What’s New in Process Technology Jun 2014 by Westwick-Farrow Media

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0614

ON THE COVER

WHAT'S NEW IN PROCESS TECHNOLOGY JUNE 2014

CONTENTS

Fluke has the broadest selection of process calibration tools in the industry, built to help instrumentation technicians keep the world’s

Choosing the right encoder

New Products

safely and reliably. Designed to withstand the

Hot products online

their-kind innovations like the mA clamp and

ACI Connect: Optimising Industry

roubleshooting remote site T networks

allows users to source, simulate and measure

As I see it

almost any process instrument. Among these,

Manufacturing gloom and the contrarian

largest process plants operating efficiently, harshest environments, and featuring first-of-

Inaugural conference and expo a success

the internal electric pressure pump, Fluke offers a full line of process calibrators and software. Fluke’s range of field and bench calibrators pressure, temperature and electrical signals to help verify and adjust test equipment or loop calibrators are essential tools for working with 4-20 mA current loops. Fluke loop calibrators provide mA sourcing, simulation and accurate measurement readouts in both mA and percentage of span, as well as 24 V loop supply and simple operation. Pressure and flow calibration are also important, as pressure, level and flow instrumentation is found in virtually every process plant. Periodic calibration of these instruments is required to keep plants operating efficiently and safely. Fluke provides a wide selection of field and bench calibration tools to help quickly and reliably calibrate pressure and gas flow instrumentation. Fluke also offers bench and field solutions for temperature calibration to ensure process

READ ONLINE!

temperature accuracy of not only the system’s

This issue is available to read and download at

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measurement output, but also the temperature sensors that initiate those signals. Fluke Australia Pty Ltd au.fluke.com/pct

CHOOSING THE RIGHT ENCODER Joe Kimbrell, Product Manager, Drives, Motors and Motion, Automation Direct

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Encoders are special sensors that capture position information and relay that data to other devices. They are used to determine the position, velocity and direction of a motor shaft or other mechanical motion. They provide information required for the precise control of a variety of applications, such as positioning a rotary table, pick and place, machine assembly, packaging, robotics and more.

Encoder geometry There are two basic geometries for encoders: linear and rotary. Although rotary and linear encoders work in similar ways, as the names imply, linear encoders measure motion along a path, and rotary encoders identify rotational motion. Thus the application determines which encoder is best suited for the job.

A linear encoder typically consists of a scale (a coded strip) and a sensing head that reads the spacing between the scales’ coding to determine position. A linear encoder’s resolution is measured in pulses per distance (pulses per inch (PPI), pulses per millimetre, etc). The scale (coded strip) has a set resolution with marks embedded into it or on it, which is read by the head. A linear encoder with 100 PPI resolution would read 100 marks for every one inch of movement. Unlike linear encoder resolution measurement, rotary encoder resolution is measured in pulses per revolution (PPR), also known as ‘line count’. A rotary encoder is commonly comprised of an internal coded disc and a sensing head used to read rotary position. A rotary encoder with 100 PPR resolution would read 100 marks on its coded disc for every revolution.

Incremental and absolute Encoders come in incremental and absolute styles that differ in wiring and movement identification. An incremental encoder only reads pulses to provide information about the relative motion of the shaft. It has no information about location when powered up; it can only show how far the shaft has moved since the encoder was powered up. It reports back these position changes with electrical pulses. These pulse streams can either be single channel (one output wire from the encoder) or dual channel (two wires). By contrast, a single-turn, rotary, absolute encoder can report back exactly what angle it’s at, even when first powered up. These encoders are typically used for applications in industrial control and robotics that cannot quickly or easily perform a homing sequence. A standard absolute encoder has a resolution similar to incremental encoders (PPR, PPI, etc), but instead of an output of high-speed pulse streams, the output is a specified in a binary format. The maximum encoder

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ncoders determine position using one of three technologies: optical, magnetic or capacitive. The most accurate of the standard styles of encoders are the optical encoders. When choosing an optical encoder, it’s important that the encoder has extra protections built in to prevent contamination from dust, vibration and other conditions common to industrial environments. Although more rugged than optical encoders - and often used in environments in which dirt, steam, vibration and other factors could interfere with optical encoder performance - magnetic encoders cannot achieve the resolution or accuracy of optical encoders. Capacitive encoders are relative newcomers as an industrial sensing technology. These encoders are as rugged as magnetic encoders but also do not achieve the high resolutions of optical encoders. But regardless of the sensing technology an encoder employs, the encoder’s electronics sense movement and translate that motion into industry-standard electrical signals. Encoders are also differentiated as light duty, medium duty, and heavy duty - indicating how much load may be applied to the shaft. A light-duty encoder may only handle 10 N radial force on the shaft. In contrast, a heavy-duty encoder may handle 100 N of radial force. Environmental ratings also become more robust as the duty increases. Light-duty encoders are typically IP40 and IP50 (dust proof); whereas medium-duty and heavy-duty encoders can be rated as high as IP65 (splash proof).

Motion Control Normal revolution (CW )

T(100%)

H Decimal

Binary code

Gray code

0000

0001

0010

0011

0010

0100

0110

0101

0111

0110

0101

0111

0100

1000

1100

Table 1: Gray code versus standard binary.

resolution = 2n where n is the number of output wires of the encoder. So, a 4 PPR absolute encoder has two outputs, an 8 PPR absolute encoder has three outputs, etc. Multiturn absolute encoders usually have a battery or super capacitor that monitors how many revolutions the encoder has turned even while power is off. A multiturn absolute encoder is similar to a measuring wheel that increments once per revolution. These encoders typically have serial communication and require special receivers to decode their position information.

Quadrature output Quadrature output utilises two different sets of ‘slots’ or channels (A and B) on the optical disc inside the encoder case, separated by 90 degrees of phase shift. These two outputs can either be ON or OFF, resulