VOL 09 | JUN-JUL 2016 | ` 100 www.industr.com
A U TO M AT I O N & D R I V E S
Automation & Drives
TREND WATCH 2016
Efficient Manufacturing
FOCUS Power & Energy P. 30 ROUND-TABLE Embedding cyber security A&D - Interview N Viswanadham Fellow IEEE and INSA Senior Scientist Indian Institute of Science (p.24)
for industrial automation P. 26
In association with Advt
Also available in China, Taiwan, Singapore, Malaysia, Thailand & Hong Kong
An age of connectivity
Š 2016 SCHUNK GmbH & Co. KG
www.gb.schunk.com/robotaccessories
More than 1,200 Modules for your Robot
Feed-through Rotary feed-through DDF 2
Connecting Adapter plate
The unique standard line of modules for mechanical, sensor and power connections of handling modules and robots.
Monitoring Collision and overload sensor OPR
Joining and compensating Compensation unit TCU
Jens Lehmann, German goalkeeper legend, SCHUNK brand ambassador since 2012 for precise gripping and safe holding. www.gb.schunk.com/Lehmann
Changing Quick-change system SWS consisting of SWK (quick-change head) and SWA (quick-change adapter)
Gripping SCHUNK gripper PGN-plus 2-finger universal gripper with multi-tooth guidance
Chainflex lasts or money back. 速
950 types for E-Chains速 ex stock.
igus速 (India) Pvt. Ltd. 36/1, Sy. No. 17/3, Euro School Road, Dodda Nekkundi Industrial Area - 2nd Stage, Mahadevapura, Bangalore - 560048, Karnataka, India Phone : +91- 80 - 4512 7800, Fax : +91 - 80 - 4512 7802
plastics for longer life速
Meet us @ Amtex 2016 Venue: Pragati Maidan, New Delhi, Hall no. 11, Stall no. C-83 Date: 8th- 11th July 2016
www.deltaelectronicsindia.com
E D I TO R I A L
Stay connected...! Manufacturing is undeniably in the midst of a technological renaissance that is transforming the way products are manufactured and delivered to customers. The changing economics of production and distribution, along with shifts in consumer demand and the emergence of “smart” products, are pushing manufacturers to explore radically new ways of creating and capturing value. In this scenario, manufacturers cannot afford to ignore the technology advances vis-à-vis unforeseen changes in the markets. By embracing the technological advances, they can improve productivity in their own plants, achieve global competitiveness, and maintain an edge with customers who are seeking their own gains from innovation. This has enticed manufacturing companies to invest in new equipment and technologies designed to improve performance for themselves and their customers. With this, it becomes important to understand, what breakthrough technologies will have the major impact on factory environments? And at a time of rapid change and limited upside, which technology investments will have a positive influence on the business? Given today’s highly competitive global environment and the most volatile global economy, it’s reasonable to envision — and prepare for — a factory of the future, where all internal and external activities are connected through the same information platform. The Cover Story in this issue highlights the five important trends in the age of connected things, which will help you make sense of what’s next and how you can use it to solve your manufacturing challenges. So, stay connected & enjoy reading this issue!
A CLASS OF ITS OWN
NEW
optoNCDT 1320/1420 Laser triangulation sensors for fast and precise measurements Compact and user-friendly: easy integration into confined spaces Robust and long-life design Reproducibility from 0.5µm Small light spot Analog and digital outputs Unique ease of use via web browser Presets for various surfaces
EDITORIAL ADVISORY BOARD
Shekhar Jitkar Publisher & Chief Editor shekhar.jitkar@publish-industry.net Vijay Srinivasan Managing Director, Global Alliances, CSC
Anant Maheshwari President Honeywell India
Dr KLS Sharma Advisor Automation Education & Training
Anup Wadhwa Director—AIA (Automation Industry Association)
Ravi Agarwal Director, Pepperl+Fuchs (Factory Automation)
Mandar Phadke CEO, Abhisam Software Director, Risknowlogy Solutions
P V Sivaram MD—B&R Automation Member – AIA
Raj Singh Rathee Managing Director Kuka Robotics India
Arcot Rajabahadur Automation Consultant
Ganapathiraman G Vice President & GM (South and South – East Asia) ARC Advisory Group
Jasbir Singh Vice President Business Development Essar Projects (India)
Thampy Mathew Chairman, Fieldbus Foundation India Regional Sales Director, Pepperl+Fuchs (Process Automation)
Overseas Partner: China, Taiwan, Hong Kong & South-East Asia
A&D India | Jun-Jul 2016
Phone +91 20 267 410 09 5 www.micro-epsilon.in/opto
CONTENTS
Market
Management
Focus
Power & Energy 08
NEWS
14
“MAKING MANUAL OPERATIONS ACCURATE�
24
30
“UNDERSTANDING DISRUPTIVE TECHNOLOGY EVOLUTION�
Interview with N Viswanadham, Fellow IEEE & INSA Senior Scientist, Computer Science & Automation, Indian Institute of Science
Interview with Yaduvendra Singh, Global Head—Sales & Marketing, GreyOrange
Event Report 58
A post-event report on the recently held Rockwell Automation Life Sciences Symposium 2016 at Mumbai
The article discusses on improving wind turbine operations and maintenance with the real-time detection and analysis of lightning strikes using the Lightning Monitoring System
Round-table
LEVERAGING TECHNOLOGY FOR QUALITY AND COMPLIANCE
ENRICHING OPERATIONS AND MAINTENANCE
26
EMBEDDING CYBER SECURITY FOR INDUSTRIAL AUTOMATION
The round-table discusses how a cyber security cell should apprehend the ingoing risks and address the knowledge of the ever-changing security challenges
Cover Story 16
AN AGE OF CONNECTIVITY
A read on the next big thing in the age of connected things and how can one use it to the fullest to solve engineering challenges
1Ĺ?œņ ŅœŊŗņ %'3437 4 [[[ FV EYXSQEXMSR GSQ %'34374 4LSRI )QEMP WEPIW MR$FV EYXSQEXMSR GSQ
CONTENTS
Technology
Advt
Cover image courtesy: National Instruments
Fieldbus & Networks 34
Manufacturing IT 50
CONNECTED INDUSTRY
The article briefs on how networking technology can make cyber world and physical world connected to enable efficient industrial production 38
IoT APPLICATION IN MANUFACTURING SECTOR
The article talks about the benefits of IoT technology and how connecting production line systems can reduce cost and help for the optimum use of resources
Test & Measurement WHY FUTURE SMT PLACEMENT NEEDS ABSOLUTE ENCODER FEEDBACK?
The article examines some of the future trends in SMT placement technology and the role of absolute optical encoder systems
Ultra-miniature connector; Ethernet switches; Curved linear guides; Remote PLC;
62
Fire survival cables; Eddy current sensors; UHF read/ write heads; Safety gate system;
63
Coreless brush DC motor; Gripper for cobots; PLC programming software; Digital measurement system
Safety & Security 54
PROTECTION AGAINST LIGHTNING IN INDUSTRIAL ENVIRONMENT
The article discusses how safe operation of all electrical & electronic systems can be achieved, while considering the appropriate protection measures to address the safety challenges
Columns 05 06 64 64
Communication & Control 46
61
COMMUNICATING RAPIDLY
An application story on how effective communication was enabled between M-Bus and the OptoEMU that enables central control and supervision of measuring devices
42
New Products
Editorial Contents Highlights – Next issue Company index
AUTOMATION NETWORK FOR IIoT
The article discusses how industries can implement IIoT using standard interfaces for successful IIoT implementation
Advt
1SVI WTIIH
1SVI TVIGMWMSR
E\MW WIVZS HVMZI [MXL W WEQTPMRK XMQI
:MVXYEP WIRWSVW JSV QSVI TVIGMWI GSRXVSP
1SVI MRXIPPMKIRGI
1SVI TS[IV
7EJI 1SXMSR YT XS 7-0 40 I 'EX
,MKLIWX TS[IV HIRWMX] MR MXW GPEWW
MARKET | NEWS
ABB connects power to the Indian grid
Next generation industrial transport technology
ABB has successfully commissioned five substations to integrate a 648 MW solar project at Kamuthi in Tamil Nadu, to the national transmission grid. The project contributes to India’s vision of achieving 100 GW of solar power by 2022. As part of this plan, the government has issued a proposal to implement 25 ultra-mega solar power projects with capacities between 500 and 1,000 MW over a period of five years. The government of Tamil Nadu is also pursuing a solar Substation commissioned by ABB at Adani’s policy, which envisages a 648 MW solar power plant solar generation capacity addition of 3,000 MW. “We are proud to support the country’s clean energy vision,” said Claudio Facchin, President—Power Grids Division, ABB. The company’s project scope included the design, supply, installation and commissioning related to the solar plant electrification and automation systems. This includes two 230 kV and three 110 kV outdoor switchyards to connect to the local transmission grid and will enable clean power supply for around 150,000 households based on average national per capita consumption.
B&R is using the SuperTrak linear track conveyance system from the Canadian company ATS Automation in order to advance the next generation of industrial transport technology and strongly enhance the market penetration of this exciting technology. With many years of practical experience in implementing its SuperTrak technology, ATS perfectly complements B&R’s automation expertise and core competencies in signal and power electronics, motor design and software. In the era of smart manufacturing, integration of automation and IT ecosystems is no B&R’s transport technology combines longer an option, but an absolute optimised productivity with reliability requirement. Low-latency, hard to ensure maximum uptime real-time synchronisation with all types of servo axes including CNC and robotic systems guarantees high-precision, high-quality production output. B&R’s transport technology is based on a highly-decentralised architecture that allows extensive track lengths to accommodate the requirements of any machine. B&R’s low-maintenance technology is based on 14 years of field experience and offers the industry-proven reliability required for today’s competitive 24/7 production environments. The systems are designed for extremely low MTTR rates and ensure maximum uptime.
Endress+Hauser selects Digi Connect Sensor
Toyota joins hands with EtherCAT
Digi International recently announced that its new connect sensor cellular gateway has been selected for Endress+Hauser’s Inventory Management Solutions. The combination of Digi’s Connect Sensor with Endress+Hauser’s field instrumentation sensors and the Endress+Hauser SupplyCare cloud platform offers a complete solution The combination provides customers better for connectivity of visibility into their systems and operations industrial sensors in remote locations. Digi Connect Sensor is a new battery-powered, enterprise-ready cellular gateway solution for wireless connectivity at locations with either no power or low power that offers the versatility and flexibility to accommodate a variety of sensors. The combination of the Digi Connect Sensor cellular gateway, Endress+Hauser sensors and cloud platform provides customers better visibility into their systems and operations. “Endress+Hauser’s selection of Connect Sensor is an important confirmation of the reliability of our solution. By providing a batterypowered cellular gateway that can accommodate a vast array of sensors, we’re expanding the possibilities to have insights never before possible,” said Kevin C Riley, COO, Digi International®.
Toyota Motor Corporation has recently selected EtherCAT as its Industrial Ethernet technology of choice and will base its new factories around the world on EtherCAT. The global announcement was made by Morihiko Ohkura, GM—Production Engineering Innovation Division, Toyota Motor Corporation, at Hannover Messe 2016. EtherCAT is also an essential part of Toyota’s new IoT deployment strategy. “In The partnership will witness major order to smoothly developments in the automotive industry introduce the new IoT concept to our factories, it is critical for us to be able to source necessary EtherCAT components in a timely manner. Thus, we strongly encourage our suppliers to prepare high-quality EtherCAT components with competitive cost,” said Ohkura. He further added, “The concept to integrate communication and power lines perfectly matches our lean production philosophy.” Martin Rostan, Executive Director—EtherCAT Technology Group, adds, “This significant development will further accelerate the global adoption of EtherCAT within the automotive industry and beyond.”
®
8
A&D India | Jun-Jul 2016
MARKET | NEWS
HARTING felicitated with HERMES award
HMS releases first EtherNet Linking Device
HARTING Technology Group has recently bagged the HERMES award for the second time. The company beat four other competitors with its Harting MICA (Modular Industry Computing Architecture), the company’s mini-industrial computer. “The HERMES award is the world’s most important innovation prize for industry. We are very excited about this important victory,” explained Philip Harting, CEO— Technology Group, Harting. The Harting MICA, which was developed by subsidiary Harting IT software development, is an open and modular platform that The company beat four other competitors functions as a core component with its Harting MICA (Modular Industry consisting of embedded Computing Architecture) hardware and software for Industrie 4.0. The jury was also impressed by the concept of lightweight virtualisation using LINUX containers, which the MICA achieves in a compact field device. The MICA provides existing machinery and systems with intelligence, making it possible to migrate existing factories towards smart factories. This, in turn, enables numerous SMEs to enter the world of Industrie 4.0.
HMS Industrial Networks has recently released the first product in a new family of EtherNet/IP Linking Devices. The new Serial EtherNet/IP Linking Device allows users to connect any serial device to a Rockwell ControlLogix ® or CompactLogix ® PLC. The main advantage of the new Linking Device is the unique integration to Rockwell’s Studio5000 Logix Designer. All configuration is made from inside Studio 5000. The Linking Device makes it possible to include any automation device with a serial RS-232/422/485 application interface in EtherNet/IP-based network An advantage of the new Linking Device architecture. Besides, being is the unique integration to Rockwell’s a more cost-effective Studio5000 Logix Designer alternative to in-chassis communication modules, the distributed EtherNet/IP Linking Device also brings other advantages such as improved system architecture, easier configuration, high performance and stability and easier system integration. “The Serial EtherNet/IP Linking Device is the first step in our linking devices programme and we will add versions for PROFIBUS and Modbus TCP later during 2016,” said Kevin Knake, Executive VP, HMS Inc.
HPS Annual User Summit
Siemens, TCS to jointly deliver Big Data Analytics
Honeywell Process Solutions recently concluded the 41 annual Honeywell Users Group (HUG) for the Americas, themed around helping industrial companies harness Industrial Internet of Things (IIoT) to transform their entire enterprise. Speaking on the theme, Vimal Kapur, President, HPS, said, “The Industrial Internet of Things will allow manufacturers to more efficiently gather and analyse a broader range of data across multiple operations and plants to use data to transform Vimal Kapur—President, HPS, addresses entire enterprises.” Woven the conference with focus on digital throughout the entire symposium transformation were numerous presentations and panel discussions focusing on how the IIoT by Honeywell can help transform manufacturing operations. Hundreds of Honeywell technology users from across oil & gas, chemical, pulp & paper and metals & mining sectors were present at the event. The three-day event featured technology displays along with dozens of Honeywell and customer-led sessions and technical discussions. It also had daily themes like What’s Next: The right technology, right now; Find opportunity: Win in a volatile marketplace and Embrace change: Engage and empower the next generation. st
10
Siemens has recently leveraged its outstanding partnership with Tata Consultancy Services (TCS) to expand and enhance the delivery of Big Data Analytics to the global manufacturing industry. Siemens’ PLM software business will support TCS’ Big Data experts in the delivery and effective use of the Siemens Omneo™ By Omneo Big Data Analytics, manufacturers can Performance Analytics unearth product performance intelligence solution. By leveraging Omneo Big Data Analytics, which is provided as a cloud-based software, manufacturers will have the potential to unearth product performance intelligence that will enable them to resolve product issues in seconds. TCS’ experience on the Omneo platform will bring extensive domain and global technology experience that will accelerate the process of continuous platform engineering and enrichment. “Combining the power of this cloud-based solution and our PLM expertise with the world-class IT services, consulting, business, and big data expertise of TCS, we can help more manufacturers worldwide leverage big data to improve product development efficiency,” said Tony Hemmelgarn, Executive VP—Sales, Marketing & Service Delivery, Siemens PLM Software.
A&D India | Jun-Jul 2016
MARKET | NEWS
Micro-Epsilon receives Red Dot award
NI launches Business Incubator programme
Micro-Epsilon was recently awarded the ‘Red Dot Award Industrial Design 2016’ for setting new standards in laser triangulation as well as functionality and design with the optoNCDT 1320/1420 laser sensors. The Red Dot award is a globally acknowledged seal of quality. The winning laser triangulation sensors convinced the jury due to the perfect interaction of several factors. The sensors are extremely compact with an integrated controller, which means they can be installed in restricted installation spaces. The new optoNCDT 1320 won the coveted These smart miniature sensors Red Dot Award 2016 come with lots of new features – both internally and externally. They provide metrological innovations, a sensor-specific colour coding of the cable bushing and an intuitive web interface. The extremely small laser spot size, which is focused through an optical system to a very small diameter, enables the measurement of extremely fine details. These predefined presets and the quality slider enable easy sensor configuration and parameter set up. The sensors can be used in numerous industries.
National Instruments (NI) India has recently launched the NI India Business Incubator programme and announced the expansion of their R&D centre in India. Both these initiatives aim to support the ‘Make in India’ programme and enable Indian engineers to become global knowledge partners. The expansion of the India R&D centre ensures that the company has access to the top talent instrumental in building a platform that meets the needs of all engineers and scientists. “We can help the Indian startup ecosystem overcome NI employees at the inauguration of the technological hurdles expanded R&D facility in Bengaluru and succeed faster,” said Scott Rust, Senior VP— Global R&D, NI. The programme will provide increased access to NI technology, technical training and support to shared local communities like domestic small and medium-sized enterprises (SMEs), academic incubation centres and startups. “For ‘Make in India’ to succeed, manufacturing in India should bring more benefits than just cost of labour. Companies can differentiate themselves by adopting smart technologies to reduce defects and improve quality,” said Jayaram Pillai, MD, NI India.
OPC Foundation collaborates with CAN
Uhlmann commences India operations
OPC Foundation recently collaborated with CAN in Automation for the development of specifications, white papers, guidelines and processes that provide the infrastructure necessary for the two organisations to promote system wide interoperability at the Hannover Fair. According to Thomas J Burke, President & Executive Director, OPC Foundation, the collaboration will provide the infrastructure necessary to achieve information modeling of The collaboration will build the data from CAN technology enabled required infrastructure to achieve devices and networks. “It enables information modeling of data from to leverage the power of OPC UA CAN technology providing generic information integration and seamless communication between devices and applications from the embedded world to the cloud,” he added. Deliverables from the collaboration between the two organisations will benefit the members of both the organisations in pursuit of developing and achieving information integration across a multitude of domains. “The intended mapping of OPC UA services to CANopen brings embedded and deeply embedded real-time networks to the factory-level communication systems. OPC UA servers can be implemented on CANopen too,” said Holger Zeltwanger, MD, CiA.
Uhlmann Pac-Systeme GmbH & Co KG recently announced the commencement of its India operations—Uhlmann India, headquartered in Pune. It is a sales and service company, which will locally support existing Indian customers and solicit new orders. The company will have another sales office in Mumbai, which will complement their presence providing assistance on the project Uhlmann India announces its India operations planning of new machines, at Mumbai the supply of tools and spare parts or support services. The announcement was made by Siegfried Drost, MD, Uhlmann Pac-Systeme GmbH & Co KG along with Sumeet Arora, MD, Uhlmann India and Holger Hochdorfer, Project Director—India, Uhlmann. It is a member company of Excellence United, a unique alliance covering the entire value-added chain of pharmaceutical production. The spectrum ranges from product development to the production of clinic samples, to production and packaging lines. “Entry into the Indian market was a natural progression for us and this will enable us to serve our clientele with our best line products and services,” shared Arora.
12
A&D India | Jun-Jul 2016
MARKET | INTERVIEW
“Making manual operations accurate” …says Yaduvendra Singh, Global Head—Sales and Marketing, GreyOrange, in this interaction with Megha Roy. He explains how automation solutions in supply chains ensure highest levels of efficiency and productivity. Excerpts… Can you brief us on your company’s developments till date? What are your plans in the future? Apart from e-commerce, are you planning to target other sectors? GreyOrange has focussed on providing robotics automation solutions to help organisations overcome operational inefficiencies in their supply chain. Bringing efficiency in the warehouse operations can have a positive impact on the bottom-line of the business. For both, e-commerce and logistics industry, warehouse operations are the backbone of their supply chain, as the companies store large quantities of goods and deliver these goods to locations across India. We have tasted success with Flipkart, Jabong, PepperFry, Aramex, Delhivery, GoJavas, etc. Our business has grown exponentially, approx 300% YoY. We started as a team of 20 in 2012 and have strength of 400+ today. We are no looking at tapping new markets around the world, with an initial focus on Asia (including China) and Middle East, followed by Europe within two years. Our offerings are relevant for supply chain optimisation across industries.
directions of warehouse to pick or put items to the right racks. The GreyOrange Butler—a goods-to-person robotic solution brings the pick/put racks to the operators, saving a significant amount of time, while reducing any damage, pilferage or stock misplacement.
Can you give us more details on your collaboration with GreyOrange Pte Ltd, Singapore? Going forward, how will this collaboration work in the global market? We are headquartered in Singapore. GreyOrange Pte Ltd Singapore is our holding company. As we look to expand our business across Asia Pacific including Hong Kong, Singapore and Japan, our presence in Singapore will be valuable.
Can you explain how automation is the solution to various pain points in warehousing and logistics specific to e-commerce? An e-commerce or logistics warehouse stores thousands of units of many items that are packaged and sent to various destinations every day. A typical warehouse has a few broad operations, i.e. receiving incoming goods, quality check, put-away of the goods at the right place, picking (order management), packing and then sorting for dispatch to the right location. However, the volume and diversity of items, widely-spread dispatch locations, varied sizes of products, specific protocols (First-in-First-Out, FirstManufactured-First-Out, First-Expiry-First-Out, etc) and the pressing need to optimally utilise the expensive real estate makes warehouse automation a viable business decision. The GreyOrange Butler can completely take care of inventory management in warehouse, including inventory storage and order management, ensuring zero downtime, faster processing window and no errors. Similarly, the GreyOrange Linear Sorter is a robotic solution that profiles and sorts order-basis complex logics, such as pin codes, packet sizes, and courier agencies, etc.
Today, there is a buzz that robots and self-service systems are replacing most part of the work done by humans. What is your take on this transition from human-labour to system automation? Robotic automation was never conceptualised or developed to replace human labour. It was rather aimed at making manual operations more accurate, efficient and effective. In warehouse automation, in a conventional scenario, a picker spends about 60% of his worktime, walking into different
How are you planning to help your customers get to 100% automation of warehousing? We have assisted one of our marque customers to fully automate one of their largest state-of-the-art warehouses in India, by not just automating the inventory management and sorting, but also providing design support for automating other processes within the warehouse to ensure highest levels of efficiency and productivity, including those of the workers in the warehouse. ☐
14
A&D India | Jun-Jul 2016
C O V E R S TO R Y | T E C H N O L O G Y
TREND WATCH 2016
An age of connectivity
In the age of connectivity, as it is rightly said, ‘When Everything is Connected, Anything is Possible,’ people have become more connected than ever before. With this, the future requires new thinking, new technologies, and changing agents for the companies to be successful. The feature analyses what’s the next big thing in the age of connected things and how can one use it to the fullest to solve engineering challenges? 16
A&D India | Jun-Jul 2016
T E C H N O L O G Y | C O V E R S TO R Y
To be successful in the market necessitates having the right information at the right time to make the right decisions when delivering ground-breaking new innovations to a world that is always eager for the “next big thing.” But what happens when the next big thing is a multitude of things outfitted with hundreds of thousands of sensors with new levels of embedded intelligence that gather massive amounts of Big Analog Data and transmit that data over hyperfast, wireless networks? It’s a future that’s rapidly unfolding before our eyes, but it’s also a trend that’s been woven into the expertise in test, measurement, and control for decades. With this level of insight and deep knowledge of the technological advances happening across virtually every industry, the following five trends from National Instruments’ point of view are making sense of what’s next and how you can use it to solve your engineering challenges.
Prototyping takes 5G from concept to reality 5G will undoubtedly evolve our wireless networks to heights never before imagined, but its advancement doesn’t come without challenges. Researchers must not only address the requirements of unprecedented wireless data rates but also find solutions for network latency and responsiveness, while accommodating a thousand-fold increase in capacity. And if all that weren’t enough, service operators are demanding that these advancements consume less energy than existing infrastructure. So, how do we begin to solve these complex challenges? The answer lies in prototypes and, more specifically, the kind of 5G prototypes that enable wireless researchers to test experimental ideas using real systems in real-world scenarios. When done right, these 5G prototypes can lay the foundation for rapidly increasing an organisation’s time-to-market schedule.
A&D India | Jun-Jul 2016
Setting a new standard: Recognising the large amount of speculation regarding 5G networks, the world’s standardisation bodies, including the 3GPP, have recently begun to transition concepts into reality. Not surprisingly, the vision painted by IMT-2020, the NGMN, and the 3GPP is expansive. 5G researchers, now, must build the framework that will redefine our very existence—from automobiles and transportation systems to manufacturing, energy, healthcare monitoring, and more. To do this, researchers are adopting new design approaches to help with the challenging task of defining, developing, and deploying 5G technologies within a random access network. Most acknowledge that conventional approaches to vetting 5G technologies take too long and incur significant costs. Therefore, building a prototype and a proof of concept earlier in the process enables faster commercialisation. Blazing a new path through research: To expedite the time it takes to produce a working prototype, many researchers have adopted a platform-based design approach that embraces a unified design flow. It starts with math and simulation and then maps the algorithm in a system and working hardware. Consider Samsung, which has built one of the world’s first demonstrators of multi-antenna technology with a base station (BTS) that includes 32 antenna elements called Full-Dimension MIMO or FD-MIMO. In a similar way, researchers at Lund University in Sweden, have taken this multi-antenna concept to the next level with their Massive MIMO prototype. The future is here: 5G offers many exciting new developments to ultimately improve our lives through enhanced connectivity and unlock tremendous economic value. But for us to reap these benefits, researchers need a faster path to prototype. Traditional approaches have grown too expensive and timeconsuming, and the world is growing impatient. A platform-
17
C O V E R S TO R Y | T E C H N O L O G Y
based design approach can deliver these new developments faster, just as the researchers at places like Lund University, Nokia Networks, NYU Wireless, and Samsung are already demonstrating. It’s time to join this wave of innovation and see where it takes us next.
Big Analog Data of the future With the proliferation of sensing and networking technologies, adding measurements to systems has never been easier and more cost-effective. In the midst of this explosion of engineering and measurement data, if companies don’t have a sound data management strategy in place, a few years from now they’ll be incapable of effectively dealing with and managing all of their data. Because of this, best-in-class measurement and analytics solutions must have two fundamental capabilities: edge analytics, and smart enterprise management and analytics. Pushing measurement analytics to the edge: Over the past decade, the intelligence of data acquisition devices and sensors has drastically increased and become more decentralised, with processing elements moving closer to the sensor. One look at the many examples of acquisition systems and nodes integrating the latest silicon and IP from companies like ARM, Intel, Hewlett Packard Enterprise and Xilinx proves as much. But in addition to measurement devices getting smarter, smart sensors have emerged that integrate the sensor, signal conditioning, embedded processing, and digital interface/bus into an extremely small package or system. As processing moves closer to the sensor, innovation in measurement system software is required to efficiently push
18
analytics to the edge. Future software for edge-based systems will be able to quickly configure and manage thousands of networked measurement devices and push a myriad of analytics and signal processing to those nodes. Going forward, companies must transition to smarter, software-based measurement nodes to keep up with the amount of analog data they’ll be producing. Creating smarter enterprise management and analytics: Once the data is captured from smart systems, the next step is to push that data to the enterprise to effectively manage, consolidate, and perform large-scale analysis on the data. An enterprise data management and analysis solution that can manage engineering data from numerous sources is paramount for getting the right data in front of the right people at the right time to make the right data-driven decisions. Two key considerations are properly documented data sets and smarter analysis: t Properly documented data sets: To accurately perform analysis across multiple sources, all data sets should include consistent metadata, or descriptive information that describes why the test data was saved. Metadata can include information such as the test setup, test outcome, units of the measurement, and so on. t Smarter analysis: Considering that analog data is the fastest growing and largest type of data that can be collected, finding new correlations and predicting future behaviours are key to maintaining a competitive edge. To do this, companies that take measurements for research, design, and validation will need to drastically improve how they collect and analyse data on the edge and manage and analyse data within the enterprise.
