we can upgrade the skills of our manpower at a pace needed by the industry, the industry will certainly use this skilled manpower instead of using capital-intensive methods like employing cobots. However, if the work needed to be done is hazardous or demands multiple skills at one location, the industry then may consider employing cobots. On the other hand, cobots themselves have become safe to work along with humans on the same factory floor. How is the progress of Industry 4.0 or IIoT globally, and in India? How ready is Indian industry to adopt these new technology concepts? Globally as well as in India, Industry 4.0 is a journey which will take some years to evolve. Several big companies in India have already started this journey and many medium and small scale companies are aware of this concept. Big companies will start implementing these concepts earlier as they have the financial capability to invest in the technology and employ skilled manpower. However, this will percolate to MSMEs as well once the industry impact of this investment made by the big companies is evident to the MSMEs. Furthermore, in order to harness the advantages of connected factory, suppliers of bigger companies may also have to become connected. ☐

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C O V E R S TO R Y | M A N A G E M E N T

“Cobot market is picking up in India” “Secured data transmission and its storage is a real challenge in digital industry. Industries are hesitant in data transfer for want of secured manner” Vivek Gupta General Manager & Head Instrumentation Department DCM Shriram Limited

What are the major technological advancements that are witnessed globally, given that the factories and energy systems are representing Integrated Industry? Currently, process & electrical energy systems are not connected in the true sense. To master the growing complexity of energy systems resulting from greater integration of renewable sources of energy, these systems have to become more flexible and smarter in the coming years. That means industrial power grids will also become more digital. As part of this digitalisation, industrial enterprises face new challenges. This requires intelligent hardware & software products and end-to-end energy management. It is also observed that the machines will recognise faults even before they appear, which is also termed as ‘Predictive Maintenance’. How is such an approach beneficial in your industry or application areas? Predictive maintenance will be quite beneficial in terms of knowing in advance the health of the machine and, thereby, taking planned shutdown rather than a breakdown. Technologies have come, which show the trend in terms of pressure, level, vibration, temperature, etc, which is in turn helpful in taking decisions. Also, manual collection of data is eliminated resulting in quicker detection of mechanical breakdowns. Industry data with analytics will play a vital role in this direction. It is important to understand how the data is captured, verified and then reproduced in an intelligent manner. What is your opinion on the growing concern over the transmission and storage of data in a secured manner? How does the overall industry address such challenges? Secured data transmission and its storage is a real challenge in digital industry. Industries are hesitant in data transfer for want of secured manner. DCS are not connected with internet and not even with SAP in most of the process industries in India. With adoption by large industries, confidence will increase and newer

methods will be invented, which will make other small/medium industries to step forward. IT giants will have to bring more robust cyber security, thus, making this trustworthy. With the evolution of cobots, today, humans and robots are working hand-in-hand in a safe and efficient manner. What is your opinion about the future of such technologies in countries like India? The cobot market is picking up in India. Economic-skilled manpower is becoming difficult. In this light, cobots are good— they are not meant to fully replace the labour, rather collaborate with them. They work alongside humans and optimise & automate time-consuming, repetitive and physically challenging activities in the production flow. They are good in task-driven industries like manufacturing, assembly, automotive and food processing. It will help the production staff to help increase productivity, quality and market competitiveness. Increased awareness, specified technical trainings and job opportunities will help technology to win over the Indian market. How is the progress of Industry 4.0 or IIoT globally, and in India? How ready is Indian industry to adopt these new technology concepts? Smart manufacturing / smart factory and Industry 4.0 calls for increasing connectedness and automation of devices. Every device or machine has to be ‘smart’. With smart human machine interface (HIS), the manpower has to be equally smart. Growing population, ever-increasing need of complying with global standards, constant need for improving operational excellence, etc are the factors that are constantly slowing the pace towards Industry 4.0. Data security is another aspect. After the announcement of ‘Make in India’, ‘Digital India’ & ‘Smart Cities’, the manufacturing sector has seen a boost. Sectors like automotive, F&B and pharmaceutical sectors have certainly started working on Industry 4.0, but SMEs are yet to step into this. ☐

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C O V E R S TO R Y | M A N A G E M E N T

“Industry 4.0 is all about connectivity” “Industry 4.0 and IoT demand continuous communication through all levels within the digital factory and into the cloud, and security is a prerequisite for making use of such services” Martin Rostan Executive Director EtherCAT Technology Group

What are the major technological advancements that are witnessed globally, given that the factories and energy systems are representing Integrated Industry? In the past, manufacturing focused on mass production—large quantities, high quality, low costs. Integrated Industry means the convergence of automation and IT for more flexible, dynamic and transparent production, including self-organisation and optimisation. One major goal is the efficient manufacturing of smaller lot sizes, such as it is required for customised products. It is also observed that the machines will recognise faults even before they appear, which is also termed as ‘Predictive Maintenance’. How is such an approach beneficial in your industry or application areas? Real-time data about the machine parameters & its overall status can be acquired by sensors & monitored centrally for appropriate alarms & alerts. Failures can be predicted and down-time can be eliminated or reduced by Predictive Maintenance. EtherCAT enables machine controllers to play an important role in achieving such results, since they can provide the real-time capability for demanding data acquisition, which is needed for condition monitoring tasks such as vibration analysis. What is your opinion on the growing concern over the transmission and storage of data in a secured manner? How does the overall industry address such challenges? Concerns regarding data security of cloud-based digitisation are still prominent and influential for the top management in industries. Trust can only be earned by handling cyber security topics carefully and seriously. Industry 4.0 and IoT demand continuous communication through all levels within the digital factory and into the Cloud, and of course security is a prerequisite for making use of such services. Since EtherCAT is not based on IP-Protocols, this Industrial Ethernet technology blocks IT cyber-attacks by design. For the vertical connectivity above the machine control level,

which requires use of IP-Protocols, the EtherCAT technology Group is cooperating with the OPC foundation (OPCF)— ETG and OPCF combine forces to integrate systems into an Industry 4.0 and IoT conformant communication. With the evolution of cobots, today, humans and robots are working hand-in-hand in a safe and efficient manner. What is your opinion about the future of such technologies in countries like India? Yes, collaborative robots have been around in India and are being used by a few automotive manufactures. Since these cobots are still expensive and require highly-skilled experts to set-up, maintain and operate, this approach requires considerable investment. We, therefore, see the short-term usage predominantly confined to areas where these systems don’t replace human workers, but where the robot precision is required for achieving the manufacturing result. How is the progress of Industry 4.0 or IIoT globally and in India? How ready is Indian industry to adopt these new technology concepts? The Indian industries, having access to their foreign partners in developed countries, are proactively positive and are already digitising essential functions within their internal vertical operations processes. But the majority of Indian companies – especially local ones and SMEs – still need to understand the core of this technology concept and attempt to increase performance of manufacturing plants. Industry 4.0 is all about connectivity. Understanding how machines enabled by real-time Ethernet fieldbus communication are efficiently and securely networked with ERP and MES systems and also with cloud-based services is essential. We see an urgent need for top & middle level management to consider and focus on digitising their processes and manufacturing technologies—not only in greenfield projects, but also in brownfield projects. ☐

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M A N A G E M E N T | C O V E R S TO R Y

“Technological progress is a mixed blessing” “Automation can’t be stopped by fiat or regulation. With our weak record so far in capital goods development and manufacturing, we are unlikely to become the centre of production of the means of automation. Thus, our push into manufacturing will take time to fructify” Chetan TA, Managing Director – India, Murrelektronik Pvt Ltd

What are the major technological advancements that are witnessed globally, given that the factories and energy systems are representing Integrated Industry? There will be an increased need for manufacturers—independent, harmonious specifications. New communication models will emerge that will bypass the controls. We will need to adapt new communication protocols like OPC US and MQTT to our devices. These advances will make communication with the cloud easier — the goal is to communicate directly from the shopfloor to the office floor. It is also observed that the machines will recognise faults even before they appear, which is also termed as ‘Predictive Maintenance’. How is such an approach beneficial in your industry or application areas? Predictive maintenance helps prevent downtime by notifying maintenance when devices have reached the end of their lifetime. This could be as simple as changing out a cable or an entire valve island or power centre. Machine builders are interested in implementing devices with PM because the more information they have regarding the condition of their systems, the maintenance will be better. Murrelektronik has embodied the PM approach in our Emparro power supplies, Mico Pro current monitoring, and we are working on a joint development project to bring this technology into our cordsets. With the evolution of digitalisation, there is also a growing concern over the transmission and storage of data in a secured manner. What is your opinion on this, and how do you think the overall industry is addressing such challenges? We see the opportunity for a security gateway that secures the communication and firewalls against hackers and manipulations attempts, as well as machine-to-machine communication (security protects safety). Another important area will be the protection of digital property and proprietary

A & D I n d i a | A p r- M a y 2 0 1 7

information – it’s vital to define transparency and publication of information, especially when components from different manufacturers are working together. Murrelektronik is part of the Leaders Circle in the German Electrical and Electronic Manufacturer’s Association (ZVEI) and is helping define the requirements and solutions to these challenges. Earlier, it was said that robots will replace human jobs, but with the evolution of cobots, today, humans and robots are working hand-in-hand in a safe and efficient manner. What is your opinion about the future of such technologies in countries like India where there is good manpower availability, but lack of technology skills? Technological progress is a mixed blessing. It is changing the nature of work in ways we don’t realise. Automation can’t be stopped by fiat or regulation. With our weak record so far in capital goods development and manufacturing, we are unlikely to become the centre of production of the means of automation. Thus, our push into manufacturing will take time to fructify. If we want it to be successful, we need to prepare for manufacturing as it will be five years from now, not the way it was five years ago. How is the progress of Industry 4.0 or IIoT globally, and in India? How ready is Indian industry to adopt these new technology concepts? Since our products are Industry 4.0 ready, we are seeing increasing demand from the last two years. In reality, the maximum growth in India for Murrelektronik has come from our Cube67 Field IO & decentralised system. But the challenge remains on our infrastructure and increased networks speeds to make shopfloors IIoT ready. There is an increasing realisation today that the manufacturing sector’s need is just not availability of space & raw materials. The digital network needs to be at par with the western countries so that we remain competitive & attract global manufacturers. ☐

C O V E R S TO R Y | M A N A G E M E N T

“Human-robot collaboration is part of Industry 4.0” “At the centre of change are industrial robots that are going from being heavy, inaccessible and dangerous machines to becoming production assistants, working side by side with a human” Pradeep David Country Head – India & Sri Lanka Universal Robots

What are the major technological advancements that are witnessed globally, given that the factories and energy systems are representing Integrated Industry? The revolution of manufacturing industry is currently in version 4.0. Industrial robotics has proven to be a key technology for flexible automation in manufacturing and assembly. At the centre of change are industrial robots that are going from being heavy, inaccessible and dangerous machines to becoming production assistants, working side by side with a human. Technical and legal norms clearly state whether a certain application is hazardous for a human and whether it is acceptable in a workplace. Emergence of collaborative robots has begun an era of new opportunities for industry, enhancing elasticity of production processes while maintaining safety. With the evolution of digitalisation, there is also a growing concern over the transmission and storage of data in a secured manner. What is your opinion on this, and how do you think the overall industry is addressing such challenges? Our cobots come with internet connectivity via the Ethernet port. We are committed to protecting the Intellectual Property of each of our clients. The following communication technologies and protocols have been used in Universal Robots: TCP/IP 100 Mbit, Modbus TCP, Profinet and EthernetIP. All four communication protocols are available for free within each cobot. A major trend in the wave of Industry 4.0 or IIoT is the DIY concept, which allows for greater customisation and ensures that the data is secured within the walls of the organisation.

availability, but lack of technology skills? According to a PwC survey of US manufacturers, over one-third of manufacturers said that the biggest impact robots will have on the manufacturing workforce in the next three years is that they will lead to new job opportunities to engineer advanced robots and robotic operating systems. Universal Robots are the leading manufacturers of advanced user-friendly and light cobots from Denmark and only recently expanded their presence in the Indian market. Human-robot collaboration is an integral part of Industry 4.0 and these cobots actively participate in IIoT and smart factories. This approach is particularly appealing to the Indian manufacturing industry because labour-intensive conditions and cobots together can help the Indian market to achieve the best of both worlds by making precise use of this technology. This is seen with some of the collaborators of Universal Robots, which include Aurolab and Bajaj Auto. In the case of Bajaj Auto, it has witnessed a gradual rise in the productivity and efficiency in their production. It also increased the productivity of their employees along with their product quality after associating themselves with Universal Robots. It has deployed over 100 cobots since 2010 and they are now the third largest motorcycle manufacturer in the world. They are of the view that some of the added benefits of the cobots include easy use, low annual maintenance and higher energy efficiency.

