What’s New in Process Technology June 2012

0612

ON THE COVER

WHAT'S NEW IN PROCESS TECHNOLOGY JUNE 2012

Today’s natural gas systems are pushing the limits in terms of ensuring maximum capacity

CONTENTS

and operational efficiency. As a result of trying to meet increasing market demands, many regulator station designs are exceeding the performance envelope of other control valve manufacturers - but not Becker’s. In highdemand natural gas regulation applications

4

IEC Standard 61131: the benchmark for industrial controllers

8

New products

performance.

14

Hot products online

manding applications with large mass flow

26

Evaluating actuators

38

Competing for the future - does wireless play a part?

(turndown ratios up to 200:1).

Stranded or unused intelligence is not the way foward

The QTCV-T4 can handle a variety of gases,

46

As I see it

Part 1

Food and beverage applications

Technology, talent and sustainability

including antisurge service, the rugged Becker QTCV-T4 Quiet Trim Control Valve series offers a reliability that will improve your system’s The bidirectional QTCV-T4 is suitable for devolumes and large pressure differentials (up to 10,400 kPA), and that require aggressive noise attenuation as well as extreme precision

from sweet natural gas to multiphase service and corrosive gas, being available in a wide range of alloys including 316 stainless steel, LF2, Duplex and Inconel. For extremely severe service and longer maintenance-free operation, a tungsten carbide overlay can provide further erosion resistance. The patented trim design of the QTCV-T4 valve not only reduces velocity to combat erosion, but also features a self-cleaning non-clogging design - suitable for applications where amines and particulate matter are present. Even at a slight opening of the control valve, the T-ball’s clean sweep feature allows the debris to flow downstream, preventing scouring, build-up and clogging.

The compact design of the QTCV-T4 affords a decreased station footprint, increased reliability and life span, and a significant decrease in fugitive emissions.

Powerflo Solutions Pty Ltd www.powerflo.com.au

NOW in DIGITAL! Your copy of What's New in Process Technology is now available as an online eMag.

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IEC STANDARD 61131: THE BENCHMARK FOR INDUSTRIAL CONTROLLERS PART 1

Harry Mulder, Engineering Manager, Omron Electronics

4 WHAT'S NEW IN PROCESS TECHNOLOGY - JUNE 2012

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There can be little doubting the profound effect the IEC 61131 suite of standards has had on industrial controller product offerings over the last 25 years. Virtually all PLC vendors have adopted if not sections of the standard, then at least some concepts or its general philosophy. In fact, many vendors of other industrial control devices, such as IPCs (industrial PCs) and embedded controllers, have also taken note. Here’s why.

F

ew would argue the almost universal acceptance industrial controllers have gained since their introduction in the late 1970s. Their appeal derives from their high reliability and years of trouble-free service. Continued market penetration through the decades has seen them used in a wide variety of industries, such as manufacturing, food and beverage, power generation, water treatment and a host of others. They now control everything from entire water treatment plants or factories, individual machine cells and right down to very small devices that were once the domain of dedicated controllers.

Beginnings Since their inception, vendors have taken widely divergent approaches in the design of industrial controllers, particularly in the area of programming. A range of different programming techniques had been developed, some using high-level languages like BASIC, C, Fortran; others using graphical techniques. All were propriety and no standard existed.

One language called ‘ladder logic’ gained particularly widespread acceptance because its graphical notation made it intuitive and easy to learn. It was also a straightforward transition for electricians, who were already well versed in electrical diagrams for hardwired circuits.

While ladder diagrams are still used today, this methodology has a number of drawbacks: • Weak facilities for software structure • Low levels of software re-use • Poor data structure • Limited support for sequencing • Limited execution control • Cumbersome arithmetic operations Moreover, each vendor’s implementation, while appearing similar, used its own unique dialect containing significant variances, often in subtle details. Also, as a number of limitations of ladder programming became evident, and as each vendor sought to address them, ever-widening variations of implementation resulted.

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These differences led to considerable human resource costs, such as training. They also created enormous confusion, with potentially disastrous results.

The problem was exacerbated by the users coming from differing backgrounds, such as technicians, maintenance personnel, system designers and programmers. These factors highlighted the need for a standard which, if implemented properly, would ensure the future of the industrial control industry and widen their application base.

A new approach Like so many industries, a degree of maturity is reached whereby certain techniques or approaches start to emerge and are seen as being superior or otherwise desirable.

They become the ‘standard’, be it de facto or official. The PLC market reached such a point in the early 1990s.

Fortunately, the need for a new standard was recognised and the IEC established the first working group in 1979. Others followed, along with various specialist task forces, and after much deliberation most of the 1131 standard suite was released in the early 1990s. Its name was later changed to 61131. Table 1 shows the complete suite of the IEC 61131 standard. An updated edition of part 3 was released in 2003, which included amendments and a corrigendum.

In 1992, the PLCOpen trade association was formed by a number of interested parties keen to see the advancement of the IEC standard, particularly in the area of product compliance.

PLCOpen is a not-for-profit, vendor-independent organisation, trying to raise awareness of standards so that the efficiency of industrial systems is increased and productivity boosted.

As a standard is only as good as its number of users and how closely they adhere to it, PLCOpen’s TC3 (Technical Committee 3) provides certification facilities where vendors can have their products evaluated by an independent body and certification published. While 61131 - particularly Part 3 - remains at the core of what they do, PLCOpen has since branched out into other complementary standards.

JUNE 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 5

Controllers

THE IEC STANDARD IS BEST KNOWN FOR FORMALLY DEFINING FIVE OF THE MOST COMMONLY USED PROGRAMMING LANGUAGES; TWO TEXTUAL ONES: STRUCTURED TEXT AND INSTRUCTION LIST AND THREE GRAPHICAL OFFERINGS: LADDER DIAGRAM, SEQUENTIAL FUNCTION CHART AND FUNCTION BLOCK DIAGRAM.

The aims of IEC 61131-3 The main objective of IEC 61131-3 is to widen the understanding of PLC programming for all who may come in contact with it. In doing so, many of the issues mentioned previously would be resolved. Moreover, once programs are better understood, overall software quality tends to improve. The standard defines improved software as having enhanced capability, better availability, greater usability and superior adaptability.

What IEC 61131-3 offers The IEC standard is best known for formally defining five of the most commonly used programming languages; two textual ones: Structured Text and Instruction List and three graphical offerings: Ladder Diagram, Sequential Function Chart and Function Block Diagram. The main reason for having five languages, each with differing strengths and weaknesses, is to present choices to the programmer. This allows them to select the most appropriate language(s) for the programming task at hand and to ultimately improve the final program.

In practice, though, nearly all programmers use a series of interwoven POUs (program organisation units - such as functions, function blocks) written in a combination of Ladder Diagram and Structured Text.

The functionality of ladder programs has expanded to allow the inclusion of snippets of Structured Text and the interconnection of multiple functions and function blocks within a single rung, effectively amalgamating all three languages. SFC is very occasionally used for very large projects requiring extensive sequence control.

However, the standard goes much deeper and enables features that have been available in higher level computer programming environments for many years. In doing so, it can require a change of mindset in programmers previously used to exclusively programming in Ladder Diagram. IEC 61131-3 establishes numerous programming structures and coding practices that ensure increased quality, time savings and ultimately costs. Some of the new practices are: • Clarification of a software model: This provides both definitions of terminology in hardware (such as configuration,

resources, program, tasks and many more) and establishes hierarchy, with the ability for upper layers to abstract (hide away) details from the previous level.

• Modularisation: The ability to break down an entire program into functional elements called POUs. Well-structured programming code requires that divisions be able to be made with great flexibility. It must be possible to employ either a top down or bottom up design philosophy. The re-use of code should be encouraged to improve software quality and speed up development.

• The formal definition of data types and the enforcement of strict adherence to them: This overcomes a common source of hard-to-find program errors and requires support from the program compiler. The IEC standard also requires support for user-defined data types, such as structures, and multidimensional arrays.

• The ability to control execution, by assigning the order and priority of execution to certain tasks or PDOs:

Part

Title

Contents

IEC 61131-1

General information

Definition of basic terminology and concepts

IEC 61131-2

Equipment requirements and tests

Electronic and mechanical construction and verification tests

IEC 61131-3

Programming languages

Software structure, languages and program execution

IEC 61131-4

User guidelines

Guidance on selection, installation and maintenance of controllers

IEC 61131-5

Message service specification

Software facilities to communicate with other devices using communications

IEC 61131-6

(Reserved for future use)

IEC 61131-7

Fuzzy logic and control programming

Extension of part 3, to include Fuzzy Control Language (FCL) elements

IEC 61131-8

Application guidelines

Guidelines for the application and implementation of programming languages

Table 1: The IEC 61131 standard suite.

6 WHAT'S NEW IN PROCESS TECHNOLOGY - JUNE 2012

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Controllers

Figure 1: Microsoft’s Windows Presentation Foundation, show here in Omron’s Sysmac Studio, is an example of the user interface applications available.

This allows certain sections of code, such as time-critical functions, to be run more often or at set intervals. The timing needs to not only be settable but guaranteed. In order for this to be implemented properly, the underlying hardware needs to support true multitasking, not just the operating system.

Function blocks and functions But perhaps the most powerful precept introduced by the IEC standard is support for function blocks (FBs). FBs can be likened to a ready-made, off-the-shelf component that can be dropped into a program much like an IC in electronic hardware design. FBs encapsulate both data and algorithm into a single self-contained entity that abstracts details from users. When implemented properly, FBs become the basic building blocks of a program; and when they can be saved as individual files, program re-use is encouraged, not just within a single program but also between programs. Many standard FBs are specified as a minimum requirement by 61131-3. They should be callable from both ladder and Structured Text programs.

Functions are similar to FBs except they cannot retain data between calls, hence they do not have instance names. Because of this, they always return the same result for a given data set. Functions are generally simpler internally and are typically used for operations such as arithmetic and trigonometric functions.

Further improvements A number of indirect consequences have arisen from each vendor’s implementation of the IEC 61131-3 software standard. Although not strictly part of the standard, numerous

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features have been added as vendors have had to update their product offering for their hardware to comply with the standard.

One is the use of virtual addressing space, where variables, of any data type, can be assigned freely and referenced only by their symbol name (or tag). Attributes like memory retention, constancy and initial values can be enabled in the declaration. Unlike traditional PLC programming, where hardware addressing was always used, hardware addresses are abstract and programmers are usually unaware of the internal memory map and where the variable physically resides. Symbols are then stored in a database within the controller and can be accessed by external devices, like HMIs. IEC does, however, require the ability for an AT attribute to be set, in which case actual addresses can be specified. Another is the improvement of programming environments for controllers.

The need to comply has led vendors to update their program development software.

In doing so, the latest developments in the runtime environment of the computer can be utilised (see Figure 1). More advanced programming systems also offer integrated simulation whereby a program can be tested not only off-site (saving any potential damage to equipment) but also without controller hardware.

What IEC 61131-3 is not Two aspects that may seem logical consequences of the standard are: interlanguage portability (the ability to convert or transpose a program written in one language to another language) and intersystem portability (porting a program written for one vendor’s compliant hardware into another vendor’s compliant hardware). Although these features may seem desirable, neither is easy to

implement, nor were they ever fundamental goals of the standard.

In summary The fact that the IEC 61131 standard is in active use today, some 20 years after its inception, and that most vendors have based their designs around it, is testament to its usefulness and effectiveness. It is clear the IEC’s original goals for 61131-3 of making programs better understood has improved software quality and thereby increased programming efficiency. This has all been to the benefit of users, who have in turn endorsed the standard.

The activities of the PLCOpen organisation, by not only promoting standards, but by also continuing to seek enhancement to existing and expansions of new standards, should ensure IEC 61131 will remain the benchmark for new industrial controller offerings for most vendors for many years to come.

In Part 2 Industrial controllers, particularly PLCs, have come a long way since the early 1990s, as more and more demands have been placed on them. The IEC standard has been expanded accordingly and we’ll have a look at how the integration of motion control functions has affected the standard and some of the challenges this has presented to hardware vendors.

Reference: Lewis, RW, 1996, Programming Industrial Control Systems Using IEC 1131-3, The Institution of Electrical Engineers, London.

Omron Electronics Pty Ltd Contact info and more items like this at wf.net.au/N938

JUNE 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 7

NEW PRODUCTS

HART CONCENTRATOR SYSTEM The HCS HART Concentrator System from Moore Industries converts HART digital signals to the serial (RS485 or RS232) Modbus RTU communications protocol. It monitors a single instrument in point-to-point HART mode or it can allow up to 16 HART instruments to digitally communicate on the same wires in a digital multidrop HART network.

The HCS maps all HART variables to Modbus registers so Modbus host systems can have access to the multiple HART process variables found in instruments such as smart multivariable mass flow, pressure, pH and temperature transmitters; Coriolis, magnetic, ultrasonic and vortex flow meters; radar and hydrostatic level transmitters; and valve positioners and damper operators.

OXYGEN ANALYSER

The HCS also allows a Modbus host system to monitor critical HART instru-

Michell Instru-

ment diagnostics by using the field device Status byte information. HART status

ments has re-

data available includes smart device configuration changes; primary and non-

leased the XTP601

primary variables out of limits; primary variable analog output fixed; cold start;

thermo-paramagnetic

and field device malfunction.

oxygen analyser to pro-

Moore Industries Pacific Inc Contact info and more items like this at wf.net.au/N426

vide fast, accurate measurements of oxygen levels in various background gases.

Capable of measuring oxygen from 0-1% up to 0-25% and suppressed zero ranges, such as 90-100%, the analyser provides solutions for applications ranging from biogas plants to monitoring blanketing gases in oil tankers.

HANDHELD DIGITAL PRESSURE INDICATOR

The XTP601 is configurable to suit specific applications and budgets with three options: a blind transmitter version

Designed specifically for pressure

(settings, controls and readings accessible via application

m eas ur em ent and ca lib ra tio n

software); a transmitter with status LEDs (settings, controls

tasks in harsh environments, the

and readings accessible via application software); and a

WIKA model CPH6300 has a meas-

full display analyser (settings and readings are accessible

uring range of up to 1000 bar. It

with on-screen controls or via application software).

features high accuracy of up to 0.1% of span.

The robust and waterproof case,

All of these options may be rated for either safe or hazardous area use. Hazardous area classifications are available for ATEX, IEC Ex with cCSAus pending approval.

with an ingress protection of IP65 and

The full display version of the XTP601 has a touch-screen

IP67, protects the handheld instrument

interface to enable easy operation without needing to remove

from outside influences in tough condi-

the lid. This means that users can calibrate, change settings

tions. It has a fast measuring rate of

and interrogate the instrument in the hazardous area without

1000 measurements/s and is well suited to the measurement

the need for a ‘hot permit’. Menus allow easy access to

of pressure peaks and spikes. A large 4½-digit backlit display

information on oxygen concentration; analyser status; a

enables the measured values to be easily read.

graph showing oxygen trends over a user-defined time pe-

A data logger that can record up to 10,000 readings is integrated

riod; alarm history; minimum and maximum concentrations;

into the instrument, as well as a function to perform leak tests. The

and other parameters to aid diagnosis of plant conditions.

sensors of WIKA’s older CPH6200 model are compatible with the

Free software is available for the XTP601 to enable users

new model without readjustment. The CPH6300 is also available

to monitor, operate and calibrate any version of the instru-

in a single- or dual-channel version.

ment remotely via a PC or control system.

WIKA Australia

AMS Instrumentation & Calibration Pty Ltd

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8 WHAT'S NEW IN PROCESS TECHNOLOGY - JUNE 2012

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Escaping steam means lost energy and lost profits. If only I could monitor my steam traps without running all over the plant.

YOU CAN DO THAT Capture elusive energy savings with real-time automated steam trap monitoring.

Knowing the status of every steam trap could enable you to save up to 20% of steam loss and $4 million dollars a year in lost energy. With the Rosemount 708 Wireless Acoustic Transmitter, you’ll have instant visibility to all your critical steam traps through a non-intrusive, WirelessHART® monitoring system. Backed by Emerson’s proven experience in Smart Wireless field instrumentation, the Rosemount 708 will enable you to effectively and easily capture significant energy cost savings without running all over the plant. Talk to Emerson. We’re the experts in wireless so you don’t have to be.

rosemount.com/stopsteamloss The Emerson logo is a trademark and a service mark of Emerson Electric Co. © 2011 Emerson Electric Co.

NEW PRODUCTS

SELV SWITCHING POWER SUPPLIES Turck has introduced a family of power supplies to expand the company’s existing range. Designed to efficiently convert AC to DC, these 24 VDC power supplies provide safety extra-low voltage (SELV), according to EN 60950, and are suitable for the 24 V supply of equipment and interface modules of the Turck series IM, IMS and IMC. Offering wide-range input of between 90 and 260 VAC, the 24 VDC power supplies can be used in diverse supply networks, worldwide. Through the use of an on-board potentiometer, the output voltage can be adjusted from 22.5 up to 28.5 VDC, and styles are available with an output current rating of 2.5, 5,

ENTERPRISE MANAGEMENT SOFTWARE

10 or 20 A.

Honeywell has launched Intuition Executive, the flagship

Featuring Class 1, Division 2 certification, and

product of its new Intuition software portfolio. Intuition

rated IP20, the Turck 24 VDC power supplies were

Executive is designed to deliver enterprise-wide information

developed specifically to guarantee a dependable DC

management, decision support and collaboration tools to

supply in industrial environments. This highly efficient

help companies in the process industries achieve opera-

power supply can be run in parallel for applications

tional excellence.

requiring redundancy and includes overload protection of up to 150%.

Companies in the process industries often use disparate systems that are usually either completely isolated or are connected with complex, custom-designed interfaces that make it difficult to use the data effectively and maintain data integrity.

The software provides a portal for integrating, visualising and analysing data, providing a window into plant activities so that users can identify opportunities, avoid problems, improve safety, mitigate risks, meet deadlines and reduce costs. It moves beyond simple data access and display to providing context a unified view of data assets that combines information from multiple sources. Continuous performance monitoring triggers notifications and tasks or workflows, enabling sophisticated dashboards and dynamic handling of problems and opportunities in near real time.

Intuition Executive is built on open industry standards and extends existing technology investments. It enables connectivity to any data source (including DCS, historians, applications, MES and ERP systems) and establishes con-

For enhanced operator control and device status,

text with tools to describe how the data from different data

a power relay guarantees a reliable functional check,

sources relates to each other, integrating and relating data

monitoring itself for voltage. The device can also

on the fly. It analyses and monitors through its calculation

bypass power failures automatically, which allows the

and event engine and triggers the right actions in the right

AC input to disappear for up to 30 ms without any

circumstances, and information is visualised in a Microsoft

effect on the output.

SharePoint portal using graphics, trends, tree maps and lists.

Turck Australia Pty Ltd

Honeywell Limited

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Check out this magazine’s website.

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WE KNOW WE CARE WE CUSTOMISE FOR YOU‌

E LE DRIV CTRIC MO ES T CONT & SOFT S ORS ROL & TA AUTO RTERS MATIO N

TOSHIBA INTERNATIONAL CORPORATION PTY LTD NSW Toshiba International Corporation Pty Ltd 2 Morton Street, Parramatta NSW 2150 Tel: (02) 9768 6600 Fax: (02) 9890 7546

QUEENSLAND Toshiba International Corporation Pty Ltd UNIT 4 / 20 Smallwood Place, Murarrie QLD 4172 Tel: (07) 3902 7888 Fax: (07) 3902 7878

VICTORIA Toshiba International Corporation Pty Ltd 411 Fern Tree Gully Road, Mt Waverley VIC 3149 Tel: (03) 8541 7960 Fax: (03) 8541 7970

NEWCASTLE Toshiba International Corporation Pty Ltd UNIT 1 / 18 Kinta Drive, Beresfield NSW 2322 Tel: (02) 4966 8124 Fax: (02) 4966 8147

MACKAY Toshiba International Corporation Pty Ltd 1st Floor 41 Wood St, Mackay QLD 4740 Tel: (07) 4951 4203 Fax: (07) 4953 4185

WESTERN AUSTRALIA Toshiba International Corporation Pty Ltd 10 Anderson Pl, Perth International Airport WA 6105 Tel: (08) 6272 5600 Fax: (08) 6272 5601

Reliable products from reliable people!

NEW PRODUCTS

Three of the 500+ panels we built in 2011

EMBEDDED SYSTEM CONTROLLER The Aaeon GES-5500F is a high-performance standalone embedded PC featuring Intel Core i5/i7 processor support, fanless operation, compact size, robust construction and low power requirements. The GES-5500F is supplied with either an i5 520M 2.4 GHz processor or an i7 620M 2.66 GHz processor to provide an energy-efficient embedded PC platform. The GES-5500F is equipped with two SODIMM sockets supporting up to 8 GB of DDR3 system memory, two 10/100/1000Base-TX RJ45 ethernet connectors, six USB 2.0 ports, three RS232 ports, one RS485 port and one 8-channel digital I/O port. A 2.5″ SATA hard drive can be internally mounted for operating system and data storage. System expansion is possible via an internal mini-Card slot. Other I/O includes dual display VGA and DVI graphics connectors, audio line-in, line-out and mic and PS/2 keyboard and mouse connectors.

The fanless design of the GES-5500F reduces the possibility of airborne corrosive or conductive materials entering the system to provide a long-term reliable industrial computing solution.

The GES-5500F can operate from a wide range 10 to 30 VDC power source, making it suitable for vehicle Intelligent Transportation Systems (ITS) as well as factory control applications. The GES-5500F can also be supplied with an external AC power adapter.

Interworld Electronics & Computer Industries Contact info and more items like this at wf.net.au/N741

MANAGED ETHERNET SWITCHES Weidmüller has updated its IES series of industrial ethernet switches. With three ranges to choose from, the series offers a broad choice of fast ethernet or gigabit ethernet managed switches with various port combinations. Users can select from entry level IES21 fast ethernet, IES31 fast ethernet with gigabit uplink, up to IES41 full gigabit ethernet switches. The switches feature ring redundancy with floating master, the latest security features, IGMP snooping and a built-in virtual cable tester.

Our Sydney Systemhaus is ISO 9001 certified for the ‘development, assembly and distribution of customised system solutions,’ making Bürkert the ideal partner for large and small scope projects. In addition to standard panels, we engineer custom panels with pneumatics, I/O, transmitters and programming to meet your wider control system needs. Call on Bürkert to build your 2012 panels.

These managed switches are equipped with Weidmüller’s W-Ring technology, which simplifies network requirements by eliminating master/ slave settings in a redundant ring, while providing a network reinstatement time of less than 20 ms. They also feature MSTP for additional redundancy, providing the possibility of spare links that automatically provide backup paths should the active links fail.

The IES managed switches also have a built-in virtual cable tester (VCT). The VCT tests a twisted pair connection status by using time domain reflectometry. It is capable of identifying the type of fault as

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well as the distance from the switch port within 5 s.

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12 WHAT'S NEW IN PROCESS TECHNOLOGY - JUNE 2012 WNIPT Ad 201203 HP.indd 1

6/02/2012 2:54:58 PM

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NEW PRODUCTS

HIGH SPEED CAMERA SYSTEM The PCO.dimax, 4 megapixel, digital high speed CMOS camera system, with a 12-bit dynamic range, provides 2012 x 2012 pixel resolution at a rate of 1100 fps. With lower resolutions, rates as fast as 56,300 fps can be achieved and it is available in both colour and monochrome.

The system features a variety of trigger options to cover all off-board applications and image data is transferred via GigE Vision or

PRE-ENGINEERED PALLETISING PACKAGE

USB 2.0 interfaces. For preview purposes, a DVI interface is integrated and the PCO.dimax

PalletPack 460 is a pre-engineered package of robotic palletising components featuring the IRB 460 robot designed

has a smart battery control which allows a full operation for 1h and a data backup for 6h.

specifically for the high-speed, end-of-processing-line palletising.