A&D India | Jun-Jul 2016
RFID CONTRINET LOW AND HIGH FREQUENCY IN ONE NETWORK
KEY ADVANTAGES 9 Powerful RS485 network for LF and HF systems 9 LF and HF Read/Write Modules (RWMs) can be mixed on the same network 9 Rugged all-metal RWMs with impervious sensing face 9 High-temperature RWMs for up to +125qC
9 Interfaces for most industrial fieldbuses and USB
www.contrinex.com
C O V E R S TO R Y | T E C H N O L O G Y
Evolving network standards for IIoT The Industrial Internet of Things (IIoT) promises a world of smarter, hyper-connected devices and infrastructure where electrical grids, manufacturing machines, and transportation systems are outfitted with embedded sensing, processing, control, and analysis capabilities. Once networked together, they’ll create a smart system of systems that shares data between devices, across the enterprise, and in the cloud. Though much of this raw, unprocessed data is not time critical and can be passed between network layers and subsystems with little regard for latency or synchronisation, there is an entire class of mission – critical, time-sensitive data that must be transferred and shared within strict bounds of latency and reliability. To support the new capabilities of IIoT-enabled infrastructure, designers and end users alike need reliable, remote, and secure access to smart edge devices. Network technologies must evolve to satisfy the requirements of these next-generation industrial systems and radically advance the way we operate our machines, electrical grids, and transportation systems. Time-Sensitive Networking: Today, industrial suppliers, IT vendors, and silicon providers are collaborating within IEEE 802 and the recently formed AVnu Alliance to update standard Ethernet protocols and provide bounded, low-latency data transfer for time-critical data in IIoT applications. This nextgeneration standard, called Time-Sensitive Networking or TSN, addresses existing network shortcomings. The AVnu Alliance, working with companies such as Broadcom, Cisco, Intel, and NI, will drive the creation of an interoperable ecosystem through certification, similar to how the Wi-Fi
20
Alliance certifies products and devices to be compatible with the IEEE 802.11 standard. The new TSN standard will provide numerous benefits, such as bandwidth, security, inter-operability, latency and synchronisation. The future will arrive on time: As IIoT adoption continues, increased amounts of data and widely distributed networks will require new standards for sharing and transferring critical information. Just as an ambulance or a fire engine receives priority among other traffic during an emergency, the TSN standard ensures that critical, time-sensitive data is delivered on time over standard network infrastructure.
Testing the Big Bang of smart devices The three core elements at the nucleus of most smart devices are battery power, wireless connectivity, and sensors. Be it a smart thermostat, fitness tracker, or smartphone, the ‘smart’ devices of tomorrow will always have sensors for interacting with the world around them, a rechargeable battery for untethered operation, and various modes of wireless connectivity to send and receive information from the internet and other devices around them. Instead of designing a unique test system for each unique DUT, test leaders must design a smart test system that can adapt to and test all smart devices. Testing a sensor requires the ability to reproduce physical stimuli often with other types of sensors or transducers. Testing a battery requires the ability to source, sink, and measure power. Testing wireless communication requires the ability to both generate and analyse RF signals. Add up this laundry list of functionality and it’s not hard to imagine a fully stacked, incredibly expensive rack of instrumentation. But thanks to Moore’s law, test
A&D India | Jun-Jul 2016
C O V E R S TO R Y | T E C H N O L O G Y
instrumentation can now benefit from the same embedded technology that’s flooding the market with smart devices of all shapes and sizes. It stands to reason, however, that testing an accelerometer is not the same as testing a force sensor, or that testing a Bluetooth transceiver is not the same as testing a cellular antenna. Given this, how can test systems truly adapt? Again, the secret comes from looking at a smart device. A tablet and a fitness tracker both have an accelerometer within, but the accelerometer plays a very different role for each device. In a tablet, it’s used to sense how the user is holding the device and then orient the screen accordingly. But in the fitness tracker, the accelerometer is used to count the steps that the user takes throughout the day. A sense of scale: Just as a smartphone’s functionality can be extended by apps and firmware updates, the functionality of a smart, software-defined test system can be extended and modified by software to keep pace with rapidly evolving device functionality. With a forward-looking investment in a hardware platform that can be easily upgraded to test the latest protocols, it’s easy to see how a test system can economically evolve at the speed of software and reverse the trend of rising test costs.
The consumerisation of software Back when pocket protectors were both functional and fashionable (an engineer can dream, right?), engineering software and consumer software were radically different—not just because of the people who used them, but also because of the inherently unique user experiences they provided. But what happens when an unstoppable force (consumer software) meets an immovable object (engineering software)?
22
In a marketplace that’s rapidly demanding convergence and the best of all possible worlds, it’s up to today’s software vendors to answer the call. The evolution of consumer software: From right-click functionality to Microsoft’s introduction of the ribbon, consumer software has long defined the user experience standards and expectations that most vendors follow. But with the recent explosion of beauty and simplicity across the general consumer market, expectations have changed. The evolution of demands on engineering software: Engineering software users of the past typically graduated from a university with an understanding of one programming language. However, things have started to change. Firstly, today’s engineers can jump in and out of Python, C#, HTML, JavaScript, LabVIEW, and Swift. This puts an unprecedented demand on approachability and removes the expectation of expertise. Secondly, the cost of accessing and acquiring data has rapidly decreased while the need for data has risen. And as technology has become more connected, the cost of processors has declined. This has accelerated the need for highly approachable software by introducing more ‘non-traditional’ programmers to the world of robotics, home automation, and even general data acquisition and analysis. An inevitable convergence: There’s no denying that our world is getting more complicated and that our challenges are becoming harder to solve. Being asked to do more with less money, fewer people, and less time only heightens the tension. The sooner we embrace the convergence of engineering software and consumer software, the sooner we’ll realise that ‘simple’ is the best way to solve ‘complex.’ ☐ Courtesy: National Instruments
A&D India | Jun-Jul 2016
MANAGEMENT | INTERVIEW
“Understanding disruptive technology evolution” N Viswanadham, Fellow IEEE & INSA Senior Scientist, Computer Science & Automation, Indian Institute of Science, reports on the game changing happenings in the global manufacturing sector and shares his recommendations on making the Indian manufacturing industry futureready and globally competitive. Excerpts from his interview with Shekhar Jitkar… What are the game changing happenings that are affecting both global and Indian manufacturing? Indian manufacturing needs to align itself with the changes in the global industry in terms of consumer attitudes, disruptive technology evolution and company valuations. Technology changes are creating new industry giants. Rise of start-ups using ordinary resources is creating concern for the established industry makers. It is not the ownership of products or assets any more. Customers are willing to share a service rather than own a product. Competition now seems to be between business models, and not between products and supply chains. The old model of possessing tangible assets of manufacturing and distribution and win through product innovation; lean, efficient processes and better execution is now less valuable. Companies now embrace technologies and intangible assets—customer, human & IP—and leverage ‘networks’ to create products and market them with its digital information and secondary values that create more value. There is a value shift from asset
24
ownership to network orchestration and digitalisation. Germany and USA are leading in Industrial automation. Germany leads the Industry 4.0 which is the essence of IoT and smart manufacturing. By connecting machines, a manufacturer can create intelligent networks along the entire value chain that communicate and control each other autonomously with significantly reduced intervention by operators. In USA, GE leads the Industrial Internet. An intelligent aircraft will tell maintenance crews the status of the aircraft subsystems and supply real-time, actionable information to help aircraft operators predict which parts need replacement and when. It is a shift from current maintenance schedules based on the number of flights to those based on actual need. A connected car communicates directly with “the cloud” to offer services such as connected navigation, dynamic routing based on traffic, weather, or road conditions, or an automatic parking spot finder that offers directions to available parking spots.
A&D India | Jun-Jul 2016
INTERVIEW | MANAGEMENT
“By connecting machines, a manufacturer can create intelligent networks along the entire value chain that communicate and control each other autonomously with significantly reduced intervention by operators” N Viswanadham
What would be your recommendations to address the current challenges and make Indian manufacturing sector future-ready and globally competitive? India produces several assembled products such as tractors, cars, two wheelers, cars, cell phones, etc, for consumption in the country. However, India imports large amounts of machine tools and designs from other countries, rather than producing them in the country. For example, 77% of telecom equipment, 78% of high-tech equipment and 35% earth moving and mining equipment are procured from other countries. Indian manufacturing currently practices reverse engineering, low cost assemblage and local marketing. It has to climb up the ladder systematically in a planned manner. This can be done in two stages. For stage I, it is necessary to improve the productivity in energy, capital, labour, relevant infrastructure, distribution and warehousing. Also, during this stage, it is important to target skill training, improve technology intensive business by the usage of mobile, Internet, Cloud, sensor enabled smart networks, Big Data & Predictive Analytics. Furthermore, it is necessary to improve the supply chain planning and execution for on-time deliveries. For stage II, the companies should concentrate on innovation, product discovery, machine & process innovations in manufacturing and distribution & service to create smart resource efficient products. Can you brief us on the potential and the best practices in automating the manufacturing supply chains? There are several disruptive changes happening in the supply chain. It is becoming highly technology intensive. There are four important business processes in a supply chain including procurement, manufacturing, distribution and retail, and finally repair and maintenance. In some verticals such as apparel, food, etc, all the first three processes are well integrated and orchestrated as farm to fork or farm to fashion chains. The manufacturing business processes are also changing their face from owning assets to orchestrating without owning any assets and concentrating on partner networking and governance. Also, the factory floor is getting automated with Internet of Things - talking parts and intelligent machines. Finally, the retail process is changing due to innovations in
A&D India | Jun-Jul 2016
Internet search and advances in machine learning and data mining. Retailers gain an understanding of how shoppers move around their stores – where they go, in what order, how long they stay, when they come to the store, and how all of these questions map to actual sales. The maintenance and repair service chain is using Big Data based analytics to predict the need for repair and additive manufacturing is being used to produce the spare parts. How do you make sure that you are prepared with the right technology and strategy to ensure the success of an automation project? This is an important question. Companies need to follow right business models which give attention to the customer attitudes, technology changes and finally how to make profit. A business model is a conceptual tool that contains three main components: customer value proposition (CVP), profit formula, and partner network. The CVP identifies the job to fulfil an important need for the targeted customers and deliver value both qualitatively & quantitatively. Identifying the customer segments and the delivery mechanisms for each segment is important. The profit formula defines how the company creates value for itself while fulfilling the needs of the customer. It estimates the cost and profit for each customer segment and identifies the revenue model. The partner network that cooperates to produce and deliver products and services to the targeted customer segments is an important component of the business model. A requirement of a successful business model is to identify partners who can share costs (companies, individuals who benefit from your venture) as well as the revenue sources. The four business model pillars are the supply/service chain processes, key human, financial and digital resources, product delivery mechanisms to various customer segments and institutional and social constraints. The business model achieves the objective of making money by producing the products/services using the resources following the social and institutional constraints and delivering to various customer segments the products and services using the secondary opportunities. One needs to make sure that the right business model is designed prepared with the right technology and strategy to ensure the success of the project. ☐
25
R O U N D - TA B L E | M A N A G E M E N T
Embedding cyber security for industrial automation Over the last decade, the rise in cyber attacks on critical infrastructure has stemmed in cyber security becoming an ultimate alarm amongst industrial automation and control system users. The round-table discusses how a cyber security cell should apprehend the cyber security risks, and address the knowledge of the ever-changing security challenges. Today, we are in a digital age, where an anonymous hacker, in no time, amidst a virtual landscape, can throw a wrench into industrial automation systems. As such, it can be said that industrial cyber security is a subject of snowballing significance. Nearly 500 million Indians use the internet today, but they do not access the internet from the same devices. With little control over the hardware used by Indian internet users as well as the information that is carried through them, India’s national security architecture faces a challenging task in cyberspace.
26
Megha Roy Features Writer megha.roy@publish-industry.net
An effective cyber protection necessitates greater network separation, stronger authentication and access controls, security management, configuration and maintenance. To achieve the same, a security deployment prerequisites to be built to secure factory automation. Speaking on the same are Rajabahadur V Arcot, Automation Consultant; Eric C Cosman, Contributing Consultant, ARC Advisory Group and Milind Kulkarni, Chief Manager— Factory Automation, Siemens.
A&D India | Jun-Jul 2016
M A N A G E M E N T | R O U N D - TA B L E
“Effective response to a coordinated attack requires that the facility has adequate configuration information in place, as well as accurate & recent backups” Eric C Cosman Contributing Consultant, ARC Advisory Group
“It is important to educate plant operators about cyber threats and leverage their experience to identify every anomalous/ abnormal/incongruent behaviour or incidents” Rajabahadur V Arcot Automation Consultant
Industrial automation connectivity For industrial automation interconnectivity, an embedded security deployment model that establishes interoperability is essential. Speaking on this, Rajabahadur says, “Current industrial automation systems have also moved to an edge-to-cloud architecture for cost and flexibility.” But here comes challenges too. They have security challenges that result from today’s interconnected world. “Regardless of application, ensuring security begins by establishing a chain of trust between devices, data & systems. Everything within the trusted system must be authenticated and validated to ensure trusted inter-operability and integrity at every point,” says Kulkarni. The current industrial control systems (ICS) are based on the foundation of information technology and involve sensors, signal transmission and communication, & information processing based on control algorithms among others. As per Rajabahadur, “There are no quick fixes for protecting the ICS from cyber attacks and the present mitigation measures are not adequate to prevent a determined cyber attacker from causing havoc in critical infrastructure.” To this, Kulkarni adds, “Industrial cyber security threats have grown from the esoteric practice of a few specialists to a problem of general concern. Now, all stakeholders have a new responsibility in promoting the safety, reliability and stability of critical industrial infrastructure.” It becomes quite clear that the level of awareness of the need for improved industrial automation security has increased greatly today. According to Cosman, “Virtually, all critical infrastructure sectors have addressed the issue, either
A&D India | Jun-Jul 2016
through industry associations, regulatory agencies or some combination. Unfortunately, this increased awareness comes with a growing understanding of the scale and complexity of the challenges faced, which in turn leads to the identification of new stakeholders who require increased awareness.”
Gauging cyber vulnerabilities While some industries have made headway in curtailing risks of cyber attacks, the barriers to advance cyber security remain high. While analysing that the behaviour of plants is imperative, Rajabahadur suggests that it is important to educate plant operators about cyber threats and leverage their experience to identify every anomalous/abnormal/ incongruent behaviour or incidents. “The automation systems can be configured to help operators identify such incidents,” he explains. There are several sources of guidance material that are applicable in the process industries. As per Cosman, “Sources such as NIST cybersecurity framework should be considered to develop a cyber security management system and respond to incidents. Effective response to a coordinated attack requires that the facility has adequate configuration information in place, as well as accurate and recent backups.” Speaking on the manufacturing landscape for the same, Kulkarni opines that security solutions must meet open standards for seamless communication and functionality, protection against mal-operations and sabotage, know-how protection, system & data integrity, data transfer in real time for efficient production processes, support throughout the lifecycle of a plant, security trail and change management, etc.