Can you give your observations on the progress of Industry 4.0 or IIoT globally and in India? How ready is Indian industry to adopt these new technology concepts? Statistics by the International Federation of Robotics state Earlier, it was said that robots will replace human jobs, but that the number of robots imported in India is about 2500 in with the evolution of cobots, today, humans and robots number, which is quite low compared to China, that imports are working hand-in-hand in a safe and efficient manner. 30 times of this amount. India has been slow to adopt this What is your opinion about the future of such technologies technology, primarily because of the low cost and abundant in countries like India where there is good manpower supply of labour. ☐

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C O V E R S TO R Y | M A N A G E M E N T

“Opportunity for further improvement” “Indian market needs to cope up with advance technologies to enter the global market, to become more competitive & match international quality for long-term sustainable growth” Ramji Singh Associate Vice President – Sales Schmersal India

What are the major technological advancements that are witnessed globally, given that the factories and energy systems are representing Integrated Industry? Fully-integrated processes as well as digitisation will be the next generation of industrial automation. We are witnessing that robots are not going into the market as a standalone solution as it is being integrated with various machine & process like— machine tool + robot, press machine + robot as well as in our day-to-day operation in personal & professional life to avoid manual operation and increase productivity. It is also observed that the machines will recognise faults even before they appear, which is also termed as ‘Predictive Maintenance’. How is such an approach beneficial in your industry or application areas? Predictive Maintenance will improve quality, ensure a better & safe workplace, increase productivity and also help in our ‘Skill India’ operation. Such system requires comparatively better-skilled personnel to operate with full efficiency, but we must also look into reliability of such systems in the Indian working environment & other environmental condition at various time frames. What is your opinion on the growing concern over the transmission and storage of data in a secured manner? How does the overall industry address such challenges? We need better infrastructure with a 360 degree approach to improve from all the sides as it is going to be a challenging task. But if we see the development in networking & IT infrastructure from the past few years, I do not see it as a concern, but as an opportunity for further improvement to align with the global market & development in industrial automation as well as encourage more Indian industries to become Indian MNCs. Earlier, it was said that robots will replace human jobs, but with the evolution of cobots, today, humans and robots

are working hand-in-hand in a safe and efficient manner. What is your opinion about the future of such technologies in countries like India where there is good manpower availability, but lack of technology skills? In the Indian market, acceptability and adaptability are important. Same is the case with the robots being presented in the industry. Now, the global market is open & it is up to us to abandon or embrace the technology as it has become a necessity in the Indian market to cope up with the advance technology to enter into global market, to become more competitive & match international quality for long-term sustainable growth. With the new government, different initiatives like ‘Make in India’, ‘Skill India’ and ‘Ease of Business’ will facilitate the job creation, foster innovation, enhance skill development and in turn, change the mindset. How is the progress of Industry 4.0 or IIoT globally, and in India? How ready is Indian industry to adopt these new technology concepts? Today, various seminars and workshops are being conducted on Industry 4.0 to increase awareness in the market, highlight benefits, infrastructure requirements, etc to encourage industries to take initiatives and move ahead with some vision. Further, education is still required as all related industries & partners need to form a committee to decide the roadmap for 2020, to spread more awareness, design implementation plan, generate reference and success stories, etc, so that it becomes a necessity in today’s market trend. This will also open an opportunity to include global safety norms & standards due to the requirement of different modes of operation of different kind of machinery for a better & safe workplace. We, as Schmersal, provide all possible contributions as one of committee to make this successful. This will generate prospects for us for internal development, including products, solution & services to align with the Industry 4.0 platform. ☐

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C O V E R S TO R Y | M A N A G E M E N T

“Moving towards intelligent sensors” “Implementing advanced technologies is useful in predicting the failures before the actual failure occurs, and reducing the down-time of the equipment” Sunil Mehta General Manager – Technical Support Factory Automation & Industrial Division Mitsubishi Electric India

What are the major technological advancements that are witnessed globally, given that the factories and energy systems are representing Integrated Industry? Today, industries are witnessing ‘Integrated Industry’ via integration of factory automation systems and IT systems. There is a global trend for integration of manufacturing facilities to ERP systems within companies and to supply chain by integrating vendor’s facilities. Smart manufacturing or Integrated Industry can be realised by integrating the lowest element (sensors) from shopfloor to topfloor over high speed Industrial Ethernet network. With technological advancements and IIoT equipment becoming more intelligent, this data produced can be easily transported in network hierarchy. Introduction of IoT is necessary for connecting production site and value chain. Edge area connecting IT systems and Big Data at the production site plays an important role in IoT introduction and in realising smart manufacturing. It is also observed that the machines will recognise faults even before they appear, which is also termed as ‘Predictive Maintenance’. How is such an approach beneficial in your industry or application areas? In today’s environment of manufacturing facilities, most of the equipment and processes are automated by using factory automation products like PLCs. The trend is moving towards intelligent sensors. Thus, implementing such advanced technologies is useful in predicting the failures before the actual failure occurs and reducing the down-time of the equipment. Our company has implemented a system at a leading automotive car manufacturer, where we have installed intelligent sensors for identified motors to monitor current, temperature and vibrations of motor. Implementation of such kind of systems will give an early intimation and major breakdowns can be avoided. What is your opinion on the growing concern over the

transmission and storage of data in a secured manner? How does the overall industry address such challenges? Today, most companies are concerned about the storage of Big Data. Industries are working on how this data can be secured and stored. Many automotive manufacturers are deciding whether to keep this data within or store it to an external cloud. Various options are available and automotive companies are taking advantage of it. With the evolution of cobots, today, humans and robots are working hand-in-hand in a safe and efficient manner. What is your opinion about the future of such technologies in countries like India? Robots are playing an important role in manufacturing industries and there is good scope for robotic business in India. Mitsubishi Electric has introduced robots in the Indian industry three years back and we are observing good growth. Robots will play a significant role in areas where production rates are high and where human operation is critical or not possible. With the advanced technologies and safety today, humans and robots are working hand-in-hand. Since skilled manpower and technicians are becoming expensive, introducing robots will be useful to make products more competitive without compromising on quality. How is the progress of Industry 4.0 or IIoT globally, and in India? How ready is Indian industry to adopt these new technology concepts? The Indian industry is getting ready for adopting Industry 4.0 or IIoT. In the last financial year, on various forums, this topic was discussed and presented by experts from different industries. We, at Mitsubishi Electric, introduced the e-Factory concept in 2003 in Japan and now here in India. This concept is integral to building reliable and flexible manufacturing systems, offering high speed information transmission over robust and high speed CC-Link IE Network. ☐

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M A N A G E M E N T | C O V E R S TO R Y

“Access to plant networks must be controlled” “Most hyperbole about Industrie 4.0 or IIoT does not address the true driving forces – the distribution of intelligence to the edge of the network. The problem is how to safely, securely, and efficiently integrate distributed intelligence into a whole system” Dick Caro CEO, CMC Associates & Certified Automation Professional (ISA)

What are the major technological advancements that are witnessed globally given that the factories and energy systems are going digital and connected? The industries in process & power sectors are gradually moving from analog measurements, data transmission, and control actuation, to digital measurements and data transmission. There are currently more than 50 million analog instruments installed with a remaining service life averaging 20-30 years. They are not easily or economically replaced even though digital standards exist and products are available. Majority of new plant construction uses digital field measurement instrumentation and positioning of control actuators. There are two innovations emerging for the process industries: 1) economical converters for analog field instruments to add the missing digital technology and adapt to an industrial Ethernetbased plant network, and 2) use of VFD on centrifugal pumps to control flow instead of using a control valve, compressed air actuator, and a digital/analog positioner. What is your opinion on the growing concern over the transmission & storage of data in a secured manner? With plant LAN of the past, security was achieved by obscurity; protocols were non-standard and wired networks were generally not accessible from outside the plant. All of this has changed since we are now favouring standard Ethernet networks and Internet connections are common. Wireless networks extend beyond the plant fence as well. Security must now be explicitly configured into these networks. While there are many methods to secure transmissions, industry must select one and only one method to enable open data interchange between devices. This has not yet been done. Access to plant networks must be controlled. In the past, this was restricted by physical access to the communications cable and terminations. Now, because access can come through the internet we must do more. Firewalls are designed to keep out unauthorised access, but they have been breached before. It is

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then the responsibility of network management to restrict access to industrial networks through a process called “provisioning” in which nodes on the communications network must be admitted through a process of authentication. For many years, we have stored data in a historian, usually for the sole purpose of producing trend lines on a graph. Now, accumulated data is being inspected using a system of “big data analytics” to attempt to extract useful data. Unfortunately, big data analytics is not a useful way to create process models by itself. To determine static and dynamic process models, specific model building techniques called statistical design of experiments must be used to analyse process response to the impulse forcing inputs in manipulated variables. While the cloud offers virtually unlimited data storage, few process control system users or their vendors have sufficient security protection to use cloud storage. Can you give your observations on the progress of Industry 4.0 or IIoT globally? Most hyperbole about Industrie 4.0 or IIoT does not address the true driving forces – the distribution of intelligence to the edge of the network. The problem is how to safely, securely, and efficiently integrate distributed intelligence into a whole system. In process control we have faced this problem since 1986 with the creation of Fieldbus systems in which field instruments were given computational power equivalent to centralised control systems. We solved most of these problems except for security through the standardisation of Foundation Fieldbus in 2001. However, Foundation Fieldbus represented an economic threat to vendors of centralised control systems (which oddly are called DCS), and have not been widely used because of these economic threats. In factory automation, there has been a continual development to distribute intelligence to remote I/O units, but no efforts have been made to integrate distributed control into a full system as has been done for the process industries by Foundation Fieldbus. Yet, it must happen and it will happen when users realise the benefits of building a fully distributed automation system. ☐

C O V E R S TO R Y | M A N A G E M E N T

“Towards capacity optimisation” “Enhanced digitalisation leading to interconnectivity & integrated processes enables efficient operating environment leading to significant improvement in productivity, energy efficiency and time to market” Arunkumar Janarthanan Practice Head, Industrial Automation & Process Controls Frost & Sullivan

What are the major technological advancements that are witnessed globally, given that the factories and energy systems are representing Integrated Industry? As per our analysis, the number of connected devices is expected to multiply significantly changing the factory and energy systems landscape. As digitalisation increases, the new matrix of crossindustry influence will emerge leading to a scenario that could be termed as ‘Industry Convergence’ (Integrated Industry). The need for industry convergence will be driven by the core endusers’ need to enhance productivity. The convergence of IT and OT will result in the creation of advanced process applications supporting real-time decision making. Productivity, energy efficiency, time-to-market and innovations are the crucial factors driving this. It is also observed that the machines will recognise faults even before they appear, which is also termed as ‘Predictive Maintenance’. How is such an approach beneficial in your industry or application areas? The situation has clearly shifted today towards capacity optimisation, rather than capacity creation. The renewed focus on cutting waste out of operations and improving asset uptime has left the plant managers with the need to increase output for a given fixed input. The primary way of achieving this is by reviewing predictive and preventive plant maintenance practices and by optimising the process. Typically, process optimisation involves operating process parameters at the edge of the envelope by utilising advanced process solutions. What is your opinion on the growing concern over the transmission and storage of data in a secured manner? How does the overall industry address such challenges? Enhanced digitalisation leading to interconnectivity and integrated processes enables efficient operating environment leading to significant improvement in diverse parameters, such as productivity, energy efficiency and time to market.

Traditionally, cyber security was always considered as the forte of IT function within the plant but we need to clearly understand that the IT function may not always be fully aware of the nitty gritties of the operational technologies. To address this scenario, the industrial control solution providers should target collaboration with cyber security firms in securing the control systems, and in turn, the plant. With the evolution of cobots, today, humans and robots are working hand-in-hand in a safe and efficient manner. What is your opinion about the future of such technologies in countries like India? Industries of the future will witness humans and robots working collaboratively through human-machine interfaces without the need for safety barriers. Unprecedented demand for working age population in the developed economies has created a significant need for skilled workforce and adoption of robotic solutions and aided human intelligence. In India, we have abundant working age population, but the skills quotient is a critical gap. In this context, we cannot assume that the demand for robotics will be less. Automation is definitely an enabler for better human productivity rather than replacement for humans. Increased adoption of robots will not only enhance productivity and quality, but also replace the unskilled workforce with skilled workforce. How is the progress of Industry 4.0 or IIoT globally, and in India? How ready is Indian industry to adopt these new technology concepts? Globally, the adoption of IIoT is expected to redefine the nature of industrial solution providers. A shift from product to process and revitalisation of supply chain is expected to emerge. Who is my customer and who is my competitor? These are the key questions asked by industrial solution providers as we witness convergence and disruption in this sector. In the Indian context, we may not be witnessing a large scale evolution in the short term, but we will definitely witness it in select areas. ☐

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C O V E R S TO R Y | M A N A G E M E N T

“Anticipating huge growth in IoT market” “Digital and analogue assistant systems will support people better than ever, taking over dangerous or difficult work. Human-machine collaboration will increase in a safe and intuitive way” Hans Bangert Managing Director Bosch Rexroth India