The 4-axis IRB 460 features a 110 kg capacity plus a reach of 2.4 m. Its compact footprint makes it suitable for integration into existing packing lines and convenient for high-speed bag or compact end-of-processing-line case palletising.

ABB’s PalletPack consists of an IRB 460 robot; a Flex-Gripper (either the claw or one-zone clamp gripper); an ABB control PLC; an ABB safety PLC; PalletWare support software; user documentation; and the ABB FlexPendant featuring an easy-to-use graphical human machine interface. A feature of the PalletPack is the wizard-enabled se-tup and programming, which makes programming very similar to that used for a traditional

Applications include: high speed particle

PLC. This enables PLC programmers - without specific robotic experience - to program

image velocimetry (PIV); short time physics;

the system, eliminating the complications that can arise when a specific programming

spray imaging and analysis; hyper-velocity

skill set is required. The programming and operation are carried out via the FlexPendant,

impact studies; automobile crash tests; mate-

the standard ABB Robotics human machine interface. This features a graphical interface

rial testing; fast flow; hydrodynamics; sparks

with four user-friendly screens; pallet and pick set-up, pallet pattern set-up, path profile

in electrical switches; combustion imaging;

and movement edition.

semiconductor quality control; fast events in

Programming time for the PalletPack 460 is claimed to be reduced by as much as 65% compared to traditional methods, shortening the return on investment.

ABB Australia Pty Ltd Contact info and more items like this at wf.net.au/N719

nature and machines; and ballistics.

SciTech Pty Ltd Contact info and more items like this at wf.net.au/N822

New ST50 Air Flowmeter for 2" to 24" diameter lines FCI's ST50 Series is the most efficient and economical flow measurement solution specifically designed for larger line size air flow measurement in plant operations. Utilizing thermal dispersion mass flow technology ST50’s compact size and simple single-point insertion makes installation a breeze and accurate, fast-response measurements a sure thing.

Its rugged construction ensures long, continuous service in demanding plant environments. ST50 is ideal for: • Compressed Air Management & Cost Reduction Initiatives • Burner, Oven and Furnace Air Flow Controls • Exhaust System and Ventilation Air Controls • Water Treatment Aeration • Industrial Dryers • Blower Air

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Unit 20, 51 Kalman Drive Boronia, VIC 3155 Australia 03-9017 8225

03-9729 9604

To get full product specifications and a free application evaluation, contact AMS today.

JUNE 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 13

HOT PRODUCTS

ON WWW.PROCESSONLINE.COM.AU THIS MONTH

RTD SIGNAL CONDITIONING The NI PXIe-4357 RTD PXI Express module is optimised for temperature

>

measurements with Pt100 RTD sensors for a variety of thermal monitoring applications.

COLOUR MEASURING SYSTEM

National Instruments Australia

The colorControl ACS 7000 is an online

WF.NET.AU/N989

colour measuring system suitable for automotive paint inspections and interior colour measurements and in the processing of plastics, wood, veneers, textiles.

Bestech Australia Pty Ltd

>

>

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COMPACT CONTROLLER

The Liquiline CM14 compact controller offers pH, conductivity and dissolved oxygen measurement and control at a lower price.

Endress+Hauser Australia Pty Ltd

WF.NET.AU/N910

>

PROCESS VALVE CONTROL HEAD

>

FIELDBUS DEVICE COUPLERS

The Burkert Type 8681 control

The TG200 fieldbus device couplers

head is designed for use in

allow for the fast and easy enabling of

hygienic processes in the dairy,

fieldbus systems by connecting devices

food and beverage, biotechnol-

to a main fieldbus trunk in a Foundation

ogy or pharmaceutical industries.

fieldbus or Profibus PA network.

Burkert Fluid Control Systems

Moore Industries Pacific Inc

WF.NET.AU/N866

WF.NET.AU/N810

14 WHAT'S NEW IN PROCESS TECHNOLOGY - JUNE 2012

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Automation helping Australia’s medical devices industry

Australia has a vibrant medical devices industry focused on exporting its products and creating overseas markets. Companies in the Australian medical devices industry undertake a wide range of activities including the research, development, manufacture and distribution of products ranging from surgical gloves and syringes to artificial joints and hearts. It has been estimated that around 17,500 people are employed in the industry. (Source: AusMedTech.)

Australia also has a large and highly advanced medical device market. The Australian market for medical equipment and supplies was estimated to be US$4,027 million in 2010, equal to US$187 per capita, with Australia accounting for around 1.7% of the total world market (Espicom Business Intelligence Report: Medical Device Market, 2010, p.3). However, the Medical Technology Association of Australia (MTAA) estimated total annual revenue for the Australian medical technology industry to be $7.6 billion in 20092010 with this figure being extrapolated from various sources of data (www.mtaa.org.au).

The industry is unique in that it imports most of what it uses (98.8%) and exports most of what it produces (97.2%), mainly to the USA, New Zealand, Europe, Japan and the UK. The global nature of the industry means that its future viability and continued success will be based on its ability to develop competitive products for export markets.

To remain competitive in a relatively high-cost economy such as Australia, the application of automation is an essential ingredient in creating sustainable medical devices manufacturing businesses. The right investment in modern, custom-designed, custom-built and fully installed automation solutions will enable businesses to achieve success in increasingly competitive global markets and grow exports into the rapidly developing economies of the world.

When applied appropriately, the benefits are clear. Automation of the manufacturing process not only drives costs down, it improves

quality, reduces waste, optimises energy use and achieves flexibility. Flexibility is important in this industry, as the need for productivity improvements is a constant challenge. Balancing production requirements against sales forecasts in a heavily regulated industry can make this difficult.

The nature of the finished product in the medical devices industry typically means that a unique manufacturing process is required, as opposed to traditional pharmaceuticals, where the equipment required is typically sourced off the shelf. This requirement for a unique process can provide the need for innovative ideas within large companies to improve their processes.

Consequently, this will foster opportunities for firms that can provide custom-engineering and automation services.

While the Australian medical devices industry largely comprises SMEs - in particular, companies with fewer than 10 employees - the top end of the industry is represented by its two truly global players: Cochlear and ResMed. Cochlear designs, manufactures and sells the Nucleus cochlear implant along with the Baha System bone conduction implant solution, with an estimated 250,000 cochlear implant/Baha recipients since establishment in 1981.

At the heart of Cochlear’s product development is one simple idea - innovation. In order to allow engineers to focus on continuing their innovation work, Cochlear outsources parts of the design and manufacturing of custom machinery for their production facilities. Custom engineering services company Precision Mechatronics has engaged with Cochlear in several projects over the last two years.

These projects have ranged from straight replication work, such as reproducing custom machinery in Precision Mechatronics’ North Ryde facility already designed and built previously

by Cochlear projects, to projects requiring the

16 WHAT'S NEW IN PROCESS TECHNOLOGY - JUNE 2012

development of custom solutions, a skill well suited to Precision Mechatronics’ experience in developing and optimising processes. These projects have ranged from the automation of labour-intensive processes, to solving material handling challenges. Precision Mechatronics has provided the full suite of its skills, including design, build, quality management and comprehensive documentation.

Process automation is a key driver to success for companies like Cochlear and all industries in Australia, where the currently high currency value, and relatively high labour costs among other factors, make the need for an efficient process critical. Process automation can contribute significantly to this.

Precision Mechatronics has recently delivered a production prototype unit to Cochlear, which via process automation will reduce the number of people movements within the cleanroom environment by at least an order of magnitude.

The system is a benchtop unit that will remove the need for the operator to make tens of trips within the cleanroom. This offers multiple benefits: a better working environment for the operator, a more efficient process and also importantly for this regulatory environment, a more consistent process with the risk of human error reduced.

While the development of the medical device industry is open to speculation, the presence of the big two, Cochlear and Resmed, does provide an excellent pool of talent to base the growth of the industry on. Already there are several small companies that have taken the lead from these two and are looking to make the next breakthrough.

By Jason Thelander, CEO, Precision Mechatronics, North Ryde, NSW Precision Mechatronics Contact info and more items like this at wf.net.au/N316

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NEW PRODUCTS

EXPANDED GEAR UNIT RANGE SEW-Eurodrive has expanded the torque range of its X-Series industrial gear units. With their finely graduated size, they cover a torque range of up to 475 kNm. Recently, the drive automation specialist rounded off the lower power range of this series and is now also offering the gear units for the torque range of 6.8 to 45 kNm. With these helical and bevel-helical gear units, nearly any mounting position or shaft arrangement can be implemented. A large amount of accessory equipment creates flexibility in terms of adjusting the unit to each respective application. This includes a wide range of modular options such as motor adapters and mounting flanges, backstops and cooling systems, as well as sealing systems for different environmental conditions.

One main area of application for SEW industrial gear units is conveyor systems in a wide variety of industries. In this context, the gear units are suitable for service in driving conveyor belts and bucket elevators for the horizontal and vertical transport of bulk material and packages. They can also be used to run the travel and hoist drive on cranes or serve as a drive with reinforced bearings for mixers and agitators.

X-Series industrial gear units can also be used in industries such as the chemicals, food and environmental industries, as well as the wood, paper, plastic and steel industries.

SEW-Eurodrive Pty Ltd Contact info and more items like this at wf.net.au/N677

PANEL-MOUNT CONTROLLERS FOR LARGER ROBOTS ABB now offers a panel-mounted controller variant for larger ABB robots, providing system integrators with easier and more flexible integration solutions.

The PMC is the same as the standard variant of the IRC5 controller, only stripped of its enclosure for flexible mounting.

The PMC consists of a drive module and a control module that can be separately mounted in a variety of configurations (on top of each other, side by side, back to back). Each module is made up of two layers. The first layer can be folded down for easy access to the second. Up to four drive modules can be connected to the same control module for multiple robot control.

Panel mounting has several benefits, including reduced floor space and internal cabling that is easier to manage, allowing machine builders and integrators to create their own enclosures to protect electronics in various environments. As an example, the food industry often requires equipment that is washdown capable. In the foundry industry a moist, dusty atmosphere calls for a sealed cooling system. In other industries the controller may be faced with ignition risk, extreme temperatures or excessive vibrations. With panel mounting, controllers can be sealed off from all of these factors with an appropriate enclosure. Since the PMC controller is fully EMC certified, there are no issues with disturbances to surrounding equipment or EMC certification of the final enclosed solution.

ABB Australia Pty Ltd Contact info and more items like this at wf.net.au/N231

18 WHAT'S NEW IN PROCESS TECHNOLOGY - JUNE 2012

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NEW PRODUCTS

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MOTOR SHAFT COUPLINGS Featuring high torsional stiffness and high dynamic load capacity, Zero-Max CD A1C

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couplings are designed to ensure reliable

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machine operation. They provide precise

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positioning under high-speed reversing loads

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couplings are suitable for reversing loads and provide

without fatigue. In addition, these zero-backlash smooth operation at high speeds. The design is compact to allow for a smaller assembly - enabling a smaller machine footprint.

Designed with improved clamp-style hubs for handling larger shafts and higher torque, the design provides good shaft engagement.

Shafts have increased clamping strength, eliminating the need for keyways for a cleaner, better-balanced design.

All components are made of premium materials. Machined hubs are made from ISO grade 7075-T6 aluminium and hubs are black

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anodised to MIL-A-8625 Type 2, Class 2 finish. Recessed fasteners are ISO 4762 grade 12.9 socket head cap screws.

The composite disc is made of high-precision composite material that is manufactured to strict aerospace and Six Sigma practices.

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This material has good chemical and moisture resistance. All components are tested with finite element analysis (FEA) software for perfect balance. All materials used are ecofriendly with no banned substances according to RoHS directives.

The couplings are available in six sizes. Torque capacities range from 40 to 564 Nm with speed ratings from 6700 to 15,000 rpm depending on model.