27
R O U N D - TA B L E | M A N A G E M E N T
“Industrial security solutions require a holistic approach based on different protection layers” Milind Kulkarni Chief Manager—Factory Automation, Siemens
Reducing threats for cyber security Cyber attack is typically driven by economic, competitive, political or social agendas. These days, the plant floor & process units have become a growing area of concern for cyber security. Addressing measures to reduce risks here, Rajabahadur recommends that it is essential for industrial companies to empower plant operating personnel to interpret, identify and report anomalous activity in control systems. Moreover, risk assessment is also an important measure in this regard. Underlining this, Cosman says, “Threat assessment information must be collected from various external sources. Information about vulnerabilities is typically provided by software & hardware suppliers. The potential consequences must be assessed by the asset owner.” As per Kulkarni, industrial security solutions require a holistic approach based on different protection layers. Explaining the layers, he says, “At plant level, blocking access for unauthorised personnel and physical prevention of access to critical components are required. At network level, controlled interfaces between office and plant network via firewalls and further segmentation of plant network will be required. At system level, antivirus software, maintenance and update processes, user authentication for plant or machine operators and integrated access protection mechanisms in automation components are key requirements.”
How should security monitoring & management be structured? More open and collaborative networks have made systems more vulnerable to attack. In this milieu, security monitoring and management should be regulated to safeguard an operation. The nature and degree of regulation that is warranted varies by industry sector, and should be commensurate with risk and previous sector performance in this area. As per Cosman, “Industry self-regulation via groups, such as trade associations and sector-specific groups has often proved to be effective. If external regulations are determined to be required, they should be performance-based, rather than prescriptive, in terms of exactly how such performance should be achieved.”
28
Emphasising on risk analysis, Kulkarni points out that once risk is analysed and isolated, the identified and unacceptable risks must be ruled out or reduced by suitable measures. “Which risks are ultimately acceptable can only be specified individually for the application concerned. However, neither a single measure nor a combination of measures can guarantee 100% security,” he believes.
Addressing cyber security solutions Beyond the common architectures, many business networks are now connected with process networks. This has opened the door for hackers and viruses to enter the production & process environments, and at the same time, calls for a cyber security solution. Signifying the need for such solutions, Rajabahadur opines, “Cyber security solution providers have to offer cyber protections that take into account this inter-connectedness. Recent cyber attacks have emanated from tech-savvy and highly-motivated attackers with deep pockets. They are constantly evolving newer ways to carry out their attacks and many of them are motivated by strong strategic intents. As of now, these motivated attackers enjoy a head start and it is necessary for automation companies and their security solution partners to run faster and nullify attackers’ initial lead.” Cyber attacks can result in significant monetary loss, damage to equipment & infrastructure, brand erosion, loss of proprietary information and quality compromises. According to Cosman, connections from business networks are only one attack vector. “Even in cases, where no such connections exist, it is possible to deliver malicious software via other means, such as remote access for support purposes, interconnection to other control systems or even the use of removal media,” he affirms. Also, plant network, office network and their convergence is increasing and this again calls for special focus on network security. To give a better understanding on this, Kulkarni explains, “Ethernet-based field bus systems are well established in today’s automation solutions. However, this trend also leads to increased risks, which have to be addressed by security measures like network protection mechanism like firewalls, which blocks or regulates communication between office and
A&D India | Jun-Jul 2016
M A N A G E M E N T | R O U N D - TA B L E
plant networks, segmentation of production networks in different secured automation networks and separation of a plant network into different subnets with limited and secure communication between these subnets.”
Executing effective cyber security strategy The inferences of cyber security and the requirement for a wide-ranging security strategy are currently being acknowledged across the industry. One important consideration for an industrial company, especially in the critical infrastructure industry sector is to recognise that cyber threats are real, take serious note of the same, and plan & implement counter measures. “It is difficult to address the security of assets if they have not been identified and catalogued. With an accurate asset inventory and network configuration documented, it is possible to use a risk assessment as the basis for segmenting a system into multiple zones, each with its own response using countermeasures, such as system hardening, network segmentation and detailed operational monitoring,” says Cosman.
A&D India | Jun-Jul 2016
Kulkarni reaffirms that risk management and recurring assessments can be used to track milestones and the maturity of a security programme to indicate progress in reaching the desired assurance level. He further explains, “Industrial organisations should undertake independent audits to assess the adequacy of system controls, determine compliance with established policies and operational procedures, and recommend necessary changes. Also, deploying a secure and reliable architecture that provides a long-term baseline for control-system availability, reliability, and safety is required.” Hence, moving forward, it should be well-thought-out how to use these core concepts to build advanced levels of embedded security, secure communications, and manageability into industrial automation systems. “It’s essential to create a command & control reporting structure to quickly handle situations that may arise in future vigilance & readiness. The way forward for owner operators is to carry out security audit, vulnerability assessment and penetration testing and implement defense-in-depth strategies at the company level, while aligning them with the national level measures,” concludes Rajabahadur. ☐
29
Image Courtesy: Shutterstock
POWER & ENERGY | FOCUS
Enriching operations and maintenance Understanding and characterising operational risks has been one of the key objectives of the wind power industry. The article discusses on improving wind turbine operations and maintenance with the real-time detection and analysis of lightning strikes using the Lightning Monitoring System. Wind turbines, due to their extreme height and open-air locations, are at high risk for damage from lightning strikes. While risks may vary from location to location and time of the year, the risk of lightning strikes is always present. To reduce this risk, exterior areas of a wind turbine are usually protected by a direct lightning protection system, while electrical and control system components are protected by surge protection devices. Lightning and surge protection schemes are essential elements in maximising a wind turbine’s availability and economic rate of return. Exterior lightning protection systems reduce but do not
30
Daniel J Sylawa Business Development Manager Renewable Energy Phoenix Contact USA dsylawa@phoenixcon.com
eliminate all risks associated with lightning. Lightning itself is extremely variable in both impact and frequency. The highly variable energy loads of a lightning strike can produce uncertain wear on lightning protection elements. Most often, this is seen in wind turbine blades, where lightning receptors must be replaced in a timely fashion to prevent additional blade damage. Manual inspection is the only method of determining the need for replacement. Balancing this need for blade inspection versus continued operation is one of the risks associated with lightning and wind turbine operational reliability.
A&D India | Jun-Jul 2016
FOCUS | POWER & ENERGY
The need for real-time lightning monitoring Understanding and characterising operational risks has been one of the key objectives of the wind power industry. From an operations and maintenance (O&M) perspective, real-time understanding of lightning exposure is one element of reducing wind turbine operational costs. Analogous to condition monitoring systems for mechanical components, real-time lightning monitoring allows for the collection and analysis of actual system loads caused by lightning strikes. Important in evaluating the operational status of lightning affected components, this information allows lightning-related maintenance to be targeted in a cost-effective manner. In the past, installation of lightning current measurement systems in wind turbines has been difficult to implement or has provided a limited range of lightning information. However, new technology incorporated in the Lightning Monitoring System (LM-S) using polarimetric sensing technology is now available. Polarimetric sensors allow for easy wind turbine installation and also provide a full range of real-time lightning information. In addition, due to their lightweight and small size, the systems are suitable for installation in both new and retrofit applications.
Polarimetric lightning current measurement Measurement principle: This new lightning measurement system uses polarimetric lightning current measurement sensors based upon the Faraday Effect. These sensors function by incorporating a linearly polarised light signal passed through a transparent dielectric material. When an external magnetic field of perpendicular current carrying conductor permeates the material, the plane of polarisation of the light signal rotates as a function of the strength of the magnetic field. Depending on the degree of the light wave rotation, the amount of light passing through an output filter is varied. This creates a measurable and evaluable light signal proportional to the magnetic field of the conductor current. Sensors based on this principle can be used to measure bidirectional current flow. The polarimetric lightning sensor: The LM-S polarimetric sensor is mounted in a housing fastened directly on the conductor being measured. For calibration purposes, the
A&D India | Jun-Jul 2016
location of the polarimetric lightning sensor must be located to a uniform depth in the magnetic field of the conductor. Sensors based on this design have shown good agreement between actual and measured surge currents. Performance investigations have shown that measurement errors for a dynamic range of 5 KA < Iimp < 200 KA are significantly below 10%. Measurement data processing: Due to the fast response of the polarimetric sensor, lightning current amplitude may be measured over the entire range of the lightning event. Coupled with the LM-S evaluation unit, polarimetric sensor data may be processed to provide complete characterisation of a lightning event, including peak current, number of impulses, lightning direction, specific energy, charge and duration and slope of the lightning current.
Wind turbine installation A complete LM-S system consists of two major component parts: up to three polarimetric sensors and an evaluation unit. The polarimetric sensors are connected to the evaluation unit via fibre-optic cables, which provide a high degree of electrical isolation and noise immunity. For wind turbine application, the LM-S polarimetric lightning sensors are mounted in the lightning down conductors within each turbine blade. Mounting in the blades ensures lightning measurement of the exterior areas most vulnerable to direct lightning strikes. The polarimetric sensors are mounted using cable ties. LM-S evaluation unit electronics are mounted with the turbine hub. Communication is via Ethernet interface. A dry remote status contact is available. Real-time evaluation and access to lightning data: Real-time evaluation and remote access to lightning data is crucial in assessing the actual stresses to the wind turbine caused by lightning strikes. Date and timestamp events of surge current amplitude, maximum current slope, charge and specific energy of a lightning strike are analysed and stored in the evaluation unit. Using the Ethernet interface, data may be viewed on the LM-S evaluation unit via an HTML interface using a standard web browser. In addition, event data can be downloaded from the LM-S evaluation unit in comma-separated variable (CSV) format and can be viewed in spreadsheet and similar programs, or archived for future reference.
31
POWER & ENERGY | FOCUS
For remote access, the LM-S Ethernet interface may be connected into the wind turbine internal network or accessed via wireless or cellular communication. Cellular communication is a convenient way to remotely access the data external to the turbine control system via cell phones, tablets and other devices.
LM-S practical application Prior to the introduction of the LM-S, practical monitoring of lightning current loads in wind turbine systems was previously limited to counting the number of lightning events or the maximum amplitude. Dynamic current characteristics were not monitored. This limited the ability of lightning monitoring to be used as a tool to determine the potential effects of lightning on a detailed basis. However, the dynamic lightning characteristics, such as charge and rise-time of the lightning surge current, are important indicators of potential damage. The expected damage caused by a long duration, low amplitude lightning strike can be as great as damage caused by a strike with many times the amplitude, over a considerably shorter duration. Frequent lightning strikes with lower amplitude also create a high load for mechanical structures. Cumulative charge can also be used as a critical parameter to characterise these effects. With the installation of an LM-S in a wind turbine, it becomes possible to provide a continuous monitoring of dynamic current characteristics of lightning events. Data gathered â&#x20AC;&#x201C; peak current, number of impulses, lightning direction, specific energy, charge and duration and slope of the lightning current â&#x20AC;&#x201C; can be used to assess lightning impact.
32
From an O&M perspective, the ability to schedule preventive maintenance of rotor blade lightning receptors and electrical system lightning surge protection systems in a more timely fashion and helps reduce unplanned wind turbine downtime.
Improving wind turbine operations & maintenance The LM-S allows the measurement and analysis of lightning surge current characteristics with high accuracy and detail. This information helps evaluate wind turbine lightning loads more extensively than simple recording of the number of strikes and maximum surge current amplitude. Additional parameters, such as surge current slope, charge and specific energy, allow inferences to be made as to the actual operational system load. From an O&M perspective, this information can be used to determine if, when and what kind of maintenance is required. If serious damage has occurred, the system can be shut down in a controlled manner to prevent secondary damage. It is not necessary to perform visual system inspection or to take readings of measured values on site. Travel and inspection costs are thus reduced, and the causes of secondary lightning damage can be detected and remedied early. These monitoring systems are suitable for new and retrofit applications. As an element of turbine condition monitoring, LM-S lightning monitoring can be used as one tool to improve the economic rate of return of wind turbine installations by increasing availability and optimising maintenance intervals. With the growing number of wind turbines located in remote areas and in offshore locations, wind turbine operators need to optimise maintenance intervals more than ever. â&#x2DC;?
A&D India | Jun-Jul 2016
FIELDBUS & NETWORKING | TECHNOLOGY
Connected industry Industry 4.0’s use of cyber-physical systems has radically altered the face of industrial production. Still, Industry 4.0 will only become a reality when the cyber world and physical world are connected. The article briefs on networking technology to make this as much a mission as it is a vision. Until today, industrial facilities have largely followed a simple concept that is all about automation tasks that are performed by automation devices. These devices need to be connected to a central controller. That’s it – nothing more is necessary for this undoubtedly extremely powerful concept. The network is merely the vehicle for the industrial Ethernet fieldbus, or stated in even more trivial terms, just the connecting line. From the perspective of automation, this is completely understandable and sufficient.
34
Andreas Huhmann Strategy Consultant— Connectivity & Networks, HARTING Technology Group
Industry 4.0, however, entails new demands on network technology, and by extension on connection technology – production in Industry 4.0 needs to be more effective, more flexible and more powerful. Control functions shift from a central controller over to the system itself. This entails a radical conceptual change in the structure of production facilities: a strictly hierarchical system gives way to a decentralised one. Plans and systems are constructed in modular form, while control tasks are relocated in the system itself. The network becomes the crucial component.
A&D India | Jun-Jul 2016
FIELDBUS & NETWORKING | TECHNOLOGY
Industry 4.0 for field level For something that admittedly sounds so simple and logical, the implementation is dependent on a number of conditions, among which the integration of cyber-physical systems (CPS) with the material world of production holds centre stage. Industry 4.0 is characterised by the integration of CPS into IT applications. This integration should be as flexible as possible, meaning that the rigid arrangement employed in conventional production is broken up. This results in two areas that need to be melded. The initial implementations revealed that the crucial interface lies between the autonomous system modules. These may be of conventional design, i.e. with central controller and decentralised I/O, however, they can also be constructed from CPS. In any case, what distinguishes them is that the modules perform a completely self-contained service on the real object in the production process. The set-up of the modules can still be performed conventionally without compromising the advantages of Industry 4.0. Modules at a production facility need to be able to be integrated into the production process at different locations in an extremely easy fashion – and above all quickly. And different modules must be able to be deployed at these sites. These two key requirements mean that cabling takes on a different character. Deployment at varying locations becomes basic setup, while its use with various modules means it constitutes a basic service. Cabling is transformed into an infrastructure.