What are the major technological advancements that are witnessed globally, given that the factories and energy systems are representing Integrated Industry? Few changes in recent past, which enabled factories & energy systems to adapt digital & connected solutions include price of sensors dropping at all time; usability of software and hardware significantly getting increased; computing power (CPU) getting more powerful, cheaper and compact day-by-day; data storage (cloud space) becoming cost-effective and available nearly unlimited; data mining giving new possibilities to analyse Big Data on practically real time and the principle of decentralised networking proving its performance & advantages in many cases. It is also observed that the machines will recognise faults even before they appear, which is also termed as ‘Predictive Maintenance’. How is such an approach beneficial in your industry or application areas? We offer this solution to our customer for their hydraulic systems and machines. It is all about collecting the data (via sensors), analysing them with respect to the application area (need sound application know-how) and visualising the data, which makes sense to the user. We are equipping our own team to use this technology (remote service support) to immediately response to the customer’s request. Once the plant is digitally connected and all data flowing to the secured cloud space is analysed with our know-how, we can help customer to do the predictive maintenance and not reactive maintenance. This approach helps customers to reduce the accidental down-time of machine and operate the plant at optimal capacity. What is your opinion on the growing concern over the transmission and storage of data in a secured manner? How does the overall industry address such challenges? Secured data storage is a hot topic these days and we at Bosch are very much focused on this concern. Software security is a

well-known topic, but hardware security is not always taken into account. Some hardware solutions are already designed with innovative chips that will hold security keys installed directly on the piece of equipment, making it impossible to tamper with, but also allowing a faster and more reliable software authentication. Risk cannot be eliminated, it can only be managed. With the evolution of cobots, today, humans and robots are working hand-in-hand in a safe and efficient manner. What is your opinion about the future of such technologies in countries like India? Digital and analogue assistant systems will support people better than ever, taking over dangerous or difficult work. Humanmachine collaboration will increase in a safe and intuitive way – but machines will continue to play a subordinate role. People’s health and well-being will be safeguarded and enhanced through adaptive workplace ergonomics, digital assistance functions, and ability amplifiers. In India, we must acknowledge that we have highly skilled manpower available with youngest average age in the world. In future, we will need differently-skilled people. How is the progress of Industry 4.0 or IIoT globally, and in India? How ready is Indian industry to adopt these new technology concepts? Whether Industry 4.0, Industrial Internet or Connected Industry – the IoT and services is making its arrival in our production facility and vice versa. With 250+ plants across the world, we are implementing these new technological concepts in our own plant. This not only helps us improving our own plant efficiency, but is a learning experience for us to improve our offerings to our customers as well. From the Indian industry perspective, we expect a huge growth in the IoT market. It is estimated that the IoT market will grow exponentially by 2020. The scope will be in the areas of utilities, manufacturing, transportation, logistics & automotive industry. ☐

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C O V E R S TO R Y | M A N A G E M E N T

“Flexible to explore technological updates globally” “IIoT has promoted the usage of smart & networked equipment that reduces downtime of any facility, keeps lesser human involvement, and implies automatic operation of devices that can communicate, interpret & adjust on its own seamlessly” Kalidas Bhangare Managing Director Testo India

What are the major technological advancements that are witnessed globally, given that the factories and energy systems are representing Integrated Industry? The latest technologies are coming from digitisation of the existing systems. Traditional methods are now getting replaced with smart solutions, networked & wireless operation and cloud technology. Machine-to-machine communication controlled & coordinated precisely has improved the operation in any industry or factory. Single touch governance of any set-up with the ease of saving & transferring data over networks makes the technology more user-friendly, interactive, cost-effective and ultimately fulfils the aim of Integrated Industry. It is also observed that the machines will recognise faults even before they appear, which is also termed as ‘Predictive Maintenance’. How is such an approach beneficial in your industry or application areas? Predictive maintenance is technically the repair or adjustment that is done to the existing system even before any actual damage happens. This approach enables the set-up to function in a smooth & steady way. As far as our product application areas are concerned, we are already using this concept to rectify several possible threats. Our range of thermal imagers easily highlight the thermal impressions of defected areas in applications such as electrical system, pipelines or ducts, thermal plants, building thermography, etc, which could be a serious concern in the future, if not noticed. What is your opinion on the growing concern over the transmission and storage of data in a secured manner? How does the overall industry address such challenges? There are hindrances when it comes to the transmission, sharing & storage of crucial data over cloud or any other online soft medium. There is a lack of confidence regarding this, also sometimes the systems are not flawless and the services offered are not upto the mark, which can be precarious, but

the industry is now opening up and accepting such challenges. People are now becoming aware about the best data storage mediums, several alternatives and benefits related to them. For instance, our WiFi Data Logger – Saveris 2 is advanced in online data monitoring system. With a secure online storage of all readings in Testo Cloud, the data can be managed & analysed online by the user via smartphone, tablet or PC, anywhere and anytime. With the evolution of cobots, today, humans and robots are working hand-in-hand in a safe and efficient manner. What is your opinion about the future of such technologies in countries like India? Today, industries have become more focused, curious and flexible to explore the technological updates globally. Even the government is now more inclined to address such issues and create a technological infrastructure that is paramount. Our manpower has also been a great learner and implementer throughout. Cobots is just another turn in the journey of advancements and India itself, being a centre of invisible discoveries, is capable enough to absorb many such technologies. How is the progress of Industry 4.0 or IIoT globally, and in India? How ready is Indian industry to adopt these new technology concepts? IIoT has become a new establishment in industrial operation and functioning. Globally, it has shown tremendous effect on almost every sector in a very small time span. Digitisation and smart solutions have become the need of the hour and is rapidly influencing the Indian market. IIoT has promoted the usage of smart & networked equipment that reduces downtime of any facility, keeps lesser human involvement, and implies automatic operation of devices that can communicate, interpret & adjust on its own seamlessly. The emergence of IIoT ensures prominent growth in the Indian market with equal acceptance and usage. ☐

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C O V E R S TO R Y | M A N A G E M E N T

“There must be a comprehensive security strategy” “There must be a comprehensive security strategy comprising multiple layers. We need to protect the network over which the components are connected with each other” Sanjay Kulkarni Managing Director Pilz India

What are the major technological advancements that are witnessed globally given that the factories and energy systems are going digital and connected, which defines ‘Integrated Industry’? Integrated Industry means creating a seamless integration at all levels and giving the devices a connection to interact with each other. In the recent times, we are seeing many technological advancements in this field. Majorly, we are witnessing tremendous growth in technologies like Artificial Intelligence, robotics, human-robot collaborations, the Internet of Things, energy storage and predictive management, which is also known as warning management. Other than that, technologies related to data processing, data augmentation and cloud computing are also becoming advanced at an unprecedented rate. Moving into the era of intelligent machines, it is observed that the machines will recognise faults even before they appear which is also termed as Predictive Maintenance. How do you think implementing such an approach will be beneficial in your industry or application areas? This approach is beneficial for any given industry. If the faults are detected beforehand, this concept will reduce downtime and ensure effective spares and production management. With this, the chances of stalled production due to product failure will come down considerably. This is specially going to be beneficial for large-scale factories having many production lines and factories producing goods in bulk. From safety point of view, this will also reduce accidents happening in industry due to product failure, as machine will not break down unexpectedly. It will help in protecting staff as well as capital. With the evolution of digitalisation, there is also a growing concern over the transmission and storage of data in a secured manner. What is your opinion on this, and how do you think the overall industry is addressing such challenges?

The challenge for security is that – unlike functional safety – security mechanisms need to adapt continuously to new threats. Thus, there must be a comprehensive security strategy comprising multiple layers. We need to protect the network over which the components are connected with each other. Factory should also be shielded from the outside world by some special firewall concept. While the confidentiality of information enjoys top priority in the office environment, in the production sphere, data availability comes top of the list because this is a key prerequisite for smooth production processes. There are many guidelines and standards currently being designed for bringing both security worlds together. With the evolution of cobots, today, humans and robots are working hand-in-hand in a safe and efficient manner. What is your opinion about the future of such technologies in countries like India where there is good manpower availability, but lack of technology skills? Collaborative robots or cobots is a concept where human and robots will work shoulder-to-shoulder for creating new avenues. Robots can be used to automate and streamline repetitive or potentially unsafe processes, whereas humans can work on creative aspects and areas, which require certain critical human sensibilities. Can you give your observations on the progress of Industry 4.0 or IIoT globally and in India? How ready is Indian industry to adopt these new technology concepts? The progress on Industry 4.0 in India is slow but steady. People are still oblivious to the concepts of Industry 4.0 or IIot but are very much interested to implement advanced technology within their budget. However, large production houses and corporates are well aware about these concepts and are working further on building factories of future considering the ever-increasing market demands and ensuring customer satisfaction. ☐

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C O V E R S TO R Y | M A N A G E M E N T

“India has an edge over other countries” “The linking of multiple digital solutions has taken in-plant connectivity beyond the precincts of the traditional plant to multiple locations – extending it to an entire collaborative industrial ecosystem. Quintessentially, this is the industrial internet of things (IIoT)” Ashish M Gaikwad Managing Director, Honeywell Automation India Country Leader, Honeywell Process Solutions (HPS) India

What are the major technological advancements witnessed globally, given that factories and energy systems are going digital and are connected, which defines ‘Integrated Industry’? With the costs of sensors and connectivity declining, the focus has shifted on mobility applications and advanced automation. The adoption and subsequent integration of these new technologies with existing automation solutions is leading to the development of a whole new ecosystem of solutions. Using these new technologies, we can now gain better insights that can help us make far better decisions that favourably impact safety & security, reliability, efficiency and sustainability. The internet provides connectivity, collaboration and context. The linking of multiple digital solutions has taken in-plant connectivity beyond the precincts of the traditional plant to multiple locations – extending it to an entire collaborative industrial ecosystem. Quintessentially, this is the industrial internet of things (IIoT). It is observed that the machines will recognise faults even before they appear, which is also termed as ‘Predictive Maintenance’. How do you think implementing such an approach will be beneficial in your industry or application areas? Our research indicates that about 67% of manufacturing executives are pressing ahead with plans to invest in data analytics. The reason is that they view data analytics – a key component of IIoT – as a viable solution to a cycle of problems that lead to downtime and lost revenue. Executives need to keep their businesses running smoothly and safely, and they are banking on IIoT technologies to help navigate challenges. This is where predictive analytics achieved through effective IIoT solutions can help companies break out of that cycle. There is a growing concern over the transmission and storage of data in a secured manner. What is your opinion

on this, and how do you think the overall industry is addressing such challenges? In the process industry, there are stringent norms of security and the data operations are always through secure clouds. There are two types of secure clouds. Large enterprises may own a cloud environment of their own – a private cloud, which only that specific enterprise can access. It has its own strong security mechanisms. Smaller enterprises who may not be able to afford a private cloud can access a cloud shared only by members in that cluster. Humans and robots are working hand-in-hand in a safe and efficient manner. What is your opinion about the future of such technologies in countries like India where there is good manpower availability, but lack of technology skills? India has an edge over other countries with its younger population being IT-savvy. Combining the power of IT with the initiatives being taken in manufacturing will open up further opportunities. The manufacturing ecosystem is also being developed and evolved by players in this industry. Companies, governments, universities and colleges, consumers and service providers are part of this ecosystem. Due to raised awareness levels, everybody is working towards similar goals, which will bring the momentum in creating this ecosystem. Can you give your observations on the progress of Industry 4.0 or IIoT globally and in India? How ready is Indian industry to adopt these new technology concepts? The potential is large and untapped when it comes to IIoT in India. It will be through building on top of what already exists today in the manufacturing industry and adapting new technologies, which will enable us to address unsolved problems and enhance overall productivity by taking advantage of the power of the internet. The best is yet to come and is surely ahead of us. ☐

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I MA G E C O URT ES Y: shutterstock

CHEMICAL & PROCESS INDUSTRY | FOCUS

ADOPTING ENERGY EFFICIENCY IN PROCESS INDUSTRIES Energy efficiency is an important consideration for operations in the process industries. This feature explores the ways in which energy efficiency can be ensured in three key sectors in manufacturing. A read on… In today’s complex environment, there has been a growing need to concentrate on reducing energy costs and improving energy efficiency is imperative. The efficient use of energy is important to industrial business performance because energy is a significant component of operating costs. The following section investigates ways in which energy efficiency can be adopted and focuses on three key sectors within manufacturing. These include a chemical facility, a petrochemical plant and a plastics manufacturing facility.

1. Energy efficiency at a chemical facility FH Tank Storage meets its need of providing overspill protection of tanks at its facility. Using Emerson wireless differential pressure and radar transmitters, the storage terminal meets the latest safety requirements.

Challenges • To meet the latest environmental and safety requirements, overspill protection was required on existing tanks storing solvents, petrol, and a range of chemicals. Previously, there was no instrumentation in place. Level measurements were performed manually, with operators climbing on tanks roofs. There was a risk of potential injury, especially during winter when temperatures fall to -20 °C (-4 °F). • The company wanted to automate these measurements and remove any potential human error when recording, calculating, and listing tank levels on a white board. • Some tanks are over 200m from the main control room and new cable infrastructure was required. This would have involved extensive groundwork at a cost of between €50,000 €100,000. While these works were being completed, fuel tanker

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FOCUS | CHEMICAL & PROCESS INDUSTRY

traffic around the site would have been seriously disrupted. The storage tanks varied in size and a number of the larger tanks have floating roofs. Minimising the number of types of level devices was preferred to enable easier maintenance and reduced inventory.