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Naismith Engineering & Manufacturing Co Pty Ltd Contact info and more items like this at wf.net.au/N601

MINIATURE INFRARED CAMERAS The Micro-Epsilon miniature infrared camera range has been extended with two models: the thermoImager (TIM) 400 and the thermoImager (TIM) 450, both of which offer optical resolution of 382 x 288 pixels.

The cameras achieve a maximum thermal sensitivity of 80 mK for the TIM 400 and 40 mK for the TIM 450, which allows smaller temperature changes to be detected. The series includes four models with temperature ranges between -20 and +1500°C. The software package included with the thermal imager, TIMConnect, allows representation of the thermal image in real

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time (80 Hz) with record function such as video and snapshots.

A LabView driver is included. The cameras have small dimensions and an environmental rating of IP67.

Bestech Australia Pty Ltd Contact info and more items like this at wf.net.au/N176

20 WHAT'S NEW IN PROCESS TECHNOLOGY - JUNE 2012

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NEW PRODUCTS

FREQUENCY INVERTERS The MOVITRAC LTP B frequency inverter is suited to a large variety of drive solutions in a wide range of applications. The unit series has been designed for universal use, offering control of both induction and permanent magnet synchronous motors (PMSM), with or without encoder feedback.

A wide range of control options are available, including an energy saving function and a wide range of I/O and communication interfaces ensure quick and efficient integration into a variety of control systems. An intuitive parameter structure, with standard factory settings and an integrated keypad, shortens the commissioning process.

The MOVITRAC LTP B frequency inverter is available in six frame sizes from 0.75 to 160 kW for a supply voltage of 230 V or 400 V and is available in two housing variants; IP20 for cabinet mounting and IP55 for field mounting. The unit is fitted with a dedicated Safe Torque Off binary input which immediately disables the drive in emergency conditions. Delivering up to 200% torque from zero speed, the MOVITRAC LTPB is suitable for applications with inherent high starting torque characteristics, including conveyors, crushers, winders and mixers.

SEW-Eurodrive Pty Ltd Contact info and more items like this at wf.net.au/N823

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JUNE 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 21

NEW PRODUCTS

INTELLIGENT SIGNAL CONDITIONERS Acromag’s IntelliPack signal conditioners with a configurable internal microcontroller are easily configured for integrator, totaliser, characteriser, comparator and limit monitoring applications.

IntelliPack transmitters are software configured via USB or a serial port using easy set-up screens. No programming is required. The desired settings are selected from a list or values can be entered to define linearisation curves, sample rates and relay trip points. Equations can be entered in a spreadsheet formula to calculate output based on arithmetic, logarithmic, exponential, conditional and other relationships. Software simulation allows equations to be tested offline for output response to varied conditions.

Intellipack transmitters can scale and total multiple 4-20 mA flow sensor signals, convert a level signal to a proportional volume signal or transmit a signal representing the average or ratio of two flow lines. They can also apply a transfer function where the output is defined by an equation or curve, detect peak and valley signal values and hold an alarm state, control relays with window/band-pass, deviation and rate-of-change limits, output a pulse signal to calculate flow, volume, weight or power, and apply pulse-width modulation or hold the output value from a critical event.

Metromatics Pty Ltd Contact info and more items like this at wf.net.au/N675

FIBRE AMPLIFIER The Banner Engineering DF-G1

How do you improve reliability and still save money?

UE Solid State Pressure Switches

Expert dual display fibre amplifier has a thermally stable electronic design with dual display, two bright digital readouts and an improved fibre clamp, making the sensor suitable for plastic and glass assemblies, including small part or wire break detection on electronics assembly machines, pill counting and high-speed detection for registration mark or product leading-edge detection. The user interface simplifies sensor set-up and displays the current light level and threshold values at a glance. The DF-G1 provides manual manipulation of all operating parameters. Users can also implement one of six Expert Teach and Set methods to ensure optimal gain and threshold selection for each application, particularly in low-contrast environments.

The DF-G1 is powered by a 32-bit microprocessor with a 12-bit analog-to-digital converter and provides response speeds of

Improve reliability with UE electronic pressure and temperature Switches.

Available for hazardous locations the One Series provides precise control and features Plugged Port detection.

200 µs for high-speed requirements and 500 µs for standard speed.

Solid State design with no moving parts ■ Field programmable for set point and deadband control ■ 2-Wire design is a drop-in replacement for mechanical switches ■ IAW®(I am working) self diagnostics ■ Pressure ranges to 4500 psi/Temp. ranges to 1000°F

assemblies to be mounted in close proximity, sensing different features

■

Pryde Measurement Pty Ltd Ph: 1800 688 211 info@pryde.com.au Melbourne ❘ Sydney ❘ Brisbane ❘ Perth

22 WHAT'S NEW IN PROCESS TECHNOLOGY - JUNE 2012

Additionally, the amplifier is capable of long (2 ms) and extra-long (5 ms) range detection.

Thermally stable electronics minimise warm-up drift and enable sideby-side mounting of multiple amplifiers with no reduction in the ambient temperature limit. A cross-talk avoidance algorithm allows two fibre-optic of the same target. The 10 mm-wide housing mounts to 35 mm DIN rail, maximising the number of sensing points available in the cabinet.

The DF-G1 high-visibility red LED sensing beam makes alignment easy, while the lever-action fibre clamp provides stable and reliable fibre clamping.

Micromax Pty Ltd Contact info and more items like this at wf.net.au/N000

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NEW PRODUCTS

UHF RFID READER

MARKING PRINTERS

IEI Technology's MODAT-335

The Bluemark CLED from Phoenix Contact is designed to make

reader features an optional UHF

labelling standard UniCard materials for marking terminals, con-

reader, a technology that is be-

ductors and devices as easy as printing on paper.

coming increasingly popular for

The system comprises a Bluemark CLED and notebook with

solving difficult RFID problems

preinstalled Clip Project planning and marking software so that

and meeting business needs

users can start to print immediately by connecting the devices

across industries. Compared to

via USB and starting to print.

the more mature HF tags, that

With up to 10,000 labels an hour, UV technology provides fast

have a 1 m reading range, on

and environmentally friendly printing. The solvent-free labelling fluid

average, the UHF tags operate in a higher frequency band, ranging

makes the Bluemark system suitable for cleanroom applications

from 860 to 960 MHz, and provide a reading range of up to 10 m.

and ensures that labelling is scratch resistant and smear proof.

The MODAT-335 includes an optional handle grip with a barcode trig-

The range of UniCard materials is available in various versions,

ger. This ergonomic design allows users to easily carry and hold the

colours and sizes for all applications involving labelling terminals,

MODAT-335 while reading tags. The angle at which the device can read

conductors and devices.

tags is greatly increased when using this accessory.

Bluemark CLED is part of the Marking system from Phoenix

The UHF RFID reader can be used for vehicle identification, verification

Contact. Labelling data is transmitted to the printer directly

and identification of vehicle transponders, as well as object or personnel

from the CAE system via the central Clip Project planning and

tracking. It assists with verifying job or order delivery assignments and

marking software.

can read multiple items at once or from a long distance.

Phoenix Contact Pty Ltd

ICP Electronics Australia Pty Ltd

Contact info and more items like this at wf.net.au/N444

Contact info and more items like this at wf.net.au/N820

EtherNet/IP ENABLING AUTOMATION CONTROL WITH I.T. INTEGRATION ON STANDARD, UNMODIFIED ETHERNET. Share secure, real time information between the manufacturing plant and the wider business enterprise.

By getting real time information in valuable and understandable formats for the different people in your organisation, manufacturers can take advantage of network convergence to greatly enhance the agility of a business and provide opportunity for greater innovation. Rockwell Automation and its partner, Cisco, have been driving these developments so that you can take standard, unmodified Ethernet and do extraordinary things.

See something extraordinary at: www.apac.rockwellautomation.com/ethernetip/WNIPTAUB

EIP_wnipt_half-pg_may12.indd 1

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14-May-12 3:59:10 PM

JUNE 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 23

EVALUATING ACTUATORS

FOOD AND BEVERAGE APPLICATIONS

© iStockphoto.com/Laurentiu Iordache

Aaron Dietrich, Tolomatic, Inc*

Motion control

Materials, design, fabrication and maintenance affect actuator performance and compliance with food safety guidelines.

P

roduction of food and beverages on todayâ&#x20AC;&#x2122;s industrial scale would not be possible without a high level of automation.

Pneumatic, hydraulic and electric actuators are critical moving components in equipment used for processing and packaging food and beverage products for world markets.

In addition to efficient production, machines used to process food must keep food safe by not harbouring or introducing bacteria, lubricating fluids or other contaminants that could harm consumers. That is why actuators used in the food and beverage industry must be manufactured from appropriate materials and designed in a way that eliminates collection points where bacteria can flourish.

Suitable actuators must also be capable of withstanding frequent washdown with water, detergents, steam, caustic soda, citric acid or other types of sanitary cleaning solutions.

There are certain ways in which actuators need to be designed and built in order to perform in this challenging environment - and process and automation engineers therefore need to select the most appropriate actuators for their food and beverage applications.

The food and beverage environment The most critical food and beverage processing applications involve dairy, meat and egg processing; and there are government authorities that are charged with regulating sanitary conditions in these facilities. However, many other types of facilities involved in food and beverage processing do not fall under government jurisdiction and yet they tend to follow the general guidelines for safe equipment selection and operation. These types of facilities include large bakeries, food packaging operations and many different types of bottling plants.

Machinery used in food and beverage processing may use several types of actuators, including rod-style, rodless or rotary depending on where they are located in the processing equipment and how they are shielded from washdown processes. The bearing system of a rodless actuator is designed to carry loads throughout the actuatorâ&#x20AC;&#x2122;s stroke and cannot be sealed adequately to prevent the ingress of liquids into the actuatorâ&#x20AC;&#x2122;s internal components and needs to be well shielded from the washdown process. For applications that require the actuator to come in direct contact with washdown solutions, the rod-style actuator is the only choice due to its sealing characteristics. Pneumatic rod-style actuators are still widely used in the food and beverage industry due to their low cost points, but electric rod-style actuators are gaining momentum for a variety of reasons including flexibility of control (multiple positions and motion profiles), efficiency (elimination of compressed air) and higher performance (precision, accuracy, repeatability).

While the working parts of a typical rod-style actuator may not ever come in direct contact with the food product or its packaging, there are invariably spills, drips and spatters that collect on various parts of the processing machinery, including the actuators. Unless this residue is removed from the equipment on a regular basis, it

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can become a reservoir of dust, bacteria, fungi and other spoilage organisms that may contaminate the food product or packaging.

Materials suitable for washdown environments Actuators used in washdown environments either have to be properly sealed and made of corrosion-resistant materials or be carefully shielded to prevent water, food products or chemicals from reaching the actuator mechanism. While shielding of more economical actuators not designed for washdown is widely practised, shields complicate equipment design and many times interfere with maintenance. Moreover, the recent emergence of catalogue-listed stainless steel rod-style electric actuators designed for washdown will likely reduce the popularity of shielding as a money-saving strategy.

Actuators intended for washdown environments need to be made of corrosion-resistant metals, and other parts such as seals, connectors and lubricating fluids need to be compatible with food processing as well. Ideally, actuators used in washdown environments should be constructed of AISI 300 series stainless steel (excluding type 301 and 302), with 304 and 316 being the most popular.

Aluminium alloy as an actuator construction material may be satisfactory for some dry product processing applications as long as it is not subjected to strong caustic cleaning solutions or to the corrosive action of dissimilar metals. While metal alloys other than stainless steel or aluminium may be suitable under certain conditions, alloys containing lead, leachable copper or other toxic metals must be avoided in food and beverage applications. Certain surface treatments or coatings may be used to reduce corrosion on components that have product contact, but the coatings need to be approved for food and beverage use.

Figure 1: The smooth rounded design of this rod-style electric actuator minimises debris collection points and enables water and other washdown chemicals to be freely shed.