Infrastructure in Industry 4.0 manufacturing Smart factory infrastructure is currently in the definition
36
phase. Ethernet will be used both for IT as well as automation. In addition, office buildings will employ application-neutral cabling according to ISO/IEC 11801, the standard provides specifications for setting up passive network infrastructure. If one applies this view to a production plant, this will entail integrating different modules into the network. In addition, all the lifelines that supply industry need to be considered, i.e. communications, 400 volt power, compressed air, auxiliary power and other signals. Consequently, the required connections are numerous, which means that simple plug-and-produce will only become possible when the connections are integrated in one interface, i.e. in one connector. Thanks to its modular construction, HanModular® can make all lifelines available. The standardisation of the module interface means that a decisive step has already been taken. Still, infrastructure development requires more than just this. In the case of industrial production, the module interface must be capable of offering a wide variety of functions in order to ensure simple and above all more secure operation. In addition to the module connector interface, this includes management with respect to diagnosis, identification of modules, energy measurement and energy switching, protection for power (400 volts) as well as safety and real-time communication. These functions can be ensured by using active network components. HARTING is intensively driving the development of these Industry 4.0 infrastructure components forward. By way of example, the company’s smart Power Network Unit brings together the topic of the administration of communications and power. This infrastructure component supports industrytypical topologies via line and ring, thereby enabling infrastructure to be put in place which facilitates the flexible use of different production modules. ☐
A&D India | Jun-Jul 2016
F I E L D B U S & N E T W O R K I N G | A P P L I C AT I O N
Communicating rapidly The Anybus M-Bus to Modbus-TCP gateway allows M-Bus devices to communicate on a Modbus-TCP network. The gateway decodes M-Bus telegrams, making it possible to map meter values to Modbus registers. This enables central control and supervision of measuring devices, which usually use the M-Bus protocol. An application story on how effective communication was enabled between M-Bus and the OptoEMU. Processcomponent in Sweden has found a way to quickly connect M-Bus sensors to the OptoEMU Energy Monitoring System. By using the Anybus M-Bus to Modbus-TCP gateway they can provide building owners with real-time data from their buildings so they can do monitoring, logging and invoicing. A modern building is not only built of concrete, wood or steel, it is also an intricate digital network linking together systems for cooling, heat, water, electricity etc. A common problem for building owners and system integrators is that not
38
all systems and machinery can communicate with each other. One example is sensors for heat, water, temperature, energy etc. Sensors and meters often use the M-Bus protocol, which cannot be understood by central system controllers on networks such as Modbus-TCP. This exact problem is what faced Swedish system integrator Processcomponent AB as they were installing a monitoring system in an apartment building in Gothenburg. The system gathers data from 72 apartments, a grocery store, and the central HVAC system. All around the building, there are
A&D India | Jun-Jul 2016
The interface to Industry 4.0
c
e
c
e
electronic ifm electronic India Private Limited Plot No. P-39/1, MIDC Gokul Sirgaon, Kolhapur - 416234 Maharashtra Ph: 0231-2672770 E-mail: info.india@ifm.com Toll Free: 1800 233 2065
F I E L D B U S & N E T W O R K I N G | A P P L I C AT I O N
The Opto 22 controller (left) and the Anybus M-Bus to Modbus-TCP gateway (right)
sensors for temperature, energy and water. The problem was that the sensors communicate via M-Bus and the energy monitoring system — the OptoEMU from Opto22 — uses Modbus-TCP. To solve this communication issue, Processcomponent found the Anybus M-Bus to Modbus gateway from HMS Industrial Networks. The gateway decodes M-Bus telegrams and maps them directly to Modbus registers. This way, the sensors can be understood by the OptoEMU and their values show up directly.
Quick and easy access to M-Bus data “What I really like about the Anybus M-Bus gateway is that it is very easy to use and quick to install,” says Jonas Karlsson, Sales Manager, Processcomponent. “All M-Bus sensors are automatically detected by the gateway without you having to do any configuration. This saves a lot of time since you don’t have to configure each meter individually — they all show up automatically, complete with serial number, name, and all current values. Indeed, you don’t even have to be on site as long as you have someone connecting the wiring from the sensor to the gateway. Before, it could take several hours to configure a single meter running M-Bus. With the Anybus gateway, we can set things up in 10 minutes!”
How it works “The actual process is quite easy,” continues Karlsson. “You do a search for available M-Bus sensors connected to the gateway, and you get back Modbus registers from the sensors. These can be interpreted by the OptoEMU and provide the customer with real-time data from the sensors.” The configuration is handled in a web-based configuration
40
tool, which allows users to set up the gateway in a web interface. No programming is necessary – the values from the metres automatically show up in the OptoEMU as Modbus registers, which it can understand and process.
OptoEMU — a solution for energy monitoring Processcomponent has been very successful in installing the OptoEMU — an Energy Monitoring System (EMU), which collects energy data from buildings, electrical subpanels, and individual equipment like chillers and compressors. The OptoEMU delivers the data, so users can view it online and use it in a business application and do invoicing for example. Users can also get alarms whenever certain levels are reached.
The results The building in Gothenburg is now equipped with Anybus gateways connected to two OptoEMU-DR2 one for the 72 apartments and one for the grocery store. The measured values can be logged to an excel file which can be downloaded via FTP. The readings can also be sent directly to an SQL database or to HMI/SCADA systems via an OPC server. Since the building owners now have access to real-time values from the different apartments in the building, they can be on top of consumption and get alarms when certain thresholds are reached. Access to meter values also enable rapid and automated invoicing to apartment owners. “The Anybus gateways have certainly made life easier for us and our customers” concludes Karlsson. “By getting M-Bus values into the OptoEMU quickly and easily, we can get our monitoring system up and running faster, which is beneficial for both us and our customers.” ☐ Courtesy: HMS Industrial Networks
A&D India | Jun-Jul 2016
Unlimited possibilities.
HBC radio controls – tailor-made perfection. From overhead cranes to mobile harbour cranes, from reach stackers to automated racks, from explosion-proof lifting equipment to ship cranes: We’ve got the radio control that SHUIHFWO\ PHHWV \RXU VSHFLŰ F GHPDQGV
Quality in Control.
HBC-radiomatic India Pvt. Ltd. 401, “Sapphire”, Plot No. 9, S. No. 46/7 & 46/8, Bombay Sappers Colony, Wadgaon Sheri Pune – 411014 • India • Phone +91 20 6522 8333 contact@radiomatic.co.in • www.hbc-radiomatic.co.in
TEST & MEASUREMENT | TECHNOLOGY
Why future SMT placement needs absolute encoder feedback? As electronic product complexity grows, the demand for high quality assurance in the SMT (Surface Mount Technology) placement processes is rising with implications for encoder feedback performance. The article examines some of the future trends in SMT placement technology and the role of absolute optical encoder systems. The global SMT placement equipment market generated revenues, in 2013, of US $4 billion from 19,000 machine shipments and is forecast to reach an estimated US $6 billion in 2020 â&#x20AC;&#x201C; with the consumer electronics and computing and storage industries accounting for 42%. Demand from consumer electronics has increased significantly since the global recession, even though unit sales growth of smartphones, tablets and LCD TVs is expected to slow down now. The SMT placement equipment market is also facing the restrictions of declining price points, very high competition and a strong used-equipment market. As a result, while there is increasing demand for machine shipments, overall global revenue from SMT placement equipment sales is expected to
42
average at 7.2% growth per annum during the period 20152020. Most SMT placement revenue generation will come from the consumer electronics, computing and storage, telecom and automotive industries. Strongest growth is expected from Asia-Pacific, which accounts for nearly half of global SMT placement equipment market revenues, due in part to the consumer electronics industry and growing demand from developing markets.
Technology trends in SMT SMT placement manufacturers are improving machine flexibility with larger feeder capacities and multi-functional
A&D India | Jun-Jul 2016
TECHNOLOGY | TEST & MEASUREMENT
placement heads, as the demand for high-mix and low to medium volume manufacturing environments continues to increase. Machine flexibility and placement speed, for greater throughput, will become two of the most important parameters in the SMT equipment marketplace. Furthermore, intelligent feeder technology is expected to become the norm with increasing manufacturing complexity and changeovers. Intelligent feeders communicate with the placement system controller and eliminate the effects of set up errors by storing information about the feeder type, any adjustable feeder parameters and the component fitted. The main drivers for near-term market growth and the role of absolute encoding are summarised as follows:
Technology innovation Technology will be a crucial driver for SMT equipment demand with manufacturers likely to emphasise the need for low cost-of-ownership and high return on investment. Product innovations and differentiators will be the ultimate decision factor in addition to price considerations for customers. Customers will increasingly demand SMT placement equipment that can maximise throughput, communicate with other SMT equipment on the factory-line, and drive efficiencies so that their production processes continue to remain competitive and viable. The impact of this driver is expected to be high over the next five years, particularly in the medium to high speed SMT placement market segments as efforts are made to stabilise price declines. Current innovations in SMT placement technology revolve around production improvement across vertical market, feeder technology, flexible and modular gantry systems, improved tracking to enhance first pass yields (FPY), superior factory management systems and inter-machine communication platforms. The recent advent of high-accuracy absolute optical
A&D India | Jun-Jul 2016
encoder systems creates new possibilities for innovations in SMT placement equipment. Absolute encoders allow improved performance with better reliability, faster initialisation, enhanced safety, lower running costs and the elimination of common crash risks.
Flexible and responsive manufacturing Demand volatility in the electronics industry further necessitates lean manufacturing and fast production response times with a focus on flexible and responsive manufacturing lines. Demand for highly flexible production gives rise to multiple-head, multiple-axis machines with dual or quadgantries and flexible conveyors requiring coordination of complex placement paths. Incremental encoder systems require that all axes home to a reference position (reference return) when restarting production after stoppages â&#x20AC;&#x201C; only, in this way, is the control system able to detect the actual position of the axes. The homing of multiple-heads from an undefined location on an axis is a significant source of additional machine downtime. If the operator has not analysed the crash paths first and selected the reference travel cycle accordingly, the installations can suffer considerable damage as a result of the collision of placement heads or even of the gantries themselves. This leads to longer unproductive times, unnecessary costs and uneconomical downtimes of the machine for a crash. The advantage of absolute encoder systems is that they calculate position on demand and Renishawâ&#x20AC;&#x2122;s RESOLUTEâ&#x201E;˘ encoder is the first to combine this feature with built-in error checking algorithms that instantly flag any misreading of scale. This protects against uncontrolled movements and related crash risks by eliminating scale miscounting, position drift and count runaway, with benefits to yield, throughput and safety. Absolute encoders, therefore, improve process reliability, reduce unproductive time and prevent expensive crashes.
43
TEST & MEASUREMENT | TECHNOLOGY
Miniaturising SMT component sizes Another area of focus includes the need to address the smaller footprint and lower cost per board aspects. Consumer products are becoming extremely densely populated and physically smaller, leading to demand for automated and highly-accurate placement requirements. The electronics industry is reducing end-product dimensions with increasing use of smaller passive components, such as the 01005, with size factors approaching <0.5 mm, ultra-fine 0.3 mm pitch/ high pin count Quad Flat Packages (QFPs) and flip-chips with 150 Οm pitch. Higher assembly densities will increase demand for automating SMT placement equipment that reduces the cost per board with advanced software and feeder technology, enhanced placement accuracy and higher speed. Furthermore, rising numbers of customers are choosing to upgrade either legacy SMT placement equipment or the complete software platform, which should also help to drive market growth over the coming years. High-performance devices are likewise expected to drive demand for state-of-the-art SMT software platforms. As product complexity continues to grow, the demand for high quality assurance in high speed placement processes is rising and overhead-gantry type and revolver head systems, whereby a revolving placement head is mounted on a gantry beam that moves in the X and Y directions, will increasingly dominate. Machines must be capable of placing many thousands of components at high speed, >100,000 components placed per hour (CPH) for chip shooters, with high accuracy positional (X,Y) and rotational (θ) alignment to ensure increasingly exacting quality standards. Modern pick and place gantry systems require encoders to be capable of high speed (for increased throughput) and high resolution (for placing small components). Digital incremental encoders have a maximum speed that is determined by the maximum input frequency (MHz) of the receiving electronics along with the desired resolution. Consequently, as the maximum receiving electronics frequency is fixed, any increase in resolution will result in a corresponding decrease in maximum speed and vice versa. Absolute encoders do not suffer from this compromise and allow for both high speed and high resolution operation. This is due to the position being determined on demand and the use of serial communications, allowing gantry designers the freedom to operate at both high speeds and high resolutions. SMT placement machines are also increasingly using
44
linear motors on the X and Y axes to enhance accuracy, speed, and servo-loop stiffness. Absolute optical encoders output reliable signals of high fidelity that permit higher servo-loop gain levels. High servo-loop gain allows increased axis acceleration and deceleration, faster settling times and reduced induction motor heating, enabling the machine to run harder and for longer while reducing the number of scheduled stoppages required for cooling. Absolute encoders further allow correct commutation to be found immediately without reference returns enabling simpler servo-design and a reduction of assembly complexity when compared with incremental encoder-based systems, which require additional sensors, e.g. Hall effect sensors, to commutate the linear motor. Moreover, the error checking algorithms of the RESOLUTE encoder enhance placement reliability by reducing board misplacements, which helps to maximise yield (FPY) and lower the total cost-of-ownership.
Future of SMT placement Fast-moving commercial markets, which demand a succession of sophisticated high-technology products, are dominating the electronics manufacturing scene. This trend is compelling manufacturers to keep pace with the continuous miniaturisation and convergence of different technologies by developing increasingly flexible, modular SMT placement equipment. The SMT placement equipment market is experiencing significant new growth opportunities within Central and Eastern Europe for consumer electronics, telecom and automotive electronics manufacturing. The region is also attractive for low-cost manufacturing locations for the top global providers, which is further expanding demand for SMT production equipment. The Asia-Pacific region remains the largest generator of SMT revenues and leads demand for highspeed SMT placement equipment. The wider adoption of high-performance absolute encoder systems will allow SMT placement equipment manufacturers to keep up with the increasing technological demands of the electronics industry. Encoder technology employed within SMT placement equipment is directly responsible for improving placement accuracy and repeatability as well as increasing the speed of each axis, thereby boosting machine throughput to higher levels. â&#x2DC;? Courtesy: Renishaw
A&D India | Jun-Jul 2016
C O M M U N I C AT I O N & C O N T R O L | A P P L I C AT I O N
Automation network for IIoT The article talks about how industries can implement IIoT using standard interfaces
Bhagath Singh Karunakaran Managing Director Kalycito
In the age of data, connectivity is of prime importance. Even the industrial world has set foot into the Industrial Internet of Things (IIoT). Data can be easily acquired if it is done using standard and open interfaces. This forms the crux of a successful IIoT Implementation.