Meeting safety requirements Emerson’s PlantWeb digital architecture, with a plant wide Emerson Wireless network based on the IEC 62591 (WirelessHART®) standard, DeltaV™ automation system, and Rosemount™ level and pressure transmitters has been installed and provides both the automated tank storage level monitoring and overspill protection. Fourteen Rosemount 3051S wireless differential pressure transmitters have been deployed on smaller size tanks and 15 Rosemount 5402 non-contacting radars on larger tanks. Emerson Wireless THUM™ Adapters are connected to each of the radars to transmit the data via the wireless network. The Rosemount 5402 devices are able to cope with very large tanks and floating roofs. A Rosemount 848T wireless temperature transmitter with four inputs connecting four temperature sensors has also been installed to provide continuous temperature information for four tanks. Measurement data is transmitted back to Emerson’s DeltaV digital automation system in the main control room. A large screen provides operators with visualisation of all the tanks and any high level alarms. Emerson’s AMS Suite predictive maintenance software is used to monitor the health of both the wireless network and the individual wireless transmitters. This identifies faults and reduces the number of trips into the field.

Implementing automated measurement system FH Tank Storage has ordered 15 Rosemount radars and Emerson THUM Adapters to automate 15 more tanks. Rosemount radar devices and THUMs are also expected to provide the level measurements and overspill protection for five tanks currently under construction. “Emerson’s Rosemount level, pressure and temperature transmitters, and Emerson Wireless network have enabled us to implement a cost effective automated measurement system,” concluded Lars Ferm, Site Manager, FH Tank Storage. In

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conclusion, this application allowed FH Tank Storage to meet the latest environmental and safety requirements with an estimated installation savings of €50,000 - €100,000 and also helped achieve reduced delivery uncertainty and increased personnel safety.

2. Energy efficiency at a petrochemical plant A petrochemical plant drives energy efficiency with Emerson wireless DP flowmeters and temperature transmitters. This solution helps the plant achieve higher efficiency, lower operations costs, lower capital costs and fast, easy installation.

Challenges • Operations personnel wanted to measure the plant’s consumption of natural gas and have tighter control over the gas metering grid to drive efficiency and reduce operating cost. • To achieve this target, gas flow needed to be measured at the steam source and temperature measured at the gas metering grid, respectively. • The plant’s layout resulted in some challenging physical limitations. For instance, at the heater and boiler system, a traditional orifice plate could not be installed due to limited straight run availability. At the gas metering grid, it was not economical to layout cables to wire the temperature transmitter to the central control room. • Furthermore, there were no available empty slots for additional analog input (AI) cards at the Distributed Control System or DCS, preventing additional data integration into the DCS without a capital expenditure. • Without the means to measure process parameters, engineers were unable to have tighter control of the process. They could not tell if the boiler and heater were consuming too much gas, resulting in an inefficient process and increased energy cost. • Installing traditional measurement devices would incur high project cost and could affect the production schedule due to the need for pipe preparation and wire trenching.

Addressing project limitations The plant called on Emerson’s Wireless capabilities to address the project limitations. Six Rosemount 3051SFC Conditioning

CHEMICAL & PROCESS INDUSTRY | FOCUS

With the wireless network in place, the plant now has more flexibility to explore other measurement points

Orifice Flowmeters with THUM adapters were installed to measure gas flow into the boiler and heater systems. The 3051SFC requires a shorter straight pipe run with its Conditioning Orifice Technology. It also has fewer leak points as it eliminates impulse lines, and is leak tested at the factory to ensure fast and easy installation between existing flanges. For the gas metering grid, two Rosemount 648 Wireless Temperature Transmitters were installed. This provided immediate temperature measurement without worrying about wiring costs. These field devices were wirelessly integrated to the existing DCS through a Emerson Wireless Gateway. The wireless solution brought data such as flow rate, gage pressure and process temperature to the control room which is critical to operations. This made gas consumption visible to the process engineers enabling them to make adjustments and make the process more efficient. The ease of installation also made the project easier to execute. Lastly, with the wireless network in place, the plant now has more flexibility to explore other measurement points.

3. Energy efficiency at plastics facility A plastics manufacturer improved energy costs with wireless flowmeters. This process allowed them to improve energy cost management, reduced operation and maintenance costs and increased the safety of plant personnel.

Challenges • A plastics manufacturer had challenges of trying to keep their process units accountable for the steam usage within the plant. The company needed to better understand their steam usage to know if there were leaks or other waste in their system. • The company needed to make six flow measurements on steam distribution lines that were located throughout their facility. Unreliable insertion vortex and turbine meters were not

•

• •

•

providing reliable steam flow measurement and constantly required maintenance. These meters would frequently fail and needed to be replaced. The measurement points are located outside in a cold environment, requiring the manufacturer to consider the use of heat tracing or other measures to safeguard the measurement instrument from freezing. Not having reliable steam flow measurement constrained their ability to effectively manage their energy costs by process unit. Furthermore, the unreliable measurement instruments increased maintenance problems that required frequent replacement of flowmeters at high installation costs. Replacing their flowmeters required maintenance personnel to climb scaffolding to reach the installations in icy and dangerous locations.

Utilising wireless technology The plastics manufacturer purchased four 3051SFC Compact Orifice Wireless Flowmeters and two 3051SFC Annubar Wireless Flowmeters. The wireless technology enabled them to install the flowmeters without the need for wiring. They utilized new top mounting installation recommendations for DP flowmeters in steam service. By direct mounting of the transmitter above the pipe, the installation eliminated impulse lines and utilized the heat of the process to safeguard the installation from freezing. This eliminated the need of costly heat tracing. Utilising reliable wireless flowmeter technology enabled the plastics manufacturer to understand their steam usage in the plant. In addition, they saved $40K in wiring costs by using wireless technology and eliminated the frequent maintenance and replacement of the unreliable flowmeters. They were also able to achieve a safer work environment for their maintenance personnel as they were not required to frequently troubleshoot failures in hazardous conditions. ☐ Courtesy: Emerson

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G E A R S & M OTO R S | T E C H N O L O G Y

Forms of closed loop stepper control Stepper motors are employed in a variety of applications across the engineering spectrum because they are inexpensive, simple to operate and offer high torque at low speeds. An application story on how the various shortcomings of stepper motors can be overcome by leveraging Galilâ&#x20AC;&#x2122;s methods of closed loop stepper control. Stepper motors suffer from drawbacks such as missed steps, decreased torque at high speeds, resonances, and high power consumption. In order to mitigate these issues, Galil has three methods of closing the loop around a stepper motor: end point correction, closed loop microstepping, and driving the stepper motor as a 2-phase brushless motor.

Stepper motor basics Stepper motors have multiple â&#x20AC;&#x2DC;toothedâ&#x20AC;&#x2122; electromagnets

arranged around a gear-shaped rotor. To make the motor shaft turn, these electromagnets are energised in a specific sequence. Figure 1 shows a simplified view of this process for a 2-phase stepper motor. Each specific sequence corresponds to one step of the motor. A stepper motor typically has 200 steps per revolution. Stepper motors do not come without some drawbacks. The first drawback of a stepper motor is that it operates at full current at all times. This leads to wasted energy and excess heat generation. Second, fundamental to the operation

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T E C H N O L O G Y | G E A R S & M OTO R S

Figure 1: Sample full-step current & rotor position

Figure 2: 24 VDC stepper motor speed-torque curve

of stepper motors is the vibration caused when they change their position in discrete steps. When the step frequency matches the natural oscillation or resonant frequency of the stepper motor, the amplitude of these vibrations will increase, leading to loss of position. Stepper motors also experience a significant torque decrease as the speed of the motor increases. A common speed-torque curve is shown in Error: Reference source not found. Lastly, the positional resolution is limited by the number of steps per revolution. If increased resolution is needed, the stepper can be driven through the process of microstepping.

Microstepping Microstepping is the method of driving a stepper motor in such a way that every whole step of the motor is broken down into smaller increments called microsteps. Microstepping typically creates between 2 and 256 microsteps per full step, which means that the 200 step per revolution motor can now have up to 51,200 of these microsteps per revolution. Figure 2 details the current waveform through each stepper motor phase with an increasing number of microsteps per full step. The actual accuracy of microstepping is largely dependent on external forces. Microstepping is accurate to within a full step of the motor, however, if more than a half step of error is present then loss of position will occur. Motion will not occur if friction, gravity, or any other force is large enough to prevent the small changes in current between two microstepping positions from affecting the position of the motor. Figure 3 shows a plot of a point to point move executed in a system driven by a stepper motor coupled with an encoder. The red

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Figure 3: Current waveform during microstepping

line is the expected position of the stepper motor, the purple line is the step pulses output to the motor, and the blue line is the motor position measured by the encoder. The black line indicates when the controller is actively profiling motion. Due to friction in the system, the stepper motorâ&#x20AC;&#x2122;s final position does not match the commanded position resulting in some steady state error.

End-point correction By utilising encoder feedback to recognise this position error, the end point can be adjusted by commanding additional step pulses to bring the motor into the correct position. Galil calls this Stepper Position Maintenance mode, or SPM. SPM still operates the stepper in the microstepping mode, but the endpoint accuracy can now be verified and adjusted. This mode works by comparing the commanded position of the stepper motor to the actual position output from the encoder just before completion of a move. Figure 4 shows the same system as Figure 3 now being operated in Stepper Position Maintenance mode. After the end of the move, the position error is recognised and the reference position is adjusted to account for this error. An error correction move is then commanded to bring the stepper to the correct position. By adding the encoder, the controller now has the ability to recognise and correct for errors present in the system. The same move which previously resulted in steady state error due to friction can now be accounted for and corrected.

Closed-loop microstepping SPM mode is intended for applications where the only

G E A R S & M OTO R S | T E C H N O L O G Y

Figure 4: Microstepping

Figure 5: Stepper position maintenance mode

concern is end point accuracy. When it is necessary to continuously correct for error, Galil offers Closed Loop Microstepping (CLS) mode. Figure 5 shows the stepper system now being driven in CLS mode. In addition to the reference position and encoder position, an error signal (green line) is now generated internally on the controller and is used to adjust the stepper motor’s position continuously. It is important to note that in CLS mode, motion is now profiled based on the encoder position, but step pulses are still generated by the controller to drive the stepper motor. The error signal generated is fed through Galil’s CLS filter, which then compensates for any error present in the system by adjusting the step pulses output to the stepper. Closed loop microstepping is a true closed loop mode of operation, and is the optimum use of a stepper motor still being driven as a stepper. Closed loop operation brings with it the risk of instability if the loop is not correctly tuned, so care must be taken to achieve stability. Furthermore, this mode is still power inefficient and has low bandwidth when compared against a classic servo system. This low bandwidth can be made even lower when using external third party stepper drives with low current loop bandwidth and nonlinear characteristics.

Driving a stepper as a 2-phase brushless motor To achieve the highest performance, the stepper motor can be treated as a 2-phase brushless servo motor. Current to the motor will then be controlled as a function of the error

Figure 6: Closed loop microstepping

signal just as with standard servo motors. Galil refers to 2-phase brushless mode, or 2PB. Figure 6 details the stepper motor system being driven in this mode. Now, rather than step pulses, a torque command signal (brown line) is generated by the controller to be fed to one of Galil’s internal amplifiers operating in 2PB mode in order to control the position of the motor. Running a stepper motor in this mode greatly improves its bandwidth, resulting in reduced move times. A stepper motor driven in 2PB mode is analogous to a classic servo motor attached to a speed reduction gearbox. As this mode operates like a standard servo motor, the full range of Galil’s advanced PID filter capabilities can be now utilised, including the notch, pole, and feed-forward filters. In order to drive the stepper motor in this way, the amplifier must be made more sophisticated to so as to properly deliver only the instantaneous required current to the motor. This results in the stepper motor running power efficiently and causes it to generate far less heat.

Closed loop stepper control By leveraging Galil’s methods of closed loop stepper control, the various shortcomings of stepper motors can be overcome. The endpoint position can be adjusted for inaccuracies with stepper position maintenance mode, the position can be dynamically adjusted with closed loop microstepping, and lastly, the stepper motor can be treated as a 2-phase brushless servo to further increase the performance and efficiency of the motor. ☐ Copyright: Galil Motion Control

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G E A R S & M OTO R S | T E C H N O L O G Y

Driving less power consumption An application story on the usage of maxonâ&#x20AC;&#x2122;s DC servo motor by the manufacturer of precision camera gimbal systems that consumes less power compared to other motors, allowing the unmanned aerial vehicle to stay airborne for longer Aerial photography and surveying can be beneficial for many businesses and industries. These include mining companies doing aerial-surveying of mine sites, oil & gas companies conducting aerial-inspections of their off-shore platforms, electricity companies inspecting high voltage transmission lines. A common problem faced in these often harsh operating environments is keeping the camera or the surveying equipment steady against wind, turbulence and vibration from the aircraft it is mounted to. This is where a high-precision stabilisation camera gimbal comes into action.