JUNE 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 27

Motion control

Figure 2: Viton washers, seals and gaskets are used in actuators designed for washdown. This illustration shows the location of a Viton seal in an actuator for ingress protection.

Figure 3: This rod-style actuator is made of all stainless steel construction and includes a protective motor enclosure.

Plastic or rubber parts on actuators, such as seals, gaskets or accessories, need to be suitable for food and beverage applications if they are in contact with the product. In addition, these seals, gaskets and accessories must be capable of withstanding the effects of the cleaning solutions used.

While there exists a list of approved plastic and rubber materials, some of the most popular of the approved products are Viton O-rings and seals and ultrahigh molecular weight (UHMW) polyethylene for some mechanical parts.

Lubricants used on actuator rods that may be subject to incidental food spatters or contact need to be food-grade oils and greases as approved by the FDA. Proper seals between the actuator body and the rod on an IP67- or IP69K-rated product typically keep lubricant exposure to a minimum.

Design and fabrication The design of electric rod-style actuators for food and beverage applications needs to be free of crevices that may harbour bacteria, be sealed for washdown and have rounded surfaces with a smooth finish that sheds moisture. Motor housings, actuator bodies, corners and edges should be rounded to promote moisture runoff. Generally, a number 4 ground finish on stainless steel that is free of pits, cracks, folds or other imperfections is suitable for washdown applications. For welded junctions, electropolishing, glass beading and shot peening are not generally acceptable alternatives to a number 4 ground finish.

Permanent joints in the construction of an actuator, such as where the motor housing joins the screw barrel, may be either welded or gasketed, but any junction should be fully cleanable when assembled. Where two parts meet with a gasket, it is important to make sure the adjacent surfaces and the gasket are flush. If the

28 WHAT'S NEW IN PROCESS TECHNOLOGY - JUNE 2012

gasket either protrudes or is recessed, it can form crevices that may collect moisture, food debris and bacteria. In cases where the actuator is assembled with O-rings instead of gaskets, make sure the O-ring completely fills the gap between the two mating parts. Actuators with grooves along the screw body to accept position switches would not be suitable for use in a food and beverage application.

Fasteners used on actuators intended for washdown environments also need to be able to shed water freely. Avoid sockethead bolts, counter-bored holes, slotted screws or fasteners with knurling, as they all have debris collection points. Hex-head bolts or dome nuts are the preferred alternative. Make sure the actuator has no fasteners with exposed threads where debris can collect.

Whether an actuator is pneumatic, hydraulic or electric, it must be sealed properly so that dust, drips and washdown solutions do not contaminate the motor or internal mechanisms. Actuators with an IP65 or IP67 rating are protected against ingress of dust and high-pressure washdown under static conditions. For extreme washdown environments, an IP69K rating offers the best protection.

While the IP69K rating is not synonymous with protection from chemical attack due to aggressive cleaning solutions, this rating does maintain a high level of ingress protection in high-pressure spray situations. It is therefore important to have an understanding of both the cleaning solutions intended to be used as well as the sealing elements employed in the actuator device to ensure compatibility.

Actuator maintenance Maintenance of food processing or packaging equipment is vital for proper sanitation and maximum uptime. The washdown environment is hard on equipment, and it is important to be constantly looking

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Motion control

ACTUATORS USED IN WASHDOWN ENVIRONMENTS EITHER HAVE TO BE PROPERLY SEALED AND MADE OF CORROSION-RESISTANT MATERIALS OR BE CAREFULLY SHIELDED TO PREVENT WATER, FOOD PRODUCTS OR CHEMICALS FROM REACHING THE ACTUATOR MECHANISM.

Figure 4: Examples of a nickel-plated rodless actuator and a stainless steel rod-style actuator. The inherent sealing properties of the rod-style actuator makes it suitable for washdown environments where actuator shielding is not possible.

for any evidence of corrosion or less than optimum operation.

Actuators, when specifically designed for washdown environments and properly sized for the application, can be very durable components. However, it is important to periodically inspect actuators for any signs of seal wear along the rod, loose components, pitting or corrosion. Pitting or corrosion can create sites that collect moisture and also harbour debris or bacteria. vActuators play an important role in processing and packaging machinery used in the food and beverage industry, where they must withstand frequent washdown. The design of actuators used in these applications is critical to the health and safety of the products being produced. The materials from which they are fabricated must resist corrosion and cleaning solutions, while not leaching toxic substances into the food products or packaging. Manufacturing engineers who select actuators that are designed for washdown and food and beverage applications will find that they are much easier to integrate into an application than actuators that need sanitary barriers or other types of shielding. With the emergence of catalogue stainless steel electric rod-style actuators, engineers now have an economical way to incorporate electric actuators into

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food and beverage applications. By consulting with their actuator distributor or manufacturer early in the design phase of an application, engineers can ensure the most efficient, economical and safe food and beverage application.

Pneumatic Products Contact info and more items like this at wf.net.au/N667

*Aaron Dietrich has an extensive background in the motion control industry and has several years of experience working specifically in the drive and controls area as a design and application sales engineer. Aaron has a B.S. in electrical engineering from the University of North Dakota and is working on completing his MBA. Aaron is currently manager of Tolomaticâ&#x20AC;&#x2122;s Marketing Department.

JUNE 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 29

MOTION CONTROL PRODUCTS

CONFIGURABLE SHUTDOWN AND SPEED MONITORING The PSR Motionstop safety module from Phoenix Contact is designed for monitoring safe shutdowns and the movement of drive components. Standard incremental encoders, safety, certified SIL rotary encoders, and proximity switches can be connected to the device, thereby implementing important safety functions in accordance with EN 61800-5-2. Semiconductor and relay outputs quickly and safely stop dangerous movements if necessary. Up to four different operating modes can be monitored for one machine in connection with external drive components and the integrated STO (safe torque off), SLS (safely limited speed), SMS (safe speed management) and SDI (safely monitored direction) safety features.

The safety module is easily configured with the removable PSR-OP service and display unit. This is not required for the basic device to function, meaning that a remotely operated PSR OP unit has maximum protection from manipulation and offers cost advantages over the use of several basic devices. The safety module is suitable for applications up to SIL 3 in accordance with EN 61508 und EN IEC 62061 and PLe in accordance with EN ISO 13849-1.

Phoenix Contact Pty Ltd Contact info and more items like this at wf.net.au/N918

PRECISION RING DRIVE The Nexen Precision Ring Drive (PRD) is designed to provide precision motion control for indexing and rotary positioning systems. By merging Nexen’s Roller Pinion System technology with a precision-grade bearing and gearhead, the PRD provides high performance for indexing and rotary positioning applications.

With accelerations twice as high as similar indexing technologies, it can reach speeds up to 300 rpm; and unlike traditional cam-driven systems, the PRD can also handle peak torque inputs at all times. It offers indexing precision up to ±11 arcseconds with repeatability up to ±1.2 arcseconds. Supported by a highcapacity cross-roller bearing, it is rated for loads up to 1575 kN. Containing a roller pinion system that is 99% efficient and a gearbox that performs at a 96% efficiency, the PRD meets current industry demands for higher performance capacities at lower energy costs. Its construction also provides continuously smooth motion, minimising vibration during operation and resulting in less noise than conventional technologies.

The elimination of oil baths allows the PRD to reduce labour and maintenance by not requiring time-consuming clean-ups, and enables the drive to be mounted in any orientation. Cabling can be filtered through the large open centre, simplifying installation and improving mounting versatility.

Norman G Clark Pty Ltd Contact info and more items like this at wf.net.au/N721

30 WHAT'S NEW IN PROCESS TECHNOLOGY - JUNE 2012

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MOTION CONTROL PRODUCTS

ABSOLUTE ENCODERS Elap Mem-Bus absolute encoders are available with direct interface for either a CANopen or Profibus network.

Mem-Bus encoders can be supplied both in a single and in a multiturn version: the singleturn encoder resolution is 13-bit, while for the multiturn type the resolution value is 29-bit (8192 steps/ revolution for 65536 revolutions).

Different mechanical versions are available to satisfy application requirements - square flanged, round flanged with servo coupling, and with hollow shaft to couple directly to a motor shaft. All the types offer different options for the shaft/hole diameter, and electrical connection is offered in two or three cable glands options. The stout aluminium case ensures a high degree of protection so that it is possible to apply Mem-Bus encoders in severe industrial environments.

Motion Technologies Pty Ltd Contact info and more items like this at wf.net.au/N250

DEVELOPMENT AND SIMULATION SOFTWARE MathWorks has announced Release 2012a (R2012a) of its MATLAB and Simulink product families. Updates include the introduction of HDL Coder, which generates HDL code from either MATLAB or Simulink for prototyping and implementation on FPGAs or ASICs, and the launch of HDL Verifier, which replaces EDA Simulator Link and adds Altera FPGA hardware-in-the-loop support. R2012a also updates 84 other products, including Polyspace embedded software verification products.

For MATLAB, R2012a highlights include: unified functions for 1D, 2D and 3D numerical integration and improved performance of basic math and interpolation functions; MATLAB Compiler Runtime (MCR) available for download, simplifying distribution of compiled applications and components; Image Processing Toolbox provides automatic image registration using intensity metric optimisation; and Statistics Toolbox has an enhanced interface for fitting, prediction and plotting with linear, generalised linear and nonlinear regression.

R2012a highlights for Simulink include: the ability to run models directly from Simulink on target hardware; Embedded Coder is now AUTOSAR 4.0 compatibile, reduces data copies and links code generation reports with Simulink Web views; and Real-Time Windows Target that allows real-time execution of models in Windows using Simulink Normal mode. Release 2012a is available immediately and is being provided to users worldwide with current subscriptions to MathWorks Software Maintenance Service for immediate installation.

Additional information on R2012a product updates is available at www.mathworks.com.au/products/new_products/latest_features.htm.

MathWorks Australia Contact info and more items like this at wf.net.au/N099

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JUNE 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 31

MOTION CONTROL PRODUCTS

COORDINATED MOTION SYSTEM

ETHERCAT DIGITAL POSITIONING ENCODER

The Allen-Bradley Kinetix 350 single-axis servo drive provides

The EPOS3 70/10 EtherCAT is a digital positioning encoder

motion scalability. It connects and operates with CompactLogix

suitable for real-time positioning of synchronised multiaxis sys-

controllers, supporting integrated motion on EtherNet/IP.

tems. Compact in size, the EPOS3 possesses a wide nominal

CIP Sync and CIP Motion technologies provide real-time,

power supply voltage range from 11 to 70 VDC and delivers a

closed-loop motion control on standard ethernet. This topology-

continuous output current of 10 A, and during acceleration and

independent network provides a simplified integration of the entire

deceleration up to 25 A. Designed for DC and AC motors with a

control solution on one network, including programmable automa-

power range up to 700 W, it provides uniform running for motors

tion controllers (PACs), human-machine interface, I/O and motion.

equipped with incremental encoders.

With its compact design, the Kinetix 350 requires less panel

The EPOS3 70/10 EtherCAT integrates as slave into real-

space and can be connected easily. In addition, users can reduce

time EtherCAT protocol-based ethernet networks, and with the

design, installation and commissioning time by re-using code

provided device description file and device-specific configura-

across various Logix control platforms.

tion guide in a Beckhoff-TwinCAT environment. A variety of Programmed with

operating modes allows efficient, flexible use in a wide range

RSLogix 5000 soft-

of drive systems in robotics, automation and mechatronics.

ware, the servo drive

The positioning controller supports a broad range of encoders.

provides a scalable

The controller offers comprehensive protection against overcur-

motion system to be

rent, excess temperature, undervoltage and overvoltage, against

used with ControlLogix

voltage transients and against short circuits in the motor cable.

and CompactLogix

It is also equipped with adjustable current limitation to

PACs. In addition, it is

protect motor and load as well as protected

equipped with embed-

digital inputs and outputs.

ded safe torque off.