Future of IIoT The office IT network is built on Ethernet and has access to the internet, cloud, etc. To access the field information from the board, the field level communication also needs to be based on Ethernet. This enables smooth transition of data without the use of gateways. But using standard Ethernet in the field is not advisable as it is prone to the Carrier Sense Multiple Access with collision detection mechanisms (CSMA/CD). In the automation world, the machines and processes demand a real
46
Srinivasan Subramani Project Manager, Embedded systems Barry Wehmiller International
Ninad Deshpande Specialist—Open Technologies B&R Industrial Automation
time deterministic communication. “Combining the needs of the industry and demands of the machines and processes, we come to the conclusion that the automation network should be open source with standard interfaces and having a deterministic system performance,” quotes Bhagath Karunakaran, Managing Director, Kalycito and further adds, “Ethernet POWERLINK satisfies all these requirements. It is completely an open source and truly hardware and software independent. It couples benefits of standard Ethernet interfaces complying with the IEEE 802.3 as in internet of things and the determinism and availability needs of the industrial IOT.” Ethernet POWERLINK provides determinism down to 100µs. Looking at the software platforms, its implementation can be over Windows, Linux, VXWorks, QNX and any other operating system or without an operating system. It is also hardware independent with implementation possibilities right
A&D India | Jun-Jul 2016
A P P L I C AT I O N | C O M M U N I C AT I O N & C O N T R O L
Open Communications enabling vertical and horizontal connectivity
from micro-controller, micro-processor, ARM, FPGA, PCI cards, and PCs. The complete source code is available open source, free of cost and is certified and managed by the Ethernet POWERLINK Standardisation Group which is a consortium of over 3,200 members and users. It equips the user to have a complete choice of topology for his machine and process viz. line, star, tree and ring or a combination of all.
Steps to start implementation There could be different needs of different players who are involved in building the machine, process or IIoT project. If one is an OEM or a system integrator looking to buy off the shelf components then you could talk with companies such as B&R, Cognex, Baumer, ABB, etc for their POWERLINK components. If one is an OEM looking to add custom built embedded components to an off-the-shelf design or a sensor manufacturer such as encoders, temperature sensors, and controllers, then one can use openPOWERLINK resources available on sourceforge and build their own hardware or one can choose a module available off-the-shelf and integrate it in their device on that platform. The openPOWERLINK stack along with the documentation can be found at http://openPOWERLINK.sourceforge.net. It includes the master and slave stack source code, reference designs on multiple silicon and operating system platforms, FPGA IP cores for high performance MAC and for daisy chaining HUBs, and configuration tools. If you are a start-up or a university student then there is a readily available openPOWERLINK implementation on Raspberry Pi2. It involves managing a node and 2 controlled nodes working on Linux and communicating data on POWERLINK. The complete procedure for installing Linux, building the openPOWERLINK libraries and downloading them in the kits is provided on the website, http://www.
A&D India | Jun-Jul 2016
ethernet-powerlink.org/en/raspberrypi2/. This is the easiest method to bring up a POWERLINK network and to work with all the features offered by the technology.
Ease of working with POWERLINK Barry Wehmiller International implemented this technology on the critical UV curing controllers needed for the printing industry. Barry Wehmiller International is a global consulting company providing engineering and automation solutions for manufacturing organisations around the world. They have developed controllers for critical UV curing applications for one of their customers in the printing industry. These controllers are equipped with multiple control interfaces like analogue HMI, web HMI, TCP messaging and Ethernet POWERLINK. “We used openPOWERLINK stack version v2.0.0 and achieved a completely real-time deterministic response without any performance issues. The protocol was easy to implement and took us just 2 days of training from Kalycito to establish POWERLINK communication,” says Srinivasan Subramani, Project Manager, Embedded systems, Barry Wehmiller International. “We also conducted a 72-hour long test and found a completely error-free, deterministic response from POWERLINK. The oscilloscope test results and wireshark traces confirmed the robustness of POWERLINK. Our engineers were impressed with the robustness and reliability of POWERLINK protocol.” The specifications and technical documentation are well drafted and available freely online on the EPSG website. The source forge forums provide a perfect arena for availing quality and timely support while implementation. Barry Wehmiller International used the v2.0.0 stack of openPOWERLINK available on the website ‘openpowerlink. sourceforge.net’. The first step tried out during implementation
47
C O M M U N I C AT I O N & C O N T R O L | A P P L I C AT I O N
was to install the openPOWERLINK demo which is also available on the same website on two laptops and establish POWERLINK communication between them. They were unknown to this technology before downloading the stack and working with the demo. When the demo was installed on laptops, they were able to see the exchange of data on POWERLINK. A wireshark trace run on one of the laptop confirmed the data exchange over POWERLINK. Srinivasan says, “We were surprised to see the demo on two Windows based laptops communicating as a managing node and controlled node in no time and without any prior experience with the technology. This gave our engineers a confidence boost to work with POWERLINK.” The system consists of a UV controller communicating to the B&R PLC acting as a main printer controller over POWERLINK. This UV controller is also equipped with a web server implementation over the same Ethernet POWERLINK network. Thus, the OEM can access the UV controller from anywhere around the world. The UV curing system was able to achieve a low response time inclusive of the web server implementation and a very high asynchronous bandwidth.
IIoT implementation needs Bhagath was instrumental in specifying redundancy in POWERLINK back in 2005 and POWERLINK, since then, has been equipped with a multi-master, media and ring redundancy. This feature minimises the downtime, has an extremely fast changeover and is easy to use. “POWERLINK is, thus, the only industrial Ethernet protocol to provide master source code and specifications free of cost,” mentions Bhagath Karunakaran. POWERLINK thus addresses the need of availability on the machine and plant level. Security also needs to be addressed as it is an important issue in the IIoT space. POWERLINK owes much of its unparalleled level of security to the fact that it is an open-source software. The stack’s source code and any modifications to it are subject to frequent review by the
48
community. This not only prevents security issues – they are discovered and eliminated long before they can do any harm – but also provides effective protection against hidden backdoor attacks. POWERLINK combines timeslot and polling procedures to achieve isochronous data transfer. How the master node addresses the controlled nodes can be configured by software developers using suitable engineering tools, though this is not transparent to other entities in the network. “The fact that there is no way whatsoever for users to access these network configuration details during system runtime eliminates the need for specific protection against fraudulent manipulations in the system itself,” says Ninad Deshpande, Specialist – Open Technologies, B&R Industrial Automation. “High speed regardless of network size, total and complete openness, high tolerance to electrical interference, line and master node redundancy and inherent security that stops attackers in their tracks – POWERLINK fulfills all of these criteria.”
Automation meets IT POWERLINK enables the user to gather data from the field in a deterministic method. On a shop floor, there could be requirements for the controllers from different machines to exchange data or a central PC working as SCADA would require the data for sending it to the ERP and MES. The machine builders could use OPC UA which is another open source protocol based on standard Ethernet for transferring the data. Being based on standard Ethernet, POWERLINK effectively merges well with OPC UA and facilitates seamless data transfer from the shop floor to the MES/SAP. With features such as openness, usage of standard interfaces, compliance with IEEE 802.3, determinism, high availability and security provided by Ethernet POWERLINK at the field level coupled with its cooperation with OPC UA to transfer data from the field level to the process, ERP, MES layers has brought IIoT implementation into reality. ☐
A&D India | Jun-Jul 2016
M A N U FA C T U R I N G I T | T E C H N O L O G Y
IoT application in manufacturing sector The article talks about the benefits of IoT technology and how connecting production line systems can reduce cost and help for the optimum use of resources The Internet of Things (IoT) is bringing radical changes in the manufacturing process and can make the entire process flow and people more informed, efficient and productive. Smart manufacturing builds an environment where all information is available from within plant floor to supply chain. With IoT, manufacturers can monitor the condition of machinery and look for indicators of predictive failure, for example, vibration, temperature, or pressure outside threshold limits. This means that the technician needs to make fewer visits, reducing costs and resulting in faster recovery.
Connecting production line systems Production line monitoring and automation is a popular IoT application. By connecting production line systems, manufacturers can move to predictive maintenance, making better use of resources and reducing unplanned downtime. It can improve equipment utilisation and plant output overall. Manufacturers can also track pallets, shipping containers and equipment, both on â&#x20AC;&#x201C; and off-site, using location-aware IoT devices. Using a mix of connectivity technologies,
50
RR Bipin Vice President Digital Services â&#x20AC;&#x201C; IoT, Embedded Product Design Division Tata Elxsi
including cellular and satellite, this tracking can cover shipments across road, rail, sea and air transport. This endto-end monitoring reduces the chance of loss or theft and additional sensors can be used to verify that perishable or fragile goods are kept in appropriate conditions and handled properly throughout their journey. In connected supply chain, by connecting the production line and plant equipment to suppliers, all units can understand interdependencies, the flow of materials and manufacturing cycle times. IoT-enabled systems can be made capable for location tracking, remote health monitoring of inventory, and reporting of parts and products as they move through the supply chain. IoT systems can also collect and feed delivery information into an ERP system, providing up-to-date information to accounting functions for billing.
Cost savings Energy is the second largest operating cost in many industries. However, many companies lack cost-effective measurement systems and/or performance and management tools to optimise energy use in individual production
A&D India | Jun-Jul 2016
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 IoT cloud platform is capable of interconnecting with various devices, collecting and analysing data and getting integrated with custom-built vertical applications
operations. There are numerous ways in which IoT can create cost savings for manufacturers. The top five objectives for incorporating smart devices or embedded intelligence into operations are to: t Improve product quality (58%) t Increase speed of operation (57%) t Decrease manufacturing costs (57%) t Improve maintenance/uptime (47%) t Improve information for business analytics (42%) Additionally, the top five IoT capabilities that present the biggest challenges are identifying opportunities/benefits of the IoT, network capabilities to handle the IoT, budget/resources to develop or expand the IoT, incorporating smart devices or embedded intelligence and adapting to existing technologies. Furthermore, manufacturing executives believe that embedding smart devices or intelligence will increase revenue from new products by 39%, increase market share by 39%, access data from products or services in the field by 34%, increase profit margins per product by 34%, improve branding/ market awareness by 27% and access to new markets/sectors by 26%.
IoT cloud platform Tata Elxsiâ&#x20AC;&#x2122;s IoT cloud platform namely TETHER is capable of interconnecting with various devices, collecting and analysing data and getting integrated with custom-built vertical applications. It is a layered platform with the base IoT platform at the bottom and provides customers with the flexibility to add domain layers of their choice on top. Its lego-like architecture allows components and applications to be developed and linked together easily.
A&D India | Jun-Jul 2016
TETHER helps reduce risk, time to market and cost of deployment and thus acts as a simple, reliable, secure and scalable platform.
Looking forward... Potential market for smart factories and factory automation technologies is estimated to be $151 billion. There are some interesting ongoing and upcoming trends in the manufacturing sector. The APAC region is projected to be the largest market for IoT in the manufacturing sector by 2020. Within APAC, China held the largest market share for manufacturing sector in IoT, whereas India is expected to grow at the highest CAGR among the major markets. Factors which are driving the IoT for manufacturing market include technological advancements in semiconductor and electronics, evolution of cloud computing technologies, standardisation of IPv6 and support from governments worldwide. The manufacturing sector is witnessing a transformation through the implementation of smart factory concept and factory automation technologies. Government initiatives such as Industry 4.0 in Germany and Plan Industrial in France are expected to drive the manufacturing IoT solutions in Europe. The rising adoption of IoT in manufacturing is expected to boost the market for networking technologies, especially wireless networks. The current landscape of IoT is growing rapidly, but it is important to have the right set of partners. The diverse yet cohesive IoT solutions require interoperability between various hardware and software. It is, thus, important to have partnerships with key vendors to provide the best solution to customers. â&#x2DC;?
51
SAFETY & SECURITY | TECHNOLOGY
Protection against lightning in industrial environment There are many equipment damages, fire incidents, loss of life and essential services due to lightning reported in various places. The article discusses how safe operation of all electrical & electronic systems can be achieved, while considering the appropriate protection measures to address the safety challenges. Lightning is a natural phenomenon, which takes place due to formation of heavy electric field between earth and the clouds. The discharge of energy, when oppositely charged ions come sufficiently closer to each other, takes place in the form of lightning strike which carries huge amount of current even up to 200 KA or more. In electrical terms, lightning is defined as a wave shape (umbrella figure), with rise time of 10 µs to 90% of its peak and time to fall to half of the peak is 350 µs (known as 10/350 µs wave). Hence, on one side, the lightning carries very high KA amplitude of current causing enormously huge I²R (heat energy) in the
54
Vikas Almadi CEO & Director DEHN India vikas.almadi@dehn.in
Sudip Sen Vice President—Strategic Segments DEHN India sudip.sen@dehn.in
conductor (e.g. building, tree, electrical equipment, etc) and at the same time creates huge induced electromagnetic field (directly proportional to di/dt) due to very high rate of change of current (di/dt). There are so many equipment damages, fire incidents, loss of life and essential services due to lightning reported in various places, in addition to injuries to operators in few many cases. Lightning has been classified as one of the identified reasons of tank fires too as extremely high energy carrying lightning flashes can easily ignite a flammable area of zone 1 or zone 2.