Customising with the needs maxon motor Australia received an enquiry from Photo

Higher in September 2011, they were looking for a small brushless DC servo motor and gearhead combination for a high-end camera gimbal that they were designing. Photo Higher is located in Wellington New Zealand; they specialise in the design, development and manufacturing of precision camera gimbal systems for Vertical Take-off and Landing (VTOL) Rotary Wing Unmanned Aircraft Systems. The Photo Higher gimbals are designed to be light weight, smooth and very stable. Their gimbals are all 100% designed and manufactured in New Zealand. The initial requirement was to have a DC servo motor combination with zero backlash, 40 rpm and 2 Nm output torque. The total weight of the motor combination needed to be less than 100 grams and the overall length needed to be less than 50 mm. This showed speed and torque was achievable, however the

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T E C H N O L O G Y | G E A R S & M OTO R S

Photohigher Halo 3000 gimbal

weight and length were proving to be an issue. To achieve 2 Nm at 40 rpm continuous with low backlash, the combined weight of the motor and gearhead was around 370 grams, which far exceeds the weight requirement by the customer. maxon engineers worked through all available options with standard backlash figures, having the intention of using a standard brushless DC servo combination first and then to work on customising a DC servo gearhead to achieve the low backlash specification afterwards. maxon engineers were able to come very close to the weight, speed and torque target but the overall length for the proposed brushless DC servo combinations was too long for the client. Why a brushless DC servo motor with such high power density? With most unmanned aerial vehicles (UAV) applications, the power consumption is important. With higher power density and higher efficiency, maxon brushless DC servo motors will consume less power compared to other motors, allowing the UAV to stay airborne for longer.

So the search continues... A right angle drive option was then considered but it was too heavy for the application. We finally settled on a flat brushless DC servo motor with a harmonic gearhead. This harmonic flat brushless DC servo combination delivers the required speed and torque in a flat compact form; most importantly, this combination has an output with zero backlash, which makes it ideal for a gimbal application. After the brushless DC servo motor selection for the large Photo Higher gimbal was completed, maxon started work on three smaller Photo Higher gimbal designs. The smaller gimbals were more price sensitive, therefore, the harmonic brushless DC servo combination could not be considered. maxon engineers then proposed several different small flat DC

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servos with low backlash gearheads, but either the price or performance made them unsuitable. After some discussion and with some smart carbon fibre structure designs by Photo Higher, they were able to use a flat DC servo motor to directly drive the gimbal. With the new gimbal design irrespective of the camera brand or model used, the end user can always adjust the gimbal mount and balance the centre mass of the overall system. With a balanced centre of mass, fast acceleration and quick response can be achieved with minimum effort from the DC servo motors. Besides providing the customer with brushless DC servo solutions for their various types of gimbals, maxon also provided the customer with a customised brushless DC servo motor controller. The customisations included the PCB shape, control parameters, gain and connectors; all have been tailored specifically to cater for the special requirements of the application. The AV and Halo series of gimbals by Photo Higher are products designed for the most demanding applications. Combined with an unmanned aircraft, it provides users with an easy and cost-effective way to collect and capture high definition aerial imagery and geospatial data. Besides UAV, the gimbals can also be mounted on various types of platforms, such as helicopters, airships, cranes, boats, etc.

Conclusion Photo Higher chose maxonsâ&#x20AC;&#x2122; brushless flat DC servo motors because of their compact, high torque density, long service life and attractive price vs performance ratio. These features combined with maxon motors ability and willingness to customise the motor and controller to meet the customersâ&#x20AC;&#x2122; application needs, made maxon motor the ideal choice for the application. â&#x2DC;? Courtesy: maxon precision motors

S A F E T Y & I N T E G R AT I O N | T E C H N O L O G Y

Two sides of the same coin With time, safety will need to guarantee the protection of man and machine as well as ensure the necessary flexibility and availability in the smart factory. The article, to be carried in two parts, discusses the holistic approach required in terms of safety and security. A read onâ&#x20AC;Ś Digital data and efficient data exchange will define the production process in future. The level of networking is increasing, providing the benchmark for factory productivity. If all communication is decentralised, the demand for secure communication will rise. Aspects of machinery safety (safety) and operational IT-security requirements (security) are involved in equal measure. With intelligent manufacturing processes in the spirit of Industry 4.0, you can significantly increase efficiency and adapt capacities exactly to the respective order situation. The aim is to manufacture individualised products using the cost structures of mass production, even for a single batch. This requires modular production plants, which are flexible and can be modified

quickly while operations are running. Prerequisites include decentralised automation systems and high-performance network communications, where numerous subscribers are connected and large volumes of data can be transferred; innovative concepts for safety and security are also required and need to apply even after the plant has been modified.

Functional safety of machinery The term safety refers to the functional safety of machinery, or in other words: protecting man and the environment from threats emanating from machinery. Safety requires that residual risks emanating from a plant or

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T E C H N O L O G Y | S A F E T Y & I N T E G R AT I O N

machine do not exceed acceptable values. This includes hazards to the plantâ&#x20AC;&#x2122;s surroundings (e.g environmental damage) as well as hazards inside the plant or machine (e.g persons inside the plant). In a nutshell, one option in the case of an emergency is to interrupt the power supply immediately and hard stop the machine. Classically, this is achieved through specific safetyrelated wiring and components such as safety relays, for example. As this approach is very hardware-based and therefore static, it is not really suitable for intelligent manufacturing processes in which the plant layout constantly needs to be changed. Further disadvantages are generally associated with a hard shutdown, whether these involve loss of productivity, extended downtimes due to more complex recommissioning procedures or a restriction in the machineâ&#x20AC;&#x2122;s operating and maintenance concept.

The dynamic approach Dynamic safety concepts, which are based on an overall consideration of changing automation processes and functional safety requirements, offer an alternative. The view of safety itself is changed; it is regarded less as a hardware feature and more as a cross-device function. With this approach, which was developed prior to Industry 4.0 and Co, processes can be safely controlled and operated, without the need to interrupt processes each time there is an error. However, the dynamic approach can only be implemented efficiently if functional safety is taken into account right from the start, when automation projects are at the planning stage. Otherwise, it may be necessary to modify the sequence of individual production stages, if not the whole process, retrospectively, making optimum solutions impossible and creating considerable costs. Advt

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S A F E T Y & I N T E G R AT I O N | T E C H N O L O G Y

The mechatronic approach aims for a standardised formation of automation objects

Safety becomes a ‘moving target’

However, until now the existing technological solutions were unable to meet expectations. Different rules and regulations for modularisation are partly the result of the ‘classic’ safety architecture. The benefits of modularisation are often undone by a rigid – and where possible still hard-wired – safety concept. Electronic programmable safety systems are almost always a reproduction of hardware-based safety – in the form of fixed safety circuits – even if these are provided in a freely programmable connection logic. The basic element of modern control architectures, in contrast, is the almost total renunciation of systemic regulations. Users are to have total freedom to enhance their systems according to their level of optimisation and modularisation. If the barrier of these different approaches for automation and machinery safety functions can be removed, then users have gained new degrees of freedom. The automation system PSS 4000 conveys the idea of modularisation and flexibility as one of its basic functions. For the first time, it is possible to manage all process variables – including those belonging to safety functions – entirely symbolically and without any reference to hardware within the system. This is demonstrated by the fact that all process variables are available system-wide and are automatically available to all control systems in the distributed automation system, thanks to the multi-master architecture. ☐ The second part of the article will be carried in the next issue of A&D India

When functional machine safety was approved in accordance with the specifications of the EC directive, plant operators had no need to worry about safety, provided the machine did not undergo any significant changes. Intelligent manufacturing requires modular plants, which enable various product types to be produced on one machine, for example. This presents new challenges to functional safety, which must still be guaranteed even if the machine itself or its module layout has been changed. In the Smart Factory, the intention is to re-configure modular plants quickly and flexibly or to re-organise them within their group. The validation for a safety solution must be able to deal with this (subsequent) flexibility, because any compilations that have not been considered as part of CE marking will not be easy for the operator to set up. It is not a simple question of transferability: CEModule1 + CEModule2 = CEOverallMachine! The functional benefit of modular machine concepts is obvious. You gain flexibility in the manufacturing process, while at the same time increasing the potential for standardisation at functional level. The highest level of standardisation can be achieved when the dividing limits of the various modules can have an identical structure – irrespective of whether the module has a mechanical, electrical, control or visualisation function. The mechatronic approach aims for a standardised formation of Courtesy: Pilz automation objects.

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PRESENTING ARC’S FIFTEENTH INDIA FORUM

Industry in Transition: Realizing the Digital Enterprise J U LY 6 -7, 2 0 17 • B A N G A L O R E

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S O F T WA R E & E N G I N E E R I N G TO O L S | T E C H N O L O G Y

Designing stronger, lighter glass containers using simulation Manufacturing glass containers involves a complex process that is hard to predict. The article highlights the challenges faced in making lightweight bottles and how the use of multi-disciplinary simulation technology has revolutionised the bottle-making process. As far as multi-disciplinary simulation challenges go, predicting how a molten lump of glass is formed into a structurally rigid (although still technically liquid) glass bottle is perhaps one of the most complex things to predict. Manufacturing a glass container involves all modes of heat transfer and structural & fluid mechanics of a material whose viscosity changes by seven orders of magnitude as it is moulded, formed and blown into a bottle or jar. In a deeply traditional industry, one company is revolutionising bottle manufacturing by deploying multi-

Stephen Ferguson, Marketing Director, CD-adapco

disciplinary simulation to understand exactly what happens inside the bottle making process and using that information to build better bottle making machines.

Creating a quality product Bottero Spa is an Italian company that specialises in making machinery for the manufacture of various types of high-quality glass products, including a â&#x20AC;&#x2DC;hollow glassâ&#x20AC;&#x2122; division that designs and manufactures bottle and container

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T E C H N O L O G Y | S O F T WA R E & E N G I N E E R I N G TO O L S

making machinery. Bottero’s aim is to allow their customers to develop innovative new lightweight glass products that are structurally superior to previous designs (and therefore more durable), but can be manufactured using less raw material and less energy, both to melt the glass and to transport the final container. Ultimately, this creates a quality product at a lower overall cost. Put simply, Bottero is using multi-disciplinary simulation to discover how to make better bottles, faster than ever before. Marcello Ostorero, Head – R&D, Bottero, who pioneered the use of engineering simulation at Bottero, and Simone Ferrari, who performs many of the STAR-CCM+® software calculations at the heart of the simulation process, put some light on this process.

The challenge: making stronger, lighter bottles Although we think of glass as a solid, it is actually a supercooled liquid, whose viscosity is so great that its molecules do not move freely enough to form crystals. Managing the way that glass flows and is cooled to its (near) solid state is critical in ensuring the strength of the final container. In simple terms, a glass bottle is formed by moulding a glob of molten glass (enough to make a single container) into a preliminary bottle shape known as a parison. This parison is then carefully cooled, while being blown into the final bottle shape by a stream of compressed air before the bottle is subjected to a number of downstream processes. “Our aim is to make lighter bottles, that use less raw materials, less energy to melt and therefore cost less to manufacture. However, since glass is a very sensitive material, we also have to ensure that the bottles are very strong,” says Simone and adds, “Not breaking is the most important thing that a bottle has to do.” In the past, the robustness of glass containers was ensured by over-engineering them to some extent, thickening the walls of the containers by adding more glass. However, this resulted in heavier products that were less consumer-friendly and more expensive to manufacture. In the past 20 years, thanks to developments in manufacturing technology and to the combined influence of consumer preference and economic

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We take glass bottles, and other glass containers, for granted. Sometime today, between now and when we go to bed, we will reach into a cupboard or refrigerator and pull out a glass container, containing food, a condiment or most likely some type of beverage. Glass is, and always has been, a key enabler of modern life. Glass bottles are the signature of a quality product. Companies such as Coca-Cola, Perrier, Orangina and Heinz have built entire brands around the distinctive shape of their glass bottle. While cheaper and lighter plastic alternatives are available, nothing protects and preserves the contents of a container as well as glass does. The oldest drinkable bottle of wine in the world dates from 1727. A Finnish sommelier recently had the opportunity to sample a bottle of 200-year-old champagne. This is how she described it, “Despite the fact that it was so amazingly old, there was a freshness to the wine. It wasn’t debilitated in any way. Rather, it had a clear acidity which reinforced the sweetness.” Almost uniquely in a world that is largely blind to the environmental consequences of ‘disposable packaging’, glass is both reusable and recyclable. Glass is 100 per cent recyclable, it can be recycled again and again without any loss of quality or unity. Recycled glass is also an important component of manufactured glass, significantly reducing the energy demand of the process. For example, in 2012, 96 per cent of the glass bottles sold in Switzerland were recycled. We have been using glass to make containers for food, drink and medicine for over 7,000 years. Although we have refined the glass making process to the extent that an individual factory can turn out two or three million bottles a day, the basic process remains the same – take a molten lump of sand, soda and limestone and make into a bottle through a multi-step process of molding, forming, blowing and annealing.

S O F T WA R E & E N G I N E E R I N G TO O L S | T E C H N O L O G Y

The glass forming process is also extremely sensitive to changes in machine timing, glass composition and environmental conditions

necessity, the weight of a typical glass bottle has reduced by over 40% without any loss in structural rigidity or increase in fragility. However, modern lightweight bottles are often much stronger than their older, heavier counterparts.

Stages in the bottle-making process “In order to make a structurally strong bottle, there are two critical stages. In the first step, a glob of molten glass is moulded into a parison, which is a preliminary bottle shape. After this, the final bottle is formed in another mould,” says Marcello and further shares, “Getting this first shape right is extremely important in ensuring the structural strength of the final bottle; it has to be very precise otherwise the bottle will break during normal usage conditions.” During the manufacturing process, the glass is cooled from over 1,000oC to ambient temperature, during which time, the viscosity of the glass increases by seven orders of magnitude (from 100P to 1e9P). If the bottle is cooled too rapidly or unequally, then internal stresses are generated in the walls of the container that reduce its overall durability.

Employing ‘trial and error’ analysis The significant problem, in this regard, is that it is impossible to understand what actually happens to the molten glass during the moulding process, which happens unseen inside the bottle making machine. Historically, the only way to judge the effectiveness of an extremely complex physical process was to look at the quality of the final product, its glass distribution and try to imagine what might have gone wrong inside the mold. “The strength of the final product depends to a great extent on how the glass is cooled during the manufacturing process,” says Simone and elaborates, “Although we can measure the temperature of the mould in the glass plant, without simulation,

we have little or no insight into the actual temperature of the glass itself. The standard approach in the industry is one of trial and error. Stopping the manufacturing process for months at a time, so that trials can be performed, costs both time and money and doesn’t really give much insight into any problem in the process itself.” A large bottle manufacturing plant can produce more than two million containers a day, or 25 bottles per second. The cost of these ‘trial and error’ investigations or unresolved problems in the manufacturing process is huge. For this reason, Bottero decided to deploy engineering simulation as a way of gaining detailed insight into the bottle making process, performing simulations that improve both the process itself and the quality of the glass containers produced.

Multidisciplinary simulation using STARCCM+ software “To make a good glass container, you need to actually study the physics of the glass,” says Marcello, relating the key insight that is at the heart of Bottero’s simulation philosophy. “Rather than thinking only of the mold, we oriented our view on the glass itself. The big advantage of the simulation is that it allows you to really understand what is actually happening inside the mould. You cannot see that from physical experiments because the mould is closed, it’s made from cast iron, so you can’t see what is happening inside.” The glass forming process is also extremely sensitive to changes in machine timing, glass composition and environmental conditions. Simone explains, “As it is nearly impossible to physically visualise what really happens inside the moulds during the different phases, numerical simulation is the only tool available to help better understand the details of the physics as they occur during the process.” “We have very complex physics,” explains Marcello. “If we look just at the machine production, structural and fluid

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T E C H N O L O G Y | S O F T WA R E & E N G I N E E R I N G TO O L S

The glass making industry is deeply conservative, sometimes relying on experience gathered over decades and passed down over centuries

dynamic aspects can be separated. If we look at the product we have to manage, they can’t. They must be treated together. They are very, very coupled. We produce machines to make containers. The container is made by the cooling down of the molten glass, but it has very hard structural requirements. Understanding the actual temperature of the glass is by far the most important factor in ensuring the strength and quality of the final container. Multidisciplinary simulation using a tool like STAR-CCM+ (software) is the only way that we can achieve that,” he said. Marcello continued, “To improve a glass container using trial and error alone can involve many weeks of lost production. We can achieve the same thing using simulation in less than a day.”

Facilitating innovation However, solving the engineering problem is not the only challenge that Marcello and his team had to face. The glass making industry is deeply conservative, sometimes relying on experience gathered over decades and passed down over centuries. Although this experience-based knowledge is always valuable as a starting point for developing new products, it is unsuitable for the sort of intelligent design exploration required to facilitate true innovation. “Many people from glass plants tell us that it is impossible to simulate the structural resistance of the glass or to simulate the forming process of the glass,” says Marcello and adds, “Maybe at the beginning, we were far-fetched. But now we are consistently obtaining good results and simulation is allowing us to discover important new markets in which we have no competition at the moment.”

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The payoff: stronger, lighter bottles How much better are the products designed through simulation? “Well, for example, not many people realise that the bottle for a sparkling beverage must resist upto at least 13 times atmospheric pressure,” says Simone and further elaborates, “At the same time, we are trying to reduce the weight of the container, save money, and increase the structural performance of the vessel. We can only do that by controlling the glass distribution in the container so that it is as close as possible to the ideal, and thereby avoid defects in the glass.” “Recently, we helped one of our customers to reduce the weight of a bottle that holds carbonated beverages using simulation,” continues Marcello. “When he tested the bottle that we helped him to produce, he was unable to make the bottle explode. This is an incredible achievement - simulation has pushed the structural performance of the bottle beyond the capability of the testing machines. This would have been impossible without simulation.” “None of our competitors make extensive use of simulation,” continues Simone. “So this has been really good for our customers. They are starting to pay us to show them how to improve their manufacturing, for example, how to design better molds and ultimately, produce better bottles. So, we are actually acquiring knowledge from simulation that is superior to that previously gained by experience alone.” In this way, by using simulation in the manufacturing process, Bottero satisfies consumer demand for a unique product by producing a bottle that is well made, lightweight and leaves a lasting impression. ☐ Courtesy: CD-adapco

C O N T R O L & C O M M U N I C AT I O N | T E C H N O L O G Y

Making flexible control system The article discusses how with the help of a multi-zone remote I/O solution can be attained a highly flexible I/O system for the process industry, which allows tailored communication in any application area – from zone 1 and 2 right through to the safe area The process is actually simple: The further the I/O level is extended into the field, the less wiring is required for connecting the field devices to the control system of an installation. Normally a remote I/O station only requires one bus cable – or two with redundant designs – to be routed from it to the control system. Remote I/O solutions also normally save space in the control room because the I/O level is moved to the field. These solutions are also easy to plan.

Remote I/O system Turck’s excom has been available for the past fifteen years to provide this kind of remote I/O system for use in zone 1. The system transmits the process and diagnostic data of the periphery and communicates, if necessary, with the HART field instrumentation.

However, not all users share the preference for I/O installations in the field. Some customers place importance on having their entire I/O technology directly in the control room and connected to the DCS solutions. The reasons for this are multiple. Wage costs for wiring the field devices are less expensive. The cost saving benefit resulting from the reduced wiring of a remote I/O solution is therefore less significant.

Flexible application scenarios with one series The use of excom as a system I/O, like the use of excom in the Ex area, provides the benefit that a separate interface technology for galvanic isolation or Ex separation is unnecessary. The little planning and space required compared to conventional interface technology applications, therefore, also pays out here. The functions and handling of the system are the same for

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T E C H N O L O G Y | C O N T R O L & C O M M U N I C AT I O N

In terms of software, the company has expanded the functionality of the gateway firmware and the DTM

both types of installation. There is a standard structure and operating philosophy, both for the integration in the DCS system as well as for DTM-based asset management. The system can in all cases be maintained and modified during operation. This applies both to adding individual measuring points as well as to extending a system with additional modules. The tried and tested redundancy options of excom are also fully supported. A standard Ex-i periphery supports signal processing and field device control from zones 0, 1 and 2. If this periphery is installed in zone 1 and 2 in order to detect signals as closely as possible to the location of the instrumentation, a specially optimised power supply unit is available for this application, which generates an intrinsically safe system voltage. The interface to the fieldbus, in this case Profibus DP, is also intrinsically safe. This configuration enables the entire system to be fully maintained during use in the Ex area. The identical Ex-i periphery can now, however, also be used in the non-Ex area. The high signal density of excom can offer here the possibility of operating up to 24 I/O modules, which further reduces the basic installation costs. The special power supply unit for this application area makes the entire system considerably more compact. A special gateway provides the necessary protection of the Ex-i periphery to the bus so that a separate segment coupler is not required for implementing the intrinsically safe physical bus characteristics of RS485-IS.

Extended portfolio for the safe area Even with exclusively non-Ex area applications, the user benefits from the advantages of the excom family: Two modules for digital 24 VDC signals were recently added to the range. A separate module for this purpose in the safe area has not been available to date. The new modules now close this gap. The DO80-N is suitable for connecting 24 VDC 3-wire digital sensors in PNP or NPN versions. It is a suitable module for digital output signals in the safe area. The DO80-N 24 VDC output supplies 24 VDC with 0.5 A. Itâ&#x20AC;&#x2122;s short circuit protection

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can be configured as locking or non-locking in order to adapt it optimally to the application at hand. Both modules are therefore ideal for migration projects since their switching behavior can be adapted to the application in the controller.

New firmware and new DTM In terms of software, the company has expanded the functionality of the gateway firmware and the DTM. The GDPIS FW 2.3 firmware for excom in zone 1 now supports all new modules. Information and maintenance functions can now also be integrated in compliance with the profile. The new software now makes excom open for DD - based asset management, such as for the predictive maintenance of field devices. HART protocols are tunneled to the field device in compliance with the profile. The new DTM likewise supports all new modules. The overview of the system status was improved with an enhanced diagnostics view. General systems states are now supported better with a DTM - based access.

Compact module rack The company is offering in the range a particularly compact module rack for smaller installations in the field. The MT08 offers space for eight electronic modules and like other module racks guarantees a high availability, thanks to a redundant power supply and redundant communication modules. The housing series for the module racks has also been standardised. The depth of all variants is 260 millimeters with the corresponding widths of 460, 650 and 800 millimeters for excom installations with 8, 16 or 24 modules. The flange plate on the bottom can now be replaced in order to adapt the cable routing to individual customer requirements. The standard flange plates provide space for up to 120 M16 or M20 cable glands and can now be replaced individually. â&#x2DC;? Courtesy: Turck India Automation

M A N U FA C T U R I N G I T | T E C H N O L O G Y

Realising enhanced production efficiency An application story on how fast-moving consumer goods firm uses NX software products to reduce product development time by more than 50% and, thereby, optimise the manufacturing process Jyothy Laboratories Limited (Jyothy) is a fast-moving consumer goods company founded in 1983 and located in Mumbai, India. The company has 21 manufacturing units in 14 locations across the country, including six business divisions: fabric care, household insecticides, utensil cleaners, fragrances, personal care and fabric care service. It is a fast-moving consumer goods company founded in 1983 with 21 manufacturing units at 14 locations across India. It has six business divisions, including fabric care, household insecticides, utensil cleaners, fragrances, personal care and fabric care service. Some of the companyâ&#x20AC;&#x2122;s brands include Ujala, Maxo, Exo,

Jeeva and Maya. Ujala is a liquid fabric whitener and is the biggest brand in the company portfolio. Fabric care contributed 44% to company revenues in 2014. The company is the largest player in the fabric whitener space in India, with a market share of 72%. To retain its competitive edge as a leading, fast-moving consumer goods company in India, Jyothy wanted to improve time-to-market for its new products. To meet this goal and achieve enhanced production efficiency, the company chose a trio of NXâ&#x201E;˘ software products from product life-cycle management (PLM) specialist Siemens PLM Software: NX CAD for computer-aided design (CAD), NX Mold Design for

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automated mould design and NX CAM for computer-aided manufacturing (CAM).

Prior to deploying NX, Jyothy performed product design with 2D CAD software that featured a manual approach and inevitably led to a significant amount of testing by trial and error. These software products were just not able to adequately address all areas of product design and development. As a result, it took Jyothy six to seven months to develop a new product design. The company found it was much easier to design with NX CAD. By combining the advantages of NX CAD with NX Mold Design and integrating them with NX CAM for the production process, they were able to reduce new product development time by more than 50% with these Siemens PLM Software solutions. “NX enabled us to substantially improve our productivity, which helped us add new products to our portfolio,” said G Viswanathan, Assistant Manager—CAD/ CAM, Jyothy.

generated tool paths using NX CAM. By integrating 3D modeling with CAM, the company found that they could more quickly introduce new, robust products with fewer design and manufacturing errors, and leverage a faster and shorter development cycle that required far less tooling rework. NX can be used for CAD, mould design and CAM. It leverages excellent training and support of Siemens PLM Software partner DesignTech. It is a key component for optimising manufacturing process. This helps to reduce product development time by more than 50%, achieve a 50% cost savings in design, improves productivity by 35%, improves quality and reduced errors by 75%, realises faster time-to-market, larger market share and produces higherquality products. DesignTech has also helped Jyothy get the most out of their NX products by providing training to designers, so they could learn and implement the required skills. The company also provided consistently strong support. “Proactive and timely support from DesignTech helped bring us up to speed and gain proficiency with the NX products, so we could make best use of them,” shared Viswanathan.