Its scalable platform

The EPOS Studio software serves as user interface for param-

is optimised for lower

eterisation. Tasks such as

axis count systems.

firmware download, automatic

The Kinetix 350 sup-

controller commissioning, I/O

ports 100 and 200 V single-phase and 200 and 400 V three-phase

configuration, test and data record-

voltage models. Power ranges from 400 W to 3 kW. Users can

ing are available through easy-to-use

reduce commissioning time with the automatic drive identification

wizards. A USB 2.0 port is also available for

of the MP-Series and TL-Series motors and actuators.

commissioning and diagnostics.

Rockwell Automation Australia

maxon motor Australia Pty Ltd

Contact info and more items like this at wf.net.au/N673

Contact info and more items like this at wf.net.au/N724

32 WHAT'S NEW IN PROCESS TECHNOLOGY - JUNE 2012

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© iStockphoto.com/josemoraes

Sparkling clean and easy to swallow

Pierre Fabre Médicament Production is the second largest independent pharmaceutical laboratory in France. The company produces a wide variety of medical products in its Gien (Loiret) factory, including tablets, sugar-coated pills, capsules, sachets, solutions and drinkable ampoules, creams and ointments. The liquid dosage production unit has a variety of tanks, mixers, pumps and transfer valves. This equipment is cleaned with a cleaning-in-place (CIP) station that has a fresh purified water tank, a return purified water tank, an acid solution tank and a sodium solution tank.

Two cleaning lines contain disinfectant.

In 2008, the plant faced a challenge.

The control system was getting old.

The plant needed a reliable, expandable control system to control the CIP and manufacturing processes and ensure that data processing conformed to US Food and Drug Administration (FDA) requirements (21 CFR Part 11). Hakim Bennouna, instrumentation, automation and process maintenance manager at Pierre Fabre Médicament Production, says he opted for a Simatic-based solution because of the availability, robustness and stability of Siemens’ automated systems.

The new control solution handles both the CIP and manufacturing processes.

The CIP station has seven recipes and the manufacturing process has 65. These recipes are stored within the operator station and sent to the programmable logic controller (PLC) as needed. Operation

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begins with a rinse using return water.

Several cleaning stages follow, with acid for stripping, sodium to neutralise the acid, disinfectant and a final rinse with fresh water. Simatic S7-300 controllers open the fluid valves (hot and cold purified water, alcohol) and a Simatic S7-1200 controller powers pumps supplying the sodium and acid.

The Siemens architecture includes a Simatic PCS 7 box; a Profinet network for inter-controller communication; a Simatic S7-1212C controller, which controls acid, sodium and disinfectant; a Simatic S7-300 controller with a 315-2 PN/DP CPU for the cold purified water loop; and a Simatic S7300 controller with a 317-2 PN/DP CPU for the hot purified water loop, which supplies the freshwater tank and the premix and mixing tanks. The system is completed with a Simatic S7-300 controller with a 315-2 PN/DP CPU for drawing alcohol.

This architecture is complemented by a communication system that ensures correct management of all processes, from CIP to drug production.

Batch processes used to be managed manually via a non-automated system in Fortran. Today, Simatic Batch within the Simatic PCS 7 Box controls production and CIP and automates recipe use. Operators have experienced a genuine revolution in their working routines.

“The real challenge was not only to ensure that operators adhered to the automated system, but also to familiarise

them with operating an automated facility,” says Bennouna. “A further challenge was commissioning. We had four months to develop the system and only two weeks to put it into service!”

O p e ra t o rs a d a p t e d v e r y q u i c k l y , following a four-hour training session.

“Soon, certain operators will even be able to change manufacturing or cleaning recipe parameters themselves,” says Gil Soustre, who is in charge of liquid-dosageform production. The automated system makes it easier for operators to become multidisciplinary. An operator in charge of manufacturing might also oversee automatic cleaning processes. In addition, the plant’s hardware configuration enables operators to use any mixer or send product through any piping system. Productivity has increased.

“The time for routine cleaning used to be 80 minutes. It is now only 60 minutes,” says Soustre. “The gain in productivity adds up to four hours per day.”

Traceability is also improved, thanks to the multiple recordings made of lead times, conductivity and temperature. Cleaning quality is better than before. After passing through the cleaned equipment, rinse water has a conductivity of 0.3 to 2.80 µS, which corresponds to chemically pure water.

This proves all the stripping, detergent and disinfectant agents have been eliminated.

Siemens Ltd Contact info and more items like this at wf.net.au/Q062

JUNE 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 33

MOTION CONTROL PRODUCTS

PROGRAMMABLE ENCODERS Sick has extended its AFS60/AFM60 EtherNet/IP family of products with single and multiturn absolute encoders that are claimed to offer flexibility combined with fieldbus connectivity.

The freely programmable, ethernet-based fieldbus encoders feature comprehensive diagnostic possibilities, which optimise security against failure and increase plant availability. The diagnostic functions integrated in the encoders include temperature monitoring, two operating hour counters, five dual LEDs which show the current operating state of the two ports, encoder functions and data transfer, and programmable position limit value monitoring. The detection of speed or rpm protects the encoder from overloading. The individual messages are hierarchically structured in the form of flags, alarms and warnings.

The EtherNet/IP encoders comply with the current specifications of the Open DeviceNet Vendor Association, including device level ring (DLR) functionality. The network monitoring system carries out continuous and active availability tests on the network participants and connections. In the case of a fault, communication between the devices is restored within 3 ms. The AFM60 EtherNet/IP multiturn encoderâ&#x20AC;&#x2122;s rotary axis function allows the steps per rotation to be represented as a fraction. This saves drive calculations and control programming, thus cutting costs during installation, maintenance and service.

The AFS60 absolute singleturn encoder and the AFM60 absolute multiturn encoder are rotative sensors for path, angular, speed and position detection. Because the encoders are freely programmable, they are a solution for producers and integrators of production processes, handling systems, production machines, print systems, as well as measurement and inspection equipment.

Sick Pty Ltd Contact info and more items like this at wf.net.au/N600

MINIATURE LINEAR GUIDES

The CPC range of miniature linear guides is available in both standard and wide carriages in a full range of sizes.

The range starts with the compact 3 mm-wide MR3 series and continues up to MR15 for size 15 mm rails.

Miniature size 3 and 5 carriages are supplied matched to the rail and precision assembled in the factory. The size 3 rail is so small it requires the mounting holes for the rail to be upwards from underneath the rail, so as to allow space for the screw head and tool.

Size 2 guides and rails (2 mm) are also available as a special order.

The size 7 and above have fully interchangeable runner blocks, allowing for easy addition or replacement of carriages at any time after initial installation. Carriage end caps with an inverse hook ball return design have been developed to overcome the forces of the moving balls on the end cap during high-speed changes of direction.

This means maximum carriage speeds of 3 m/s are now possible.

Motion Technologies Pty Ltd Contact info and more items like this at wf.net.au/M494

34 WHAT'S NEW IN PROCESS TECHNOLOGY - JUNE 2012

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MOTION CONTROL PRODUCTS

DC-POWERED ACTUATORS Exlarâ&#x20AC;&#x2122;s Tritex II DC-powered line of actuators integrates power and control electronics with brushless servo motors and actuators in one package.

These actuators include advanced thermal management modelling to maximise power in smaller packages, without sacrificing performance or reliability. They offer continuous forces of 4.5 kN, 5.7 kN peak and speeds reaching 83 cm/s. By housing the servo drive, digital positioner and actuator in one integrated package, a self-contained motion control solution is created that eliminates the need for large control panels, costly servo power and feedback cables, as well as reducing labour costs for mounting and wiring.

A wide range of I/O capabilities is available, such as digital I/O, analog I/O and communication buses including EtherNet/IP, Modbus TCP and Profinet IO. Featuring multiple protocol options and operating from 12-48 VDC, the actuator easily connects to industrial electronic devices on the same network.

Tritex II DC actuators provide motion control in both linear and rotary applications, allowing them to accommodate a wide range of applications, including demanding environments. Linear actuators employ Exlarâ&#x20AC;&#x2122;s roller screw technology to convert rotary motion to robust linear motion, with no additional mechanisms required for conversion. Tritex II DC rotary motors and gear motors provide high response and precise control of a rotatable shaft similar to that found in any electric motor.

Applied Automation Contact info and more items like this at wf.net.au/N113

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JUNE 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 35

MOTION CONTROL PRODUCTS

DIRECT-DRIVE LINEAR AIR BEARING STAGE The ABL1500 direct-drive linear air-bearing stage from Aerotech meets the needs of demanding scanning and inspection applications with its active preload, high stiffness and geometric characteristics. Its positioning tolerances exceed the capability of conventional ball-screw and mechanical-bearing systems. The non-contact design is intended to result in years of maintenance-free operation.

The stages are suitable for critical applications in any industry that requires smooth and accurate linear motion to manufacture, test or inspect a product. These include semiconductor, data storage, medical and genome devices and any industries requiring cleanroom operation.

The stage is driven by a brushless linear servomotor with an ironless forcer for zero cogging, and no attractive forces, resulting in smoothness of motion. Because there is no mechanical contact between moving elements, the stages experience no wear or performance reduction over time. Service life is claimed to be virtually unlimited with no lubrication.

A large air-bearing surface with opposing thin-film pressure accommodates heavy or offset loads with high acceleration and accuracy. The thin film fills small surface voids and allows for other irregularities, reducing pitch, roll and yaw, and improving straightness and flatness.

Lastek Pty Ltd Contact info and more items like this at wf.net.au/M743

36 WHAT'S NEW IN PROCESS TECHNOLOGY - JUNE 2012

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NEW PRODUCTS

ROBOT GUIDED SENSORS Displacement laser triangulation sensors from Micro-Epsilon Messtechnik are designed to be able to provide highprecision laser sensing solutions for robot measurement tasks, such as distance measurement and guidance. These sensors are small with integrated electronics. Measuring ranges are from 2 to 1000 mm and fast measuring cycles of up to 50 kHz widen the scope of application.

The gapControl sensor can be installed on a robot arm

DC-DC CONVERTER POWER SUPPLIES

for measuring various types of gaps. Here, gap measure-

Quint DC/DC converter power sup-

ment data is used to guide the robot along the work piece

plies equipped with selective fuse

or for controlling welding robots. The reflectControl system

breaking (SFB) technology now

can be integrated into a robot for detecting paintwork defects using deflectometry. A robot

have approvals by Germanischer

continuously adjusts the position of the system to help complete measurements within a

Lloyd and they can be used in

short time frame.

hazardous zones.

Bestech Australia Pty Ltd

With SFB technology, faulty cir-

Contact info and more items like this at wf.net.au/N668

cuits are selectively shut down so that the fault is localised and important system components remain operational. With rated output currents of 5-20 A, these devices supply peak currents of 30-120 A for 12 ms to magnetically trip circuit breakers. The voltage converters operate with DC input voltages of between 18 and 32 VDC and the range is expanded to between 14 and 32 VDC during operation.

Depending on the device type, potentiometers at the front of the device can be used to adjust the output voltage for the ranges 5-18, 18-29.5 and 30-56 VDC. By boosting the voltage on long supply lines, the modules change the voltage level or compensate for loss-related voltage drops. Primary switched-mode switching devices have an internal intermediate circuit that serves as a filter so that, for instance, grounded circuits can be separated from non-grounded ones, or critical loads can be protected against voltage fluctuations.

Comprehensive diagnostics are provided by the constant monitoring of input and output voltages and currents. This preventive function monitors critical operating states and signals them to the control system via the active switched output or the isolated relay contact before faults occur in the plant or system.

Phoenix Contact Pty Ltd Contact info and more items like this at wf.net.au/N524

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JUNE 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 37

COMPETING FOR THE FUTURE DOES WIRELESS PLAY A PART? STRANDED OR UNUSED INTELLIGENCE IS NOT THE WAY OF THE FUTURE

© iStockphoto.com/TommL

Brett Biondi, Wireless Business Development Manager ANZ and Michael Totten, Wireless Specialist ANZ, Emerson Process Management

38 WHAT'S NEW IN PROCESS TECHNOLOGY - JUNE 2012

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Industrial wireless

There can be no doubt that the heart of any operation is the process control system. More recently, industry is embracing a paradigm shift away from localised operations via distributed control, to embracing the need for remote operations centres controlling and monitoring multiple facilities.