A&D India | Jun-Jul 2016
TECHNOLOGY | SAFETY & SECURITY
Special consideration is required to define the path of the down conductor so that it does not come dangerously close to any other metal part
Ensuring safe operation In general, an industrial infrastructure houses number of sophisticated motors, generators, electrical and electronic devices, PLC & DCS and field mounted electronic sensors/ transmitters. Reliability and efficiency of working of these systems is most important for uninterrupted operation (production). Therefore, safe operation of all electrical & electronic systems is of vital importance in addition to the need of human safety and fire safety. The latest standard being followed internationally is IEC 62305:2010 (BIS has also adopted IEC standards for lightning protection in 2015 as Indian standard), having four chapters to discuss different aspects of lightning protection. The risk analysis methods has been thoroughly discussed in chapter 2 of IEC 62305 lightning protection standard. Standard
Details of the title
IS/IEC 62305-1 :2010
General principles of lightning
IS/IEC 62305-2 :2010
Risk management
IS/IEC 62305-3 :2010
Physical damage to structures and life hazards
IS/IEC 62305-4 :2010
Electrical and electronic systems within structures
Four different lightning protection levels (LPL) have been classified in this standard with respect to variation in lightning current amplitude and interception probability of the applied lightning protection system (LPS) design. Depending upon the vulnerability and risk of loss (life, services, assets), the LPL has to be considered during design of LPS. Special consideration is required to define the path
A&D India | Jun-Jul 2016
of the down conductor so that it does not come dangerously close to any other metal part (cables, infrastructure, pipe, tank body) enabling an uncontrolled flash-over or jump of heavy current, causing a high energy carrying arc in explosive zone 1 / zone 2 environment. Appropriate positioning of air termination rods will bring specified areas under zone of protection and using rolling sphere method the LPS design can be made very effectively. Direct or distant lightning can damage the electrical & electronic equipment physically or by corrupting the software loaded in the equipment. Following two major effects develop surge threats to equipment: 1. When a lightning strikes, a huge current passes through the associated soil or earth pit. Even if a very moderate level of lightning current (e.g. 100 KA) is passing through a very good earth pit (1 Ohm), it will raise the ground potential (GPR) around the earth pit to a level close to 100 KA x 1 Ohm = 100 KV due to Ohmâ&#x20AC;&#x2122;s law effect. Ground potential will get dissipated gradually as we measure it for more and more distance from the point of strike. This will create a ground potential imbalance within a distributed area industrial plant scenario. If any metal wire is connected between two physically distant locations then a surge current will flow due to this ground potential difference between the two locations. 2. Due to very high steepness (10/350 Âľs) of current flow during lightning, very high induced surges (EMI) are generated (proportional to di/dt). These surges get coupled on power & data cables connected to all electrical and electronic equipment placed in and around the facilities.
55
SAFETY & SECURITY | TECHNOLOGY
Use of appropriately designed lightning & surge protection system reduces chance of fire, damage of assets, failure of electronic/ electrical equipment due to direct/distant lightning strikes
Risk due to GPR & EMI effects There are some risks because of GPR and EMI effects due to lightning. They include fire in explosive zones; damage of fire fighting system; failure of security system; weighing system; air conditioning system; IT & telecom network; failure/damage of PLC/DCS cards; drives and field mounted electronic devices; failure/dmage of fire protection system and ESD; rise of step and touch potential-risk of loss of life as well as loss of production-loss of profit.
Advantage of using surge protection device There are a host of advantages of using surge protection device in association with structural lightning protection system. Use of appropriately designed lightning & surge protection system reduces chance of fire, damage of assets, failure of electronic/electrical equipment due to direct/distant lightning strikes. Some of the advantages are as follows: t Ensuring safe arrest, controlled guiding and same
56
t t t t t
discharge of lightning current Ensuring equipotential bonding on lightning strike Reducing the loss of equipment due to voltage spikes Reducing equipment downtime & maintenance costs Maximum run time and best productivity of the system Improving human safety, plant performance and reliability of operation
Conclusion Lightning incidences that may be a direct strike or a distant strike brings in very high level of threats for the infrastructure and electrical/electronic equipment (due to GPR and EMI), especially increasing the risk multifold in a potentially explosive environment. Appropriate protection measure needs to be considered after analysing the risk by using proper mathematical model provided in IEC62305:2010 standard. Lightning arrester system, earthing and equipotential bonding system and surge protection devices, all need to be installed in tandem to ensure comprehensive protection. â&#x2DC;?
A&D India | Jun-Jul 2016
EVENT | REPORT
Leveraging technology for quality and compliance The recently concluded Rockwell Automation Life Sciences Symposium 2016 at Mumbai, witnessed industry experts discussing the latest trends in the pharmaceutical industry and highlighting the role of technology in mitigating risks of quality & compliance. A post-event reportâ&#x20AC;Ś
Megha Roy Features Writer megha.roy@publish-industry.net
According to latest reports from the life sciences industry, suggest and deliver the outcomes of the same, Rockwell from discovery to commercial realisation, the cost of drug Automation Life Sciences Symposium 2016, was recently held development has increased by 18% and the forecasted peak at Mumbai, with a view to discuss the global challenges and sales of a given drug have declined by over 40%. This clearly solutions observed currently in the pharmaceutical industry. states that the life sciences industry is under pressure and has The day-long event witnessed 110+ attendees from around a long way to walk through to address the challenges faced in 60 organisations. Speaking on the state of Indian industry at the symposium, Dilip Sawhney, Managing Director, Rockwell the industry. Today, more and more manufacturing companies are Automation India, said, â&#x20AC;&#x153;Awareness and emphasis on seeking solutions that increase quality, safety, reliability, automation is the key to fight challenging situations in the profitability, cost control and production throughput. Indian pharmaceutical industry. There has been a lot happening Providing a platform for industry experts across the country to over the past decade. The industry has seen a growth of
58
A&D India | Jun-Jul 2016
REPORT | EVENT
23 billion US$ in 2012 from 23 million US$ in 2002. Moving ahead, we have to prepare ourselves for living in a highlyregulated world, where we ought to be prepared for all steps, that includes processes, workflow, etc.â&#x20AC;?
Âť DILIP SAWHNEY SPEAKSâ&#x20AC;Ś t
Highlights The first-half of the day witnessed several keynote sessions addressed by industry experts from the life sciences industry. The other half of the day hosted several breakout sessions on pharma manufacturers & consultants and pharma machinery manufacturers. The symposium started with a brief on the challenges of the pharmaceutical industry, rightly pointed out by Kumar Kanti Mitra, Regional Headâ&#x20AC;&#x201D;West, Rockwell Automation. While emphasising on the trends in the industry, he spoke on how latest technologies can address the ongoing challenges and how latest advances can drive through the current pharmaceutical industry. The keynote session begun with a presentation on â&#x20AC;&#x153;Indian pharma growth story: opportunities & dependenciesâ&#x20AC;?, wherein Gopal Nair, Immediate Past Chair & Director Board, International Society for Pharmaceutical Engineering, India Affiliate, explained the leveraging technologies in the pharmaceutical industry. â&#x20AC;&#x153;Today, the major challenges faced by the Indian companies are to leverage the compliance to US FDA,â&#x20AC;? explained Nair. Also, since increased process control makes more efficient use of materials that result in less scrap, he stressed the need of labour-intensive operations, while highlighting the importance of future factories.
t
t
5PEBZ BVUPNBUJPO IBT BO JNQPSUBOU SPMF UP QMBZ JO UIF HSPXJOH QIBSNBDFVUJDBM BOE MJGF TDJFODFT JOEVTUSZ 'BDFE CZ DIBMMFOHFT JO UIF IFBMUIDBSF MBOETDBQF MJLF SFHVMBUPSZ TDSVUJOZ HMPCBM DPNQFUJUJPO DPTU PG EFWFMPQNFOU BNPOH PUIFST PSHBOJTBUJPOT BSF SFBMJTJOH UIF WBMVF PG UFDIOPMPHZ BT BO FOBCMFS UP NJUJHBUF CVTJOFTT BOE PQFSBUJPOBM SJTLT JODMVEJOH RVBMJUZ DPNQMJBODF 5IFSF JT OP POF QSJDF UBH GPS JOEVTUSJBM BVUPNBUJPO EFQMPZNFOU 4PMVUJPOT BSF TDBMFE UP PQFSBUJPOBM PCKFDUJWFT BOE CVTJOFTT ,1*T UIF PSHBOJTBUJPO XBOUT UP BEESFTT 5IF CFTU BVUPNBUJPO JOWFTUNFOU SFBMJTBUJPO DBO CF BDIJFWFE CZ DMFBSMZ BMJHOJOH UIF UISFF DSJUJDBM FMFNFOUT UP ESJWF PQFSBUJPOBM FYDFMMFODF WJ[ QFPQMF QSPDFTTFT BOE UFDIOPMPHZ 8F BU 3PDLXFMM "VUPNBUJPO LFFQ B MPOH UFSN WJFX PG UIF JOEVTUSZ BOE DPOUJOVPVTMZ TUSJWF UP CFUUFS PVS DBQBCJMJUJFT CZ MFWFSBHJOH PVS EJGGFSFOUJBUJOH UFDIOPMPHJFT BOE HMPCBM FYQFSJFODF UP QSPWJEF JNQSPWFE WBMVF UP UIF NBOVGBDUVSFST 8F CFMJFWF 5IF $POOFDUFE &OUFSQSJTF FOBCMFE CZ *5 o 05 DPOWFSHFODF QSPWJEFT B WFSZ TUSPOH SFTQPOTF OPU POMZ UP NFFU TUSJOHFOU HMPCBM RVBMJUZ SFRVJSFNFOUT CVU BMTP NFFUJOH DPNQMJBODF CZ QSPWJEJOH B QMBUGPSN GPS EBUB JOUFHSJUZ
manufacturing excellenceâ&#x20AC;? by Rishal Shah, Managing Director, Jekson Vision. As an active member of the Indian Pharma Machinery Manufacturers Association, he also highlighted few trends in the Indian life science industry. The next presentation was compiled by Warford Reaney, Founding Partner & CEO, Aveta Lifesciencesâ&#x20AC;&#x201D;USA, Inc; Quality & Compliance Consultant. In his presentation on â&#x20AC;&#x153;Impact of global quality trends on Indian life sciences,â&#x20AC;? he opined that life sciences companies continue to face Addressing challenges in the pharma industry unprecedented compliance challenges in ensuring data Moving ahead, there was an insightful presentation on integrity. He further explained the recent regulatory changes â&#x20AC;&#x153;Pharma machine suppliers: A catalyst for achieving pharma globally, and how it affects the Indian manufacturing and
A&D India | Jun-Jul 2016
59
EVENT | REPORT
automation industry. The attendees were also addressed with several FDA 3D printing and data integrity guidelines by him to deliver better efficiency in operations. The highlight of the event was the presentation on “The Connected Enterprise for pharmaceutical manufacturing” by Sawhney. His presentation highlighted a few challenges in the life sciences industry, which includes compliance & good manufacturing practices; public & government pressure to drug prices affordable; changing healthcare landscape as well as meeting DSCSA deadlines. Sawhney also explained, “Smart manufacturing should be highly responsive to market demand, improve plant availability and reliability, enable secure access and reduce operational costs.” While touching upon the Connected Enterprise, he shared a few application benefits of Connected Enterprise in action for a ‘digital company’ in progress.
where he explained the pharma value chain and different levels of automation and information infrastructure. His presentation also included the benefits of plant-wide integration. A few of them include data reliability, time synchronisation, centralised monitoring, less human errors and more operational activities. The last presentation of the keynote session was hosted by Devashish Bakshi, Managing Director, Tapasya Engineering Works. His presentation on “Solutions for enabling quality by design: machine builder’s perspective”, explained the endpoint measurements for users. “While the traditional endpoint measurement methods include power consumption, torque rheometer and impeller torque; the emerging technologies are acoustic, near-infrared, FBRM and torque transducer/sensor,” he shared. The sessions were concluded by an interactive panel discussion, sharing expert’s opinion on the way forward journey of the Indian pharmaceutical industry. The discussion Global drivers, trends & implications was attended by thought provoking keynote presenters with The symposium also witnessed a presentation by Anil an active participation from the attendees, present at the Kumar Kartha, Site Head—Patalganga, Cipla, on “Achieving event. This was followed by a host of breakout sessions by manufacturing excellence through plant-wide integration”, eminent industry leaders. ☐
60
A&D India | Jun-Jul 2016
NEWS | TECHNOLOGY
Ultra-miniature connector
Ethernet switches
Fischer Connectors has launched an even smaller ultra-miniature connector, MiniMax 06, as an extension of its miniature high-density product range, the Fischer MiniMaxTM Series. The MiniMax 06 connector can include up to 12 power and signal contacts in a footprint of only 10 mm. This corresponds to a density factor of 0.83 – a unique MiniMaxTM Series technological feature for a connector with standard 0.5 mm contacts. The new MiniMax 06 connector also includes a new unique configuration with 2 signal and 2 high-power 1.3 mm contacts for applications needing 10 Amps or more power, doubling the standard 5 Amps current rating of the existing MiniMax product line. It is ideally suitable for handheld or body-worn applications when space is limited, in such fields as defence & security, instrumentation, testing equipment, civil or military unmanned aerial vehicles (UAVs), among many others. Tested for high-speed protocols such as HDMI and data transfer up to 10 Gb/s, the series also addresses the growing market need for higher data transmission rates.
HARTING has introduced the new Plug-&-Play Full Gigabit Ethernet switches that are smaller, faster and more efficient. The rapidly growing number of Ethernet-capable field devices with high bandwidth requirements requires an equally increasing number of ports for Ethernet switches. Boasting 16 RJ45 Full Gigabit ports, the new variants of the Ha-VIS eCon family provide the perfect solution for this requirement. Optimised and developed for use in harsh Plug-&-Play Full Gigabit Ethernet switches industrial environments, the ‘unmanaged’ Ethernet switches enable the cost-effective expansion of existing network infrastructures as well as the construction of new industrial networks. The extremely flat design permits the Ha-VIS eCon 2000 switches to also be deployed in installations where installation space is limited in the direction of the front-side cable connection. Thanks to their slender design, HARTING’s Ha-VIS eCon 3000 switches permit very high packing density on the DIN rail. With over 200 switch models, users have the ability to choose the combination of features and port combinations that perfectly fits the application at hand.
Fischer Connectors India | Gurgaon Email: raman.kalra@fischerconnectors.in | Tel: +91-124-4255642
Harting India | Chennai Email: in@HARTING.com | Tel: +91-44-43560415
Curved linear guides
Remote PLC
igus offers curved linear guides with different radii that offers more freedom in designing, thanks to the adaptable guide drylin carriage. The adaptable carriage can, thus, go into a curve from a straight line and is, therefore, suitable for a variety of applications in industry ranging from furniture to stage equipment. The Curved linear guides with different radii company addressed the users' demands for more and more customised requirements and perfect space utilisation. Application examples here are in the control cabins of construction and agricultural machinery. The advantages of drylin linear guides are ease of installation and maintenance-free use because the bearings do not have to be lubricated. To compensate for the rail spacing, a pivoting spherical ball made of abrasion-resistant iglidur plastic is used in the new drylin carriage. Thus, the carriage can move on flat rails as well as on concave or convex curved rails. Just as the carriage for a fixed radius, the new version is also available with manual clamping, whereby the carriage can be fixed at any position.