Reducing errors

Gaining market share

In addition to seeking to reduce time-to-market, the company also wanted to cut development time and costs as well as decrease design and manufacturing errors & defects. This had been an issue in the past because they had inadequate methods for tooling and production, so they often needed to do a lot of rework in tool design. “There’s no question that the integrated solutions of NX CAD, NX Mold Design and NX CAM helped us realise faster time-to-market, gain a larger market share and produce betterquality products,” said Viswanathan. Jyothy conducted product design in NX CAD, used NX Mold Design to perform moud analysis and mold design, and

Jyothy found that NX had helped them achieve accomplishments, such as reduced costs associated with design by 50%, enhanced productivity by 35%, improved product quality by 75% and significantly reduced errors. “There’s no question that the integrated solutions of NX CAD, NX Mold Design and NX CAM helped us realise faster time-to-market, gain a larger market share and produce better quality products. NX enabled us to realise a substantial enhancement in productivity, which helped us add new products to our portfolio,” concluded Viswanathan. ☐

Cutting development time

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Courtesy: DesignTech Systems

M A N U FA C T U R I N G I T | T E C H N O L O G Y

Towards smart & sustainable manufacturing Today, digital technology is impacting every aspect of business, creating more opportunities for growth. Strategists are challenged by how best to harness this digitisation to make profitable, valuedriven decisions, and manufacturers are realising that adopting advanced, smart manufacturing technologies are a qualification to be in the game. Companies have started integrating many advanced automation & cloud technologies in their operations. A read onâ&#x20AC;Ś To gain a competitive position in the market, manufacturers need to actively understand consumer behaviour and accordingly revamp the companyâ&#x20AC;&#x2122;s role in the ecosystem of partners, suppliers and customers. In the journey towards smart and sustainable manufacturing, to achieve a complete value chain transformation, industries are required to not only digitise essential functions within the internal vertical operations, but also integrate with their horizontal partners along the entire value chain.

Lokesh Payik GM & Business Domain Head - Connected Industry Robert Bosch Engineering & Business Solutions

In order to accomplish this, transparency and clarity on the status of all aspects of production system in real time is essential. Industry 4.0 delivers this visibility that enables organisations to see the different elements of manufacturing and recognising the different connections between them. It provides the much needed visibility on the most important performance metrics like quality, production output, defect percentage and overall equipment efficiency.

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T E C H N O L O G Y | M A N U FA C T U R I N G I T

The change is here The production landscape is changing. Information from different entities of manufacturing form new relationships. There are new links between different nodes of production. The data of a particular production entity can be combined in new ways to solve problems of another entity. Bosch works with customers from diverse industries and there is clear indication that concepts of Industry 4.0 are having a major impact on businesses. It appeals to organisations as a new form of digital business design that can enable them to be fast, reliable and highly flexible.

Shaping the future of ‘Connected’ world Delivering smart manufacturing concepts, with value driven services requires experience in both cross domain system integration and efficient product manufacturing. Bosch considers both sides of the equation equally important. Hence, we set out a dual strategy approach, playing the role of both the solution provider and user. In the 250+ plants spread across the world, Bosch produces world class automotive components for mobility solutions, industrial tools, components and several other consumer goods. Most of the Industry 4.0 solutions offered to external customers have already been deployed in our own plants and fine-tuned to produce outstanding results. This practitioner approach is what sets us apart in the customers’ view and positions us as a competent partner to implement such technology intensive solutions.

Future shopfloors & Industry 4.0 portfolio The shopfloor of the future would have smart machines that are connected to each other and also to a central network

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system and would support smooth and flexible operations. The revolutionary multi-product line in Bosch Rexroth, Homburg produces 200 variants of hydraulic valves in the same line economically and with no retooling effort. The assembly line connects people, machine & products seamlessly through autonomous workstations that reconfigure themselves to suit the various production needs of the facility and can accommodate a batch size as small as one product. The Blaichach plant, is a paperless factory with fully automated flow of goods, lean logistics, standardised maintenance procedures and has about 5000 connected systems in the production network. In a typical shopfloor, to perform manufacturing operations seamlessly and efficiently, the right information should be available to the right personnel at the right time to enable them to be present in the right place. Our portfolio of shopfloor management solutions supply this critical production data in real time with situation-oriented information, which enables stakeholders to respond as quickly as possible to faults and malfunctions. Also, it orchestrates the interplay between man, machine, and material for the most optimum resource utilisation and makes ‘paperless manufacturing’ a reality. Traceability provides valuable history of a manufactured lot – to track product genealogy to optimise warranty spends, ensure effective supplier charge backs and to comply with regulations. Data analytics also benefits in understanding and predicting demand, by recognising patterns in the consumer behaviour, thereby, helping companies alter the way they design, market and deliver products and services. Millions of measurements from cycle times, waste rates, production volumes, etc help in the predictive maintenance of machines, reduce the scrap rate and reduce machine downtime. Sensors are indispensable to a wide range of industries and developments in industrial sensors are happening at a

M A N U FA C T U R I N G I T | T E C H N O L O G Y

Delivering smart manufacturing concepts, with value driven services requires experience in both cross domain system integration and efficient product manufacturing

phenomenal rate. Smart sensors like Bosch’s XDK can be easily installed in manufacturing equipment to automatically log data like temperature, humidity, vibration, hours of operation, etc. It can be used to monitor heavy equipment performance and transmit critical data to trigger timely machine maintenance. Operator assistance systems for real time representation of equipment health, maintenance of support systems like operator mobility solutions (on tablets and mobile phones) and remote diagnostics (real time status and control) provide everyday tangible support to operation and maintenance personnel. Our flexible automation solution, the APAS Robot, is truly an Industry 4.0 innovation. Its integrated 3D image processing enables it to recognise objects and has a sensitive three finger gripper. Contrary to the common sight where robots are put to work in cages, the APAS is safe for human robot collaborative work environment and has a speed switch that would slow down movements when it senses a human in its workspace.

Need to adopt Industry 4.0 In India, we see a steady rise in companies increasing their overall level of digitisation. Companies with conventional set-ups are realising that they may be engulfed in technological obsolesce and left behind. Manufacturing

plants, which are struggling to achieve higher quality and productivity due to old processes and systems, are making a bold move to new and innovative technologies. Industrial leaders are keen on digitising their essential functions and believe that adopting Industry 4.0 concepts in their operations will help advance their operational efficiency and hence revenue growth. Many industries are leaning towards beginning their digital journey by implementation of pilot projects and using them to establish proof of concept. This idea of targeting a confined scope and validating the business value of executing it would help industries make an informed decision towards extending it to their entire ecosystem. In conclusion, manufacturers need to actively understand consumer behaviour and accordingly revamp the company’s role in the ecosystem of partners, suppliers and customers. The conventional model of products being pushed in to the market would transit and herald the new norm of ‘Co-Creation’ where customers will have a collaborative role in the design of products & services. To stay up to date in this digital age and prepare for this transformation, manufacturers need to upgrade their strategic mindset and encourage their employees to think and act in digital terms, be willing to experiment with new technologies and learn new ways of operating, thereby leading a companywide transformation. ☐

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NEWS | TECHNOLOGY

mapp technology

Data logger

B&R simplified the development of machine software with the introduction of mapp technology. These pre-coded and thoroughly tested modular software components have been making life easier for OEMs by taking low-level programming tasks for basic functions off their hands. Encouraged by outstanding market acceptance in this short time, the company has continued to expand its software framework – offering mapp technology customers even greater savings, while at the same time improving the quality of the resulting software. The mapp components provide pre-coded functions that developers can quickly configure in a simple user interface. Each mapp component is subjected to rigorous multi-stage testing, both individually and in combination with other components. This in turn improves the quality of application software they are used to create. B&R has also harmonised the version and released data for all of its software, making it easier for machinery and equipment builders to plan when specific functions will be available. Users no longer need to be concerned with dependencies between software versions.

NOVUS is launching an ideal temperature data logger for logistics operations—TagTemp-S. The data logger is coupled directly to sensitive products, communicates via NFC interface (Near Field Communication) and enables access to recorded data at any time by cell phone. Temperature monitoring and alarms are crucial for ensuring transportation and storage at the ideal standards. It’s compact structure features IP65 splash protection, memory capacity of up to 4000 logs in programmable interval and measurement range from -30°C to +70°C. Registered temperatures can be read without needing to stop TagTemp-S recording data. This lets the user make decisions quickly before compromising the quality of products. Information acquired with the data logger can be viewed in the LogChart-NFC app for ANDROID, available free-of-charge from the Google Play store. The software also allows for viewing the temperature chart, alarm occurrences and for sharing information via email. Moreover, the information can also be accessed on a computer via an NFC interface with the LogChart-II software.

B&R Industrial Automation| Pune Email: office.in@br-automation.com | Tel: +91-20-4147-8999

NOVUS Automation| Brazil Email: rodrigo.zereu@novusautomation.com | Tel: +55-51-3323-3636

Data communication protocols

Smart measurement systems

Beckhoff offers a new extension of the OPC UA specification for direct integration of OPC UA Pub/Sub UDP communication into the TwinCAT 3 runtime. This paves the way for straightforward configuration of publishers and subscribers, as well as exchange of data in real-time. Through the early integration of the Pub/Sub UDP extension, the company has emerged as an early adopter of OPC technologies. One particular advantage is the much simplified configuration Integration of OPC UA Pub/Sub resulting from direct integration UDP extension into the TwinCAT 3 engineering environment. Communication is initiated directly from the TwinCAT 3 runtime, creating a deterministic and, therefore, real-time-capable communication channel via OPC UA. The conventional client/server applications are decoupled from one another in publisher/subscriber-based data communication and no longer need to know each other. The publisher simply sends its data, as a UDP multicast in this case, to a multicast group. The subscribers receive the data by subscribing to the multicast group instead of the actual device. These advantages can be utilised in many areas of industrial automation.

Testo India offers new product ranges with smart and easy measurement techniques using the smartphone interface. Currently, the company’s products are used for HVACR applications among others with parameter measurement like temperature, humidity, pressure, RPM, lux, electrical etc, data monitoring, flue gas analysis, combustion and emission controls and thermography. The traditional methods and processes are now testo Smart Probes getting replaced with smart solutions to keep in pace with the new advancements prevailing around. Thus, the company’s new product range—the air capture hood testo 420 and the new range of smart probes equips the users with smart and easy measurement techniques using the smartphone interface. It offers WiFi Data Logger – Saveris 2, which is advancement in data monitoring system. With a secure online storage of all readings in Testo Cloud, the data can be managed & analysed online by the user via smartphone, tablet or PC. The latest solution to the industry is a new range of thermal imagers with smartphone integration designed to deliver networked thermography.

Beckhoff Automation | Pune

Testo India | Pune

Email: info@beckhoff.co.in | Tel: +91-20-4000-4800

Email: info@testoindia.com | Tel: +91-84080-57707

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TECHNOLOGY | NEWS

Decentralised drive solutions

PCB connectors

NORD Drivesystems offers decentralised drive units with integrated PLC that can control both simple and complex applications directly. This reduces the load on the higher level system control unit and enables modular system designs and autonomous production units. Launching the label ‘NORD 4.0 READY’, German manufacturer NORD DRIVESYSTEMS provides Decentralised drive solutions for Industry 4.0 scalable electrical drive systems and software to cover the full spectrum of tasks, from simple actuators to complex networked systems. Machine and plant designs that live up to the German ‘Industry 4.0’ framework and the similar concept of the Industrial Internet of Things require smart drive technology with high flexibility and functionality. The drives must be seamlessly integrated into communication networks, ensure efficient data processing, and support modular, decentralised control concepts. To meet this requirement, the company developed these decentralised drive solutions. The company offers a wide range of products that include geared motors, motors, industrial gear units, frequency inverters, motor starters and frequency inverters for decentralised drive control.

Phoenix Contact has expanded its PTSM product range for LED applications with the new PTSM 0,5/.. PL PCB connectors. The PCB connectors have positive latches on the side, which ensure stable latching with the counterpart. When used in combination with inverted PCB connectors from the same series, the miniature connectors are particularly suitable as a compact wire-to-wire connection. The white PCB connectors connectors are available with 2.5 mm pitch. They are designed for currents up to 6 A and voltages up to 320 V. Thanks to the convenient Pushin connection, conductors with cross sections from 0.14 mm² to 0.75 mm² can be connected quickly and reliably. Thanks to the small and flat design, the entire PTSM product range is ideal for LED applications. The range includes PCB connectors and PCB terminal blocks, as well as board-toboard and wire-to-wire connectors. Black and white versions are available for various areas of application. Together with customers and partners, the company designs solutions for the future using trend-setting connection and automation technology.