B

roader control of multiple facilities would not be possible if it weren’t for advances in sensor-based technology, fieldbus communications and in some cases wireless sensors and adapters. Sensors now not only provide information on the health of the device but also the health of the process, making it possible to determine how the process can be improved. This information is communicated up to the control room and to the remote operations centre personnel tracking things like production, pending issues in the process and in measurement devices and the like.

Recent examples include the coal seam gas industry where, despite marginal well heads and the scarcity of experienced personnel, the use of remote diagnostics has made possible timely, cost-effective decision-making. Further examples include applications developed to retrofit and proactively monitor essential assets which have long been overlooked but are at the centre of production slowdowns or even shutdowns. Such applications help to ensure losses in the hundreds of thousands, if not millions of dollars, are avoided.

There are many issues that need to be considered in the implementation of a wireless sensor network. This article looks at these issues from the perspective of WirelessHART technology, but whatever wireless technology is used, the end user needs to take the following factors into consideration.

Network availability, reliability and management A plant is often a challenging environment for radio frequency (RF) communications. RF systems must contend with having to communicate in the presence of piping, vessels, structural steel, moving objects such as vehicles and other devices emitting an RF signature (which may or may not be noise at the communicated RF signal). It must also do this without user intervention in a self-managed fashion.

Modern wireless sensor systems, such as WirelessHART, have therefore been developed to overcome these issues by providing self-organising, self-healing, adaptive networks featuring multihop, deep mesh architectures. At the heart of such a system is the wireless gateway, controlling communications and perennially challenging the network and devices for path optimisation and alternate path options. Multiple paths are maintained such that when a new obstacle blocks the path, an alternate path is used for the information to reach the gateway and control system. All transmitters - regardless of manufacturer - participate in the mesh topology to ensure a multitude of communication paths are available and that reliability needs are met. If required, redundant gateways are available to provide

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redundant communication masters that self-monitor and can perform ‘hot swaps’ - change over in the advent of a failure reporting the event to the control host.

Naturally, some applications require faster updates and lower latency than others: some, of course, are the exact opposite in a relative sense. WirelessHART, for example, is a user-defined, time synchronised/scheduled communications protocol. WirelessHART transmitters timestamp measurements from the original point of measurement allowing latency to be tracked and have a selectable update period adjustable from 1 second to 1 hour.

The user therefore has control over the devices’ reporting rate (and power module life) with time-stamped communications.

This functionality is all achieved behind the scenes, without user intervention, by the gateway and devices reporting the network availability and alternate path options.

Coexistence Being based on global standards, a wireless field network potentially has to operate in close proximity to other wireless network technologies in the same 2.4 GHz band (such as Wi-Fi, Bluetooth and ZigBee etc) that may cause in-band interference.

To help overcome interference issues, WirelessHART and other wireless sensor technologies use the IEEE 802.15.4 standard utilising direct sequence spread spectrum (DSSS) but also with frequency hopping spread spectrum randomly channel hopping from one communications channel to another on a packet-bypacket basis. If momentary use of the selected channel is detected, the network will migrate to another available channel and re-establish communications. If broad use of a selected number of channels is evident (eg, a Wi-Fi network), the WirelessHART blacklists those channels and communicates within the known set of available channels. Intelligence such as this embedded into the communications protocol ensures coexistence in the event of of in-band interference.

Security Understandably, security has been at the forefront of end-user concerns in the adoption of wireless technology. In the case of WirelessHART, security measures may be classified into data protection and network protection.

Data protection Data protection (or confidentiality) is concerned with the privacy and integrity of the data communicated. When transmitting, the WirelessHART standard uses end-to-end (data source to data recipient) 128-bit AES encryption on a message-by-message basis. It also uses CCM*1 technology to check for tampering during transmission (superimposing or altering data), attacks

JUNE 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 39

Industrial wireless

SENSORS NOW NOT ONLY PROVIDE INFORMATION ON THE HEALTH OF THE DEVICE BUT ALSO THE HEALTH OF THE PROCESS, MAKING IT POSSIBLE TO DETERMINE HOW THE PROCESS CAN BE IMPROVED.

Figure 1: The use of EDDLs and user-friendly management software allows field personnel and those in remote operations centres to quickly diagnose issues and save on overheads.

trying to change the network routing information and to ensure devices and the information shared are authenticated (proven to be from a known source on the network). In addition to this, a separate common network encryption key (autonomously routinely changed subject to site security policy) is shared by devices when broadcast information is shared across the network (eg, challenging network path efficiency). Devices attempting to join the network must pass a separate 128-bit â&#x20AC;&#x2DC;joinâ&#x20AC;&#x2122; encryption key test or their access will be denied. In effect, information is checked on transmission for authenticity, packet size/alteration, source and destination and network verification.

Network protection Network protection is concerned with ensuring the network remains functioning. Attacks may emerge from devices impersonating authenticated devices to steal legitimate information, attempting to insert malicious code or to disrupt network services in the form of a denial-of-service attack. Regarding impersonation, as above, WirelessHART will look to authenticate and validate device communications and deny service to the unauthorised device(s). Moreover, the size of the data frame is small and of a predetermined known size, so that checks via CRC and CCM* 1 mitigate this threat. With respect to denial of service, using a random hopping algorithm with channel blacklisting helps to make DOS attacks more difficult.

In both cases (data protection and network protection) these security mechanisms are on permanently and transparent to the user. All that site personnel have to do is to ensure they follow routine procedures such as not giving out password access to the gateway and then configuring the transmitters via a wired maintenance terminal in the normal fashion. It should also be pointed out that when wireless sensor/instrumentation networks use a Wi-Fi backhaul network, the end user should also consider the security of the backhaul network.

Interoperability and interchangeability Using a wireless sensor network based on an IEC standard ensures that multivendor interoperability is possible. Process applications require many types of measurements such as flow, level, valve position, pH, conductivity, vibration, tem-

40 WHAT'S NEW IN PROCESS TECHNOLOGY - JUNE 2012

perature, pressure and acoustic, as well as contact input and level switches. These measurements may come from different transmitter manufacturers and all vendors using WirelessHART, for example, undergo certification from the HART Foundation.

Therefore, certified WirelessHART transmitters of many different types, from many manufacturers, integrate into the system in the same way using the same application protocol.

Transparent system integration There are many considerations in designing and commissioning a wireless network. Plants already have digital devices using hardwired and bus integration into intelligent device management software, using one of the common device description languages available on the market. However, using wireless technology that supports a common device description standard can streamline integration yet provide for many of the benefits such as device and process diagnostics. The WirelessHART standard supports EDDL technology enabling WirelessHART transmitter integration in existing intelligent device management software that utilises EDDL. When the EDDL file for the WirelessHART transmitter is loaded, the system automatically picks the correct EDDL file for the transmitter, requiring no manual intervention.

Forward and backwards integration A control system has an expected lifespan of 15 years or more.

Over its life cycle, new types and versions of wired and wireless transmitters will come into the plant. The control system must be kept up to date with these in order to avoid technical obsolescence. Therefore, using a device integration technology which has no dependency on version releases of Microsoft Windows ensures backwards and forwards compatibility between system and wireless transmitters. With technologies that are text-based, such as EDDL, this means that new versions of WirelessHART transmitters can be deployed without having to upgrade the Windows version on the control system.

Power module considerations Preserving power is important to extend battery life in remote wireless instrumentation. WirelessHART uses the extremely low-

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Industrial wireless

A PLANT IS OFTEN A CHALLENGING ENVIRONMENT FOR RADIO FREQUENCY COMMUNICATIONS. RF SYSTEMS MUST CONTEND WITH HAVING TO COMMUNICATE IN THE PRESENCE OF PIPING, VESSELS, STRUCTURAL STEEL, MOVING OBJECTS SUCH AS VEHICLES AND OTHER DEVICES EMITTING AN RF SIGNATURE.

power IEEE 802.15.4 radio communications with sensors turned off between measurements to preserve the life of the power module. Careful selection of vendor can mean that transmitters in a mesh topology may provide a battery life of up to 10 years (depending on sensor type and the configured update period).

Wireless network management diagnostics Preventing network disruptions and providing for effective troubleshooting are key issues for network design, maintenance and selection. Key metrics in network management diagnostics entail communication statistics such as missed updates, discarded updates, reliability, path stability, signal strength, latency, number of re-joins, timestamps for last join, maintenance of a ‘live list’ of devices, service denials due to network load and power module status/health. The wireless technology that is chosen should provide communication status for all of the above and provide for user-friendly graphics to aid interpretation of information.

Diagnosing wireless devices A question often asked by end users concerns any potential differences in diagnosing device issues in a wireless system.

This is another area where it is important that the wireless devices comply with a known standard. The WirelessHART standard forms part of the HART 7.1 standard and, as such, no new equipment, training on devices should be required. Universal commands and specific commands are used to access diagnostics in the transmitter, making the transmitters easy to troubleshoot. If an asset management application is used, the richness and ease of use of the wireless system becomes apparent. This can be exemplified by adding a wireless interface to a legacy non-wireless device to provide insights into the device and possibly the process’s health (depending on the revision date of the legacy device).

Wireless today and in the future The increasing uptake of wireless instrumentation and sensor technology due to standards such as IEC 62591 WirelessHART means that it is now applied to a plethora of applications by a

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diverse range of end users. It is used in diverse industries from the traditional petrochemical, metals, mining and manufacturing to food and beverage and, more recently, retail operations.

While a generalisation, wireless sensor use could be classified as conforming to applications of: 1. Process and asset reliability monitoring and control, including motor, pump and valve automation monitoring.

2. Process throughput and efficiency improvements, including automated steam trap monitoring, tank level, rotating kiln and rotating device measurement, and better boiler profiling.

3. Personnel productivity improvement by replacing manual gauge monitoring labour, reducing the need to access hazardous areas.

4. Environmental, health and safety applications including emissions and discharge monitoring, pressure relief valve monitoring, and eye wash and safety shower activation.

In summary, the historical aim has been to optimise production relative to demand needs. Forward-thinking organisations operating in a globally competitive environment are now looking to reduce energy and utility costs to optimise production costs.

Wireless sensor technology such as WirelessHART forms part of that planning as firms look to create a competitive framework for the future.

Emerson Process Management Contact info and more items like this at wf.net.au/Q089

Notes: 1. CCM mode (Counter with CBC-MAC) is a mode of operation for cryptographic block ciphers. It is an authenticated encryption algorithm designed to provide both authentication and confidentiality. CCM mode is only defined for block ciphers with a block length of 128 bits. Cipher block chaining message authentication code (CBC-MAC) is a technique for constructing a message authentication code from a block cipher. The message is encrypted with some block cipher algorithm in CBC mode to create a chain of blocks such that each block depends on the proper encryption of the previous block. This interdependence ensures that a change to any of the plaintext bits will cause the final encrypted block to change in a way that cannot be predicted or counteracted without knowing the key to the block cipher.

JUNE 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 41

INDUSTRIAL WIRELESS PRODUCTS

NEW White Papers

now available online!

RTU CONTROLLER WITH COMMUNICATIONS REDUNDANCY The Moxa ioLogik W5348-HSDPA-C series is a metal-encased, all-in-one micro RTU controller that combines a cellular modem, an I/O controller and a data logger into a compact device that provides communication redundancy with built-in GPRS/HSDPA.

Oxygen measurement on air separation plants Industry consumes vast quantities of oxygen and nitrogen annually, all of which is obtained from the air around us. There are two main techniques used to separate these two primary gases from air. These processes are cryogenic separation and pressure swing adsorption (PSA).

Along with a variety of mixed I/O combinations, users can choose standard C/C++ for more application-oriented and advanced customisations. The device supports stand-alone data logging in a storage space expandable up to 32 GB, and comes with Active OPC Server software, based on push technology.