InnoVista Sensors offers em4, a fully connected nano-PLC and a perfect control system for specific markets and applications. A small PLC able to communicate as part of the Internet of Things, em4 is more than just an innovative, high-performance and easy-to-use nano-PLC. It constitutes a real growth platform for OEMs and integrators who are looking for an easy way to em4 move their application into the digital era. It enables remote management & maintenance on a PC & mobile devices. It opens up a new ready-to-use infrastructure to them, plus an ecosystem of online tools and services, creating new added value for their customers. The entire range of em4 lab includes em4 soft—the most intuitive PLC software in the market; remote access platform—“em4 web” and “em4 app” to remotely control from a PC or a mobile device. With its exceptional performance, uniquely precise analog I/Os and easy connectivity, em4 is particularly adapted to segments, such as water & waste treatment, access control, small industrial machines and embedded applications.
A&D India | Jun-Jul 2016
igus (India) | Bengaluru
InnoVista Sensors | Bengaluru
Email: vinayak@igus.in | Tel: +91-9341136381
Email: india@crouzet.com | Tel: +91-80-41132204
61
TECHNOLOGY | NEWS
Fire survival cables
Eddy current sensors
Lapp India has launched ÖLFLEX® FIRE survival cables that are safe and environment-friendly for circuit integrity application in the event of fire. These cables are passed through C/W/Z fire resistant test and can provide optimum cabling solutions in fire mishaps by maintaining circuit integrity for temperatures up to 950°C, 650°C and 950°C as per application requirements. The inner and outer sheaths of the cables are specially made of halogen–free compound, which reduces emission of fumes and acid gases in the event of fire. ÖLFLEX® FIRE survival cables are designed for major infrastructure installations such as – airports, metro rail, rail terminal, bus terminal, etc along with building and construction management. The use of the fire survival cable in building management, fire and security systems ensure that vital systems remain functional in the event of a real life incident, which requires an emergency evacuation. The cables are ÖLFLEX® FIRE made of halogen–free compound that reduces survival cables emission of fumes and acid gases in case of fire.
Micro-Epsilon has introduced the compact eddy current sensors, eddyNCDT 3001 and eddyNCDT 3005 model with integrated controller that provides a ‘clean performance’ in dirty conditions. The eddyNCDT 3001 eddy current sensors are perfectly suited to the reliable monitoring of the oil gap in hydrostatic bearings. As the sensor is resistant to oil and water splash, as well as high temperatures, in combination with its compact design, these sensors are ideal for harsh industrial environments. The eddyNCDT 3005 model is a compact, robust sensor system that is also eddyNCDT 3001 + 3005 temperature-compensated and can operate in temperatures from -30°C to +180°C. Even with high temperatures or temperature fluctuations prevalent in the production environment, these sensors achieve extraordinary measurement accuracy, despite the fact that temperature is an essential factor that influences measurement results. Controller, cable and sensor are pressure-resistant up to 10 bar. Compact, robust sensor designs and high measurement accuracy, combined with a favourable price/performance ratio, make these sensors suitable for high volume applications and for integration into plant and machinery.
Lapp India | Bengaluru Email: info@lappindia.com | Tel: +91-80-47405222
Micro-Epsilon | Pune Email: pragnesh.mori@micro-epsilon.de | Tel: +91-20-26741009
UHF read/write heads
Safety gate system
Pepperl+Fuchs offers new UHF read/write heads that function reliably even under harsh ambient conditions, while still offering a high level of flexibility. The F190 UHF read/ write head is designed to be the ideal solution to potentially problematic applications where the installation space is limited and for which read distances of 1 m to 2 m are sufficient. It is precisely these functions that are increasingly in demand within the framework of F192-UHF read/write head Industry 4.0—a development stage that requires identification as early as during production processes and not after products have been completed in the subsequent logistics chain, as was the case previously. The F192 UHF read/write head is supplementing the product family with its outstanding properties to also cover logistics applications in the future and achieve read distances in excess of 2 m. The F192 is ideally suited for applications involving large distances. The device can read and write up to 200 tags simultaneously, enabling a particularly fast throughput and in turn increasing productivity.
Pilz has added PSENmlock to its range of safety gate systems with immediate effect. PSENmlock offers safety gate monitoring and safe guard locking for the protection of personnel and processes to the highest category PL e in one device. The slimline yet robust design and the many different installation options make PSENmlock both PSENmlock flexible to use and easy to install. The new safety gate system is a reliable door guard both for small and for larger, heavy doors and gates, whether swing and sliding gates or covers and flaps. Above and beyond these possible applications the flexibly mounted actuator ensures high tolerance compensation and unrestricted functionality even with sagging gates. Thanks to a bistable magnet, the currentless guard locking system reduces the energy consumption of the safety gate system. Diagnostic data is easily identifiable in many installation positions: LEDs on three sides of the housing support user-friendly diagnostics whatever the installation situation. The robust safety gate system combines safe guard locking with personnel and process protection in one device.
62
Pepperl+Fuchs India | Gurgaon
Pilz lndia | Pune
Email: fa-info@in.pepperl-fuchs.com | Tel: +91-12-4389-4000
Email: info@pilz.in | Tel: +91-20-24213994
A&D India | Jun-Jul 2016
NEWS | TECHNOLOGY
Coreless brush DC motor
Gripper for cobots
Portescap has introduced the new DCT range of Athlonix™ brush DC motors. The 24DCT miniature motor features energy efficient coreless design with an optimised self-supporting coil and magnetic circuit, which ensures higher performance is delivered, all in a compact 24 mm diameter size. With torque carrying capabilities reaching up to 14.96 mNm, the 24DCT provides high performance with efficiency reaching up to 90% while maintaining a long lifetime. Due to the inherent design of the 24DCT motor, it can deliver higher torque per ampere which leads to better battery life. This 24DCT coreless brush DC motor makes it ideal for battery driven applications such as medical and industrial pumps, drug delivery systems, robotic systems (bionic fingers), miniature industrial power tools, tattoo machines, mesotherapy guns, dental tools, watch winders and more. Other applications such as lab automation, security and access and humanoid robots can also excel using the 24DCT Athlonix motor. Athlonix 24DCT miniature DC motors are available in 2 variations, precious metal commutation and graphite commutation with a Neo magnet inside.
SCHUNK has introduced Co-act gripper JL1, a new generation of grippers, specially designed for collaboration between humans and robots. This gentle powerhouse is the world's very first collaborative gripper capable of directly interacting and communicating with humans. Its features are its flexible outer skin with curved edges, integrated protection against workpiece loss as well as the LED panel used as an interface for communication with humans. Even at a basic level, the SCHUNK Co-act gripper JL1 satisfies the most critical requirements of safe human/robot collaboration: it never loses grip of an object, it always detects contact with humans and it will never cause injury SCHUNK Co-act gripper JL1 when gripping. A safe drive provides for both a wide gripping force range and functional safety. If a process is interrupted, such as in the case of an emergency stop, the part is ensured to remain in a reliable grip. With the help of an environment sensor, the gripper continuously detects factors in its environment and processes the data using integrated software.
Portescap | Mumbai Email: sales.asia@portescap.com | Tel: +91-22-42006200
SCHUNK Intec India | Bangalore Email: info@in.schunk.com | Tel: +91-80-40538999
PLC programming software
Digital measurement system
Turck offers a simple PLC functionality, ARGEE programming software, for its multiprotocol block I/O modules in IP20 and IP67. ARGEE enables PLC functions to be programmed directly on the modules of the TBEN-L, TBEN-S, BL compact and FEN20 block Turck’s block I/Os can take over simple I/O series. In this way, controller tasks with ARGEE simple controller functions can be outsourced to the I/O modules, thus, relieving the workload on the central PLC and the bus communication. The ARGEE programming environment is a simple web application. It simply requires a Windows PC with a web browser such as Chrome or Firefox. The company’s multiprotocol Ethernet, modules pre-programmed in this way can be used in Profinet, Ethernet/IP or Modbus TCP networks. Simple requirements can also be implemented on the Turck block I/O modules completely autonomously with ARGEE. Programming could be easier. In Simple mode, which is like a ladder diagram editor, drop-down fields provide the means by which inputs and outputs can be linked with Boolean operators and actions. This makes possible to program basic functions.
Testo extends its range of digital measurement solutions with the new Testo Smart Probes. The company has now integrated the feature of smart working into measurement tasks as well and result is eight compact measuring instruments, which can be connected to the smartphone or tablet via Bluetooth, and conveniently and intuitively operated via App. So, all the time consuming, manually driven operations can now be governed with just one click of the smartphone making the process more easy, accurate, fast and Testo Smart Probes reliable. This innovative, pocketsized instrument with the customary pro-measurement technology is suitable for all important temperature, humidity, pressure and flow velocity measurements. They are the ideal entry-level instruments for contractors with an enthusiasm for technology and also for measurement professionals, who need frequent measurements and report generation, that allows to save and send measured values as .pdf or excel on Android smartphones. Monitor measured data wirelessly for up to six smart probes at the same time, using trending graph or table, e.g. during system adjustments.
A&D India | Jun-Jul 2016
Turck India Automation | Pune
Testo India | Pune
Email: india@turck.com | Tel +91-7768933005
Email: info@testoindia.com | Tel: +91-84080-57707
63
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 - Aug/Sep 2016 IMPRINT
Automation & Drives
Publisher / Chief Editor ShekharManufacturing Jitkar Efficient
shekhar.jitkar@publish-industry.net 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
» Automotive & Machine Tools With sluggish demand in the automotive industry, a significant need for new approaches to automotive manufacturing across the supply chain has emerged. The next issue will feature the latest automation solutions for the automotive industry with emphasis on new age robotics that have improved productivity & processes. Further, featuring the automation needs of machine tool builders, the issue will provide case studies into latest automation solutions for this segment of the industry.
» Control & Regulation Future trends in control technology imply that total solutions in which tasks are distributed according to free capacity are growing in importance, while the individual components are becoming irrelevant to the customer. Advances in control and regulation technology bring in enhanced productivity and efficiencies. Keeping up with the latest developments and innovations on this front, the upcoming edition will stress on the applications of these technologies for multiple sectors, while ascertaining their future scope.
» Wireless Automation Despite several benefits, including flexibility & cost reduction, the rate of adoption of wireless automation has been slow due to various challenges and concerns among end-users. However, featuring among the top technology trends that are likely to change the gears in the automation business world-wide, wireless automation holds the key for multiple businesses. Featuring the latest developments on this front, the subsequent edition deals with implementation and technology platforms for this new age concept.
Advertising Sales Sagar Tamhane (Regional Head - North & East) Contact: +91 9820692293 sagar.tamhane@publish-industry.net Dhiraj Bhalerao (Regional Head - West & South) Contact: +91 9820211816 dhiraj.bhalerao@publish-industry.net Prabhugouda Patil 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 Jogindar J Dumde (Graphics Designer) jogindar.dumde@publish-industry.net Editorial & Business Office publish-industry India Pvt Ltd 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001, Maharashtra, India Ph: + 91 - 20 - 6451 5752
COMPANY INDEX Name . . . . . . . . . . . . . . . . . . . . . . . . . Page ABB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ARC Advisory Group . . . . . . . . . . . . . . . . . . 26 B&R Industrial Automation . . . .Cover, 6, 7, 8, 46 Bosch Rexroth . . . . . . . . . . . . . . . . . . . . . . . 9 Contrinex Automation . . . . . . . . . . . . . . . . . 19 Dehn India. . . . . . . . . . . . . . . . . . . . . . 15, 54 Delta India Electronics . . . . . . . . . . . . . . . . . . 3 Endress+Hauser . . . . . . . . . . . . . . . . . . . . . 8 Festo Controls . . . . . . . . . . . . . . . . . . . . . . 53 Fischer Connectors . . . . . . . . . . . . . . . . . . . 61 Grey Orange . . . . . . . . . . . . . . . . . . . . . . . 14 Harting Technology Group . . . . . . . . 10, 34, 61 HBC Radiomatic. . . . . . . . . . . . . . . . . . . . . 41 HMS Industrial Networks . . . . . . . . . 10, 35, 38 Honeywell Process Solutions . . . . . . . . . . . . 10 Hummel Connector Systems . . . . . . Back Cover
64
Name . . . . . . . . . . . . . . . . . . . . . . . . . Page ifm electronic India . . . . . . . . . . . . . . . . . . . 39 igus India. . . . . . . . . . . . . . . . . . . . . . . . 2, 61 Indian Institute of Science . . . . . . . . . . . . . . 24 InnoVista Sensors . . . . . . . . . . . . . . . . . 21, 61 Intelligent Motion Technology . .Back Inside Cover Inteltek Automation JV. . . . . . . . . . . . . . 23, 57 Kuebler Automation . . . . . . . . . . . . . . . . . . 49 Lapp India . . . . . . . . . . . . . . . . . . . . . . . . . 62 Micro-Epsilon . . . . . . . . . . . . . . . . . 5, 12, 62 Mifa Systems . . . . . . . . . . . . . . . . . . . . . . . 29 Murrelektronik India. . . . . . . . . . . . . . . . . . . 33 National Instruments . . . . . . . . . . . . . . . 12, 16 OPC Foundation . . . . . . . . . . . . . . . . . . . . . 12 Pepperl+Fuchs . . . . . . . . . . . . . . . . . . . . . 62 Pentair Technical Solutions . . . . . . . . . . . . . . . 1 Peschel Dynamics. . . . . . . . . . . . . . . . . . . . 11
Name . . . . . . . . . . . . . . . . . . . . . . . . . Page Phoenix Contact . . . . . . . . . . . . . . . . . . . . . 30 Pilz India . . . . . . . . . . . . . . . . . . . . . . . . 4, 62 Portescap . . . . . . . . . . . . . . . . . . . . . . . . . 63 Renishaw . . . . . . . . . . . . . . . . . . . . . . . . . 42 Renu Electronics. . . . . . . . . . . . . . . . . . . . . 37 Rockwell Automation. . . . . . . . . . . . . . . . . . 58 Schunk Intec India . . . . . . Front Inside Cover, 63 Siemens . . . . . . . . . . . . . . . . . . . . . . . 10, 26 Sick India . . . . . . . . . . . . . . . . . . . . . . . . . 13 Tata Elxi . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Testo India. . . . . . . . . . . . . . . . . . . . . . . . . 63 Toyota Motor Corporation. . . . . . . . . . . . . . . . 8 Turck . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Uhlmann . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Weidmueller Electronics India . . . . . . . . . . . . 45
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: `600 AandD.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://www.industr.com/in/en Digital edition http://issuu.com/publishi/docs
A&D India | Jun-Jul 2016