NORD Drivesystems | Pune Email: india@nord.com | Tel: 1800-200-2042

Phoenix Contact | New Delhi Email: works@phoenixcontact.co.in | Tel: +91-11-3026-2700

Gripping modules

Laser sensors

SCHUNK offers BSWS-MPG-plus standardised finger blank gripping modules. This features an integrated quick-change jaw system to shorten time for a jaw change in small parts grippers of the SCHUNK MPG-plus series to fewer than 30 seconds. Compared with a conventional jaw change, the system reduces the set-up times by up to 90%. An easily accessible form-fit locking mechanism ensures finger change at a repeat accuracy within seconds by a 90° turn of an allen key. Since no through-bores through the entire finger are necessary, as opposed to other standard solutions on the market, users additionally BSWS-MPG-plus benefit from maximum freedom in the design quick-change fingers of the finger contour: the entire length of the fingers can be adapted to the individual workpiece without having to take into account the jaw change and the required screw connections. The finger blanks with the integrated quickchange system are available in aluminium or steel. The higher force and maximum moment enable longer gripper fingers and higher gripping forces in modules of the same size.

Micro-Epsilon offers new optoNCDT 1320 and 1420 laser triangulation sensors that are now more versatile. Additional measuring ranges of 100 mm and 200 mm enable even more application possibilities in terms of displacement, distance and position measurement. The optoNCDT 1320 and 1420 laser triangulation sensors measure displacement, distance and position on a non-contact, wear-free optoNCDT 1320 & 1420 basis. With the additional measuring ranges, the sensors can now be applied in measurement tasks that require a larger measuring range. The optoNCDT 1320 is now available with a 100 mm measuring range, the optoNCDT 1420 with additional ranges of 100 mm and even 200 mm. The sensors provide high-precision measurements along with a compact design, offering high performance across a wide variety of applications. Furthermore, the sensors stand out due to their excellent price/performance ratio, an innovative web interface and their ease of use. The measurement task can be selected using the quality slider and can be further optimised using the video signal display, signal peak selection and individually adjustable signal averaging.

SCHUNK Intec India | Bengaluru

Micro-Epsilon | Pune

Email: info@schunk.com | Tel: +91-80-4053-8999

Email: pragnesh.mori@micro-epsilon.de | Tel: +91-20-2674-1009

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NEWS | TECHNOLOGY

Energy chains

3D measurement system

igus has developed the E6.1 series of e-chains for extreme dynamics with very low noise. This can be used for applications where very low-abrasion energy chains are required, for example, in the clean room in semiconductor manufacturing. Instead of a pin/ bore connection, elastic polymer spring elements in the side elements serve as connectors for a dampened and very smooth running of the chain. The very small pitch and contour of the chain links ensure that the polygonal effect is E6.1 series of e-chains reduced to a minimum and the chain rolls very smoothly. Thanks to the narrower design compared to the E6, roughly 30% can be saved with the same inner dimensions. For all installation sizes of the E6.1, the crossbars can be removed along the inner and outer radii, so that quick filling is possible. This means that when the chain is already installed in the machine, additional cables or hoses can easily be drawn in. Almost all of the crossbars are also equipped with a grid marking.

ISRA Vision offers SCREENSCAN-RD (Reflected Distortion), a fully automated 3D measurement system that makes possible for the first time to objectively assess the reflection quality of curved automotive glass. As such, the innovative system makes it possible to leave behind manual inspection processes, which in view of the ever-growing complexity of the various glass forms can no longer efficiently satisfy the demands of today’s industry. With its leading-edge functions, based on patented no-contact measuring processes, the measurement system guarantees the production of highly-attractive automotive windshields with absolutely no flaws. This, Application of SCREENSCAN-RD thus, achieves maximum attractiveness, safety, and the potential for enormous savings. ISRA equips SCREENSCAN-RD with intelligent tools, which offer much more than just inspection. It starts with a target-actual comparative feature against CAD data, and is followed by an evaluation option to compare freely definable critical values and individually particularly relevant regions. Even a simulation using known grid processes is defined in the software. Tools for data analysis round-off the full range of additional functions.

igus (India) | Bengaluru Email: Harish@igus.in | Tel: +91-80-49127809

ISRA Vision India | Mumbai Email: info.india@isravision.com | Tel: +91-20-2674-1000

Condition monitoring system Turck offers IMX12-CCM (Cabinet Condition Monitoring) cabinet guard, a new multi-function device, which can be installed and also retrofitted in virtually any control cabinet or box in order to continuously monitor the actual degree of protection. The railmounted device uses a simple switch signal to indicate to the control system any incorrect closing of doors or the exceeding of limit values for temperature and interior humidity. The 12 mm wide IMX12-CCM comes with an intrinsically safe 2-wire isolating transducer interface, thus, IMX12-CCM enabling it to be used also in explosion hazardous areas. The simple teach-in process can be carried out directly on the device without the need for computer or any additional tools. The standard HART interface is provided for additional diagnostic options, such as for reading out the absolute measured values. Besides the interface technology, Turck’s control cabinet guard offers a range of sensors, which monitor the actual status of the environment—a temperature sensor, an absolute humidity sensor and a triangulation sensor.

Statement about ownership & other particulars about A&D, as required to be published in the first issue every year after the last day of February 1. Place of Publication: 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001 2. Periodicity of Publication: Bi-monthly 3. Printer’s Name: Shekhar Jitkar Address: 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001 4. Publisher’s Name: Shekhar Jitkar Nationality: Indian Address: 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001 5. Editor’s Name: Shekhar Jitkar Nationality: Indian Address: 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001 6. Names & addresses of individuals who own A&D and partners or shareholders holding more than 1% of the total capital in publish-industry India Pvt Ltd, 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001 Details of the shareholders of publish-industry India Pvt Ltd who are holding more than 1% of the paid up equity share capital of the company as on 22-04-2017: a) publish-industry Verlag GmbH, NymphenburgerStrasse 86, 80636 Munich, Germany b) Kilian Mueller, NymphenburgerStrasse 86, 80636 Munich, Germany I, Shekhar Jitkar, hereby declare that all the particulars given above are true to the best of my knowledge and belief. Dated: April 22, 2017 Sd/SHEKHAR JITKAR Signature of the Publisher

TURCK India Automation | Pune Email: india@turck.com | Tel: +91-7768933005

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H I G H L I G H T S | C O M PA N Y I N D E X | I M P R I N T

Highlights - June/July 2017 IMPRINT

Automation & Drives

Publisher / Chief Editor ShekharManufacturing Jitkar Efficient

shekhar.jitkar@publish-industry.net Senior Features Writer Megha Roy megha.roy@publish-industry.net Features Writer Maria Jerin maria.jerin@publish-industry.net Sub-editor & Correspondent Suchi Adhikari suchi.adhikari@publish-industry.net

» Power & Energy The global energy industry is undergoing unprecedented changes. Rapid increase in energy consumption in the developing world will be the key driver of growth for the global energy market. Market participants have to start preparing for the oncoming spike in demand. To help companies effectively navigate the market and successfully achieve growth objectives, the next issue takes a look at the power and energy industry and gives a take on its current status as well as the future trends.

» Fieldbus & Networks Although fieldbuses have been around for more than a decade, recent years have seen an increase in focus on application of this technology for drives. One of the problems that has impeded the rapid adoption of fieldbus technology has been the lack of standardisation. Several competing alliances were created that all strived to develop an open fieldbus that would establish itself as standard. The result is that, today, there exists a plethora of standards for open fieldbuses. In the subsequent issue, we take a look at some of the standards and recent developments in this sector.

» Test & Measurement Wireless is changing the face of test & measurement equipment at a pace never seen before. The test and measurement industry centres on the production of tools used to analyse, validate, and verify measurements of electronic and mechanical systems. This industry creates both general use and highly specialised tools and caters primarily to high-tech industrial, automotive, communications, and medical electronics industries. The upcoming issue gives an insight into the recent advancements and looks at how beneficial the systems can be to industries.

Advertising Sales & Marketing Sagar Tamhane (General Manager – North & East) Contact: +91 9820692293 sagar.tamhane@publish-industry.net Dhiraj Bhalerao (General Manager – West & South) Contact: +91 9820211816 dhiraj.bhalerao@publish-industry.net Prabhugoud Patil (Senior Manager – Bengaluru) Contact: +91 9980432663 prabhu.patil@publish-industry.net Advertising Sales (Germany) Caroline Häfner (+49 - 89 - 500 383 - 53) Doreen Haugk (+49 - 89 - 500 383 - 27) sales@publish-industry.net Overseas Partner Ringier Trade Media Ltd China, Taiwan & South-East Asia Tel: +852 2369 - 8788 mchhay@ringier.com.hk Design & Layout Tarun Kumar Pyne Senior Graphic Designer (Print & Web) Editorial & Business Office publish-industry India Pvt Ltd 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001, Maharashtra, India Tel: + 91 - 20 - 6451 5752

COMPANY INDEX Name . . . . . . . . . . . . . . . . . . . . . . . . . Page ABB India . . . . . . . . . . . . . . . . . . . . . . . 8, 12 Aerotec . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Apex Dynamics . . . . . . . . . . . . . . . . . . . . . 36 ARC Advisory Group . . . . . . . . . . . . . . . 17, 57 B&R Industrial Automation . . . Cover, 6,7, 18, 69 Beckhoff . . . . . . . . . . . . . . . . . . . . . 1, 20, 69 Bentley Systems . . . . . . . . . . . . . . . . . . . . . 12 Bosch . . . . . . . . . . . . . . . . . . . . . . . . . 38, 66 CD-adapco . . . . . . . . . . . . . . . . . . . . . . . . 58 Contrinex Automation . . . . . . . . . . . . . . . . . 19 CST Sensors . . . . . . . . . . . . . . . . . . . . . . . 11 DCM Shriram . . . . . . . . . . . . . . . . . . . . . . . 24 Delta India Electronics . . . . . . . . . . . . . . . . . . 3 DesignTech Systems . . . . . . . . . . . . . . . . . . 64 Emerson . . . . . . . . . . . . . . . . . . . . . . . . . . 44 EOS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 EtherCAT Technology Group . . . . . . . . . . . . . 26 Frost & Sullivan . . . . . . . . . . . . . . . . . . . . . 36

Name . . . . . . . . . . . . . . . . . . . . . . . . . Page Galil Motion Control . . . . . . . . . . . . . . . . . . . 48 HMS Industrial Networks . . . . . . . . . . . . 10, 37 Honeywell . . . . . . . . . . . . . . . . . . . . . . 10, 43 Hummel Connector Systems . . . . . . Back Cover IESA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 IFM Electronic India . . . . . . . . . . . . . . . . 22, 39 Igus . . . . . . . . . . . . . . . . . . . . . . . . . . . 2, 71 Inteltek JV . . . . . . . . . . . . . . . . . . . . . . . . . 51 ISA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 ISRA Vision . . . . . . . . . . . . . . . . . . . . . . . . 71 Katlax Enterprises . . . . . . . . . . . . . . . . . . . . 15 Kubler Automation . . . . . . . . . . . . . . . . . . . 41 Lanxess . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Lapp India . . . . . . . . . . . . . . .Back Inside Cover Maxon Motors . . . . . . . . . . . . . . . . . . . 29, 52 Micro-Epsilon . . . . . . . . . . . . . . . . . . . . . 5, 70 Mifa Systems . . . . . . . . . . . . . . . . . . . . . . . 55 Mitsubishi Electric . . . . . . . . . . . . . . . . . . . . 32

Name . . . . . . . . . . . . . . . . . . . . . . . . . Page Murrelektronik . . . . . . . . . . . . . . . . 12, 13, 27 Nord Drivesystems . . . . . . . . . . . . . . . . 47, 70 Novus Automation . . . . . . . . . . . . . . . . . . . . 69 Peschel Dynamics . . . . . . . . . . . . . . . . . . . 21 Phoenix Contact . . . . . . . . . . . . . . . . . . . . . 70 Pilz India . . . . . . . . . . . . . . . . . . . . 23, 42, 54 Renu Electronics . . . . . . . . . . . . . . . . . . . . 43 Rittal India . . . . . . . . . . . . . . . . . . . . . . . . . 14 RS Components . . . . . . . . . . . . . . . . . . . . . . 8 Schmersal India . . . . . . . . . . . . . . . . . . . . . 30 Schunk Intec India . . . . . . . . . . . . . . . . . . . 70 Sick India . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Siemens . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Testo India . . . . . . . . . . . . . . . . . . 31, 40, 69 Turck India Automation . .Front Inside Cover, 62, 71 Universal Robots . . . . . . . . . . . . . . . . . . . . 28 Voith Industrial Services . . . . . . . . . . . . . . . . . 8 Yaskawa India . . . . . . . . . . . . . . . . . . . . . . 25

Board of Directors Kilian Müller (CEO – Worldwide) Hanno Hardt (Head – Marketing & Business Development) Frank Wiegand (COO – Worldwide) Shekhar Jitkar (Publisher / Chief Editor) Subscription Cover Price: `100 Annual Subscription Price: `1000 em.india@publish-industry.net Tel+91-20-6451 5754 Printing Kala Jyothi Process Pvt Ltd, S.No 185, Kondapur, R R District, AP 500 133, INDIA Copyright/Reprinting The publishing company holds all publishing and usage rights. The reprinting, duplication and online publication of editorial contributions is only allowed with express written permission from the publishing company. The publishing company and editorial staff are not liable for any unsolicited manuscripts, photos and illustrations which have been submitted. Internet http://industr.com Digital edition http://issuu.com/publishi/docs

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