Benefits include reductions in data transmission, lowered hardware

Eliminate impulse piping, heat trace and purge lines on DP level measurements Measuring level with differential pressure is a well understood and reliable method, although accurately measuring differential pressure on tall towers and tanks has always been challenging.

For information on a possible solution to better enable operators to control tank level and pressure, download this paper.

Alarm rationalisation Alarm rationalisation is a systematic process to evaluate potential or existing alarms, qualify which are legitimate, specify their design and capture rationales which can be used to guide operator response. This paper describes the SILAlarm solution and other tips for setting up and sustaining an effective alarm rationalisation process.

costs and reduced deployment and maintenance costs.

The RTU is suitable for industrial applications such as pipeline monitoring for water, oil and gas, and pump or lift station monitoring.

Madison Technologies Contact info and more items like this at wf.net.au/N602

3G SECURE REMOTE-ACCESS SOLUTION Danish company Secomea has added a 3G model to its secure remote-access SiteManager range. Providing true end-to-end connections, Secomea provides direct access to PLCs, HMIs, drives or almost anything with a data port.

The solution is designed to allow an electrician without specialist knowledge to unpack, install and power up the device.

Configured prior to delivery, the SiteManager then initiates a connection to the cloud GateManager making it available to

Are water operators as safe as they could be?

Are water operators as safe as they could be? A recent survey conducted with operators and engineers questions this. This paper summarises the findings of this survey and details explanations for them.

a remote user with an appropriate LinkManager client licence.

This approach to 3G remote access provides a number of benefits. Set-up time is under 15 minutes and, using a system comparable to DDNS, there is no need for costly 3G static IP addresses.

Security is provided by defence-in-depth embracing AES/SSL encryption, two-factor authentication, and a firewall that filters traffic based on the configured destination devices.

By connecting both the LAN and 3G uplinks, the failover function ensures the connection is maintained when one uplink fails. Inbuilt SIM card recognition for all major telecoms eliminates incompatibility issues commonly experienced when requiring international access. GateManager can be hosted by the user or used as a cloud service. There is no need to worry about IP addresses, TCP ports or encryption settings, a common source of error - this is all automated and automatic backup configuration is part of the service.

For these and more White Paper downloads, visit www.processonline.com.au/white_papers

42 WHAT'S NEW IN PROCESS TECHNOLOGY - JUNE 2012

Daanet Pty Ltd Contact info and more items like this at wf.net.au/N928

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INDUSTRIAL WIRELESS PRODUCTS

WIRELESS I/O DISTRIBUTION The Radioline wireless system from Phoenix Contact is specifically designed for wireless signal transmission at large facilities. I/O mapping distributes signals from up to 250 stations within the system without any software. Here, input signals receive I/O addresses by means of thumb wheels, with these addresses being mapped to corresponding output modules. Because identical signals can also be outputted several times, it is possible to set up intelligent distribution and signal multiplication in the field.

Radioline and its integrated functions can be used universally for different applications, including I/O signals, serial data or the implementation of I/O to Modbus. The stations can be arranged as needed in point-to-point, star or mesh structures. Each station can also be used as a wireless repeater for other stations.

The devices use this feature on the licence-free, 2.4 GHz frequency.

The I/O stations can be expanded modularly. The modules also feature high-quality galvanised channel-to-channel isolation and can be switched out easily while the system is in operation. Additionally, the digital channels are also equipped with wide-range inputs and relay outputs for many possible applications up to 250 V. Phoenix Contact Pty Ltd Contact info and more items like this at wf.net.au/N919

PlantPAx, extending your DCS applications to the new horizon.

PlantPAx process automation system is your solution for DCS applications and more. With its proven capabilities in consumer-driven industries and primary resource-driven industries, PlantPAx is helping users obtain plant-wide optimisation with its ability to integrate process control, power, safety and information through one control platform.

Discover more at: http://discover.rockwellautomation.com/plantpax

PlantPAx_Half-Page_wnipt-may2012.indd 1

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14-May-12 2:30:18 PM

JUNE 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 43

INDUSTRIAL WIRELESS PRODUCTS

DATA RADIOS Schneider Electricâ&#x20AC;&#x2122;s range of Trio data radios is claimed to reduce installation and maintenance costs associated with the monitoring and control of remote telemetry systems while ensuring data integrity over short- and long-haul distances.

Key characteristics and benefits of the Trio data radios include ethernet and serial interfaces, and multiantenna support, as well as repeater and bridge modes to extend networks beyond the operational range of an individual radio or to bridge disparate data networks together.

Network traffic is optimised with support for multiple, simultaneous protocols on one network, with configurable Stream Identifier Codes and simultaneous data stream delivery. The MTBF specification of these radios is claimed to be greater than 2 million hours. Typical applications include cathodic protection, metering, leakage detection, custody transfer, emergency shutdown and monitoring of flow, level, pressure and temperature.

Schneider Electric (Australia) Pty Ltd Contact info and more items like this at wf.net.au/N355

WIRELESS I/O FOR NI COMPACTRIO National Instruments has announced the NI 9795 C Series wireless gateway and the NI WSN-3230 and WSN-3231 measurement nodes, extending the capabilities of the NI wireless sensor network (WSN) platform. With NI LabVIEW system design software, engineers can easily integrate wired and wireless measurement and control systems and deploy autonomous programs to WSN nodes that perform local control, data analysis and event-based alarming or notification.

The NI 9795 C Series gateway aggregates measurement data from distributed WSN nodes, making data available within deployed LabVIEW Real-Time applications running on CompactRIO. It adds to existing programmable and nonprogrammable WSN gateways to offer choices for cost and flexibility. The NI WSN-3230 (1-port RS232) and NI WSN-3231 (1-port RS485) serial nodes feature one serial port and two digital I/O channels for discrete inputs, event detection and programmatic control. Query and parse algorithms can be embedded directly on the WSN node with the LabVIEW WSN Module to create an autonomous programmable interface to a variety of serial-based instruments, sensors and control boards.

National Instruments Australia Contact info and more items like this at wf.net.au/N716

44 WHAT'S NEW IN PROCESS TECHNOLOGY - JUNE 2012

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NEW PRODUCTS

EMBEDDED CONTROL PC The Aaeon AEC-6872 is a high-performance standalone embedded PC featuring 10 serial communication ports, fanless operation, compact size, robust construction and low power requirements. The AEC-6872 is supplied with an Atom D510 1.6 GHz processor and two SODIMM sockets supporting up to 4 GB of DDR2

PRESSURE CONTROL GAUGE The Mercoid Series EDA elec-

system memory, two 10/100/1000Base-TX RJ45 ethernet connectors, four USB 2.0 ports, nine RS232 ports and one RS485 port for communication.

A 2.5â&#x20AC;ł SATA hard drive can be internally mounted while an internal Compact Flash slot is

tronic pressure control gauge is a

provided for additional storage. System expansion is possible via a PCI Express slot or an optional PCI bus

compact package that can replace

slot. An internal mini-PCI slot and mini-Card slot provide additional expansion options. Other I/O includes VGA

a separate gauge, two switches and

graphics, audio and PS/2 keyboard and mouse connectors. The fanless design of the AEC-6872 reduces the

a transmitter in a system saving

possibility of airborne corrosive or conductive materials entering the system to provide a long-term reliable

money, installation time and panel

industrial computing solution.

space. The EDA incorporates two

The AEC-6872 can operate from a wide range 9 to 30 VDC power source or an external AC power adapter.

SPDT relays that have the on and

Interworld Electronics & Computer Industries

off points fully adjustable over the

Contact info and more items like this at wf.net.au/N740

range for control or alarm use. The front face has LED indicators for switch status and a large backlight two-line display showing process value and indication units.

Programming is easy with simple menu structure, two-line display and external programming buttons. The weatherproof housing is suitable for a wide variety of applications with panel-mount, flush-mount or pipemount ability. Features include zero set, adjustable dampening, menu lock out, peak and valley indication, removable terminal blocks, adjustable time delay and scalable transmitter output.

Pressure can be displayed in psi, kg/cm2, bar, in Hg, ft w.c., kPa, MPa, %FS, in w.c., mbar, cm w.c., mm Hg, or oz/in2, depending on the chosen range. A test mode simulates input over the range without pressuring to easily test switches and transmitter output function.

Failsafe capabilities are provided for sensor failure, over pressure, high temperature limit, low temperature limit, or keypad short, with user-selctable choice of relay de-energised, energised or no action. With the transmitter option, the user can choose an output of 3.6 mA, 22 mA or no action. There is also a selectable alternation of set points between the relays for even wear on duplex pump applications.

Dwyer Instruments (Aust) Pty Ltd Contact info and more items like this at wf.net.au/N279

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JUNE 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 45

AS I SEE IT A.B.N. 22 152 305 336 Head Office Cnr. Fox Valley Road & Kiogle Street, (Locked Bag 1289) Wahroonga NSW 2076 AUSTRALIA

TECHNOLOGY, TALENT AND SUSTAINABILITY

ph: +61 2 9487 2700 fx: +61 2 9489 1265 www.westwick-farrow.com.au ph: +61 3 9381 2952 Editor Glenn Johnson wnipt@westwick-farrow.com.au Chief Editor

T

he word sustainability has become a passionate collective term for all the research, dreams, ideals, actions and even legislation to protect, nourish and plan for our environment and our resources. But do we have the same awareness of how people skills fit in this quest for sustainability? Looking at the field of process control and automation in Australia, I would say no.

TECHNOLOGY The capability and reputation of low-cost producers in Asia continually improves, making high-tech products available at ever-decreasing prices. At the same time, new technologies emerge so quickly and so prolifically that this blur of inexpensive advances is almost monotonous, leaving us oblivious and unappreciative of the underlying technology in the items we use every day. This is totally acceptable; as the technology is only as good as its utility. Utility, however, depends solely on the talent of those who adapt and apply it.

From simple process sensors through to control systems and manufacturing execution systems, getting the most out of new technology depends on people talent, which in Australia is scarce. More provocatively put: our talent is under siege, due to the lack of training and academic direction.

TALENT - AN OLD PROBLEM OR IS IT? It all starts with training; how much, what type and where. The ‘dual trade’ which aimed to upskill artisans with measurement and control knowledge was introduced to increase flexibility and reduce costs. Popular opinion would say it has achieved the opposite and that it has failed by expecting too much and doing too little. The scope of what was required was grossly misunderstood and underestimated. The complaints and agonised pleas from academics and other interested parties were, and still are, interpreted as cries of self-preservation, leaving many experts alienated from those who direct the future of our talent in this area.

A contradiction of logic is that the training and skills situation is worsened by the wealthy resource industries like mining, or oil and gas, whose competitiveness depends on pre-

Janette Woodhouse

mium process control and automation. These industries operate ‘fly in fly out’ workforces, meaning that the skills shortage in Western Australia can only be addressed by improving training in Victoria or New South Wales.

Vendors do provide their employees access to first-class overseas training, but then lose the investment they have made to the higher paying resource giants - not a great incentive to provide training.

SUSTAINABILITY This might all sound depressing, but there are people who energetically support and drive associations and councils to change this. These people are from industry, vendors, TAFEs and associations like the IICA, and they participate in, or work with, government structures like the TAC (Training Advisory Committee) and the ITB (Industry Training Board). These people have driven training agendas within their employers and established registered training centres. So in this core there is a lot of hope.

Commoditisation of products means that astute vendors have started to include more people talent in their offering to industry, which offers a quick and tangible payback.

The need to develop a specialised talent base for the field of process control and automation is gaining recognition, but the dual trade needs to be maintained, reviewed and properly resourced so that it serves both the trainee and industry better.

A will and vision for a better skill base is very alive; in my opinion, the key missing ingredient is national and comprehensive coordination.

G r e g Fe rra r h a s 25 years’ experience in the field of Process Automation and Control. He has a well-rounded understanding of industrial processes having spent seven years in the mining industry as an engineering manager before joining Endress+Hauser in Sales and Marketing.

46 WHAT'S NEW IN PROCESS TECHNOLOGY - JUNE 2012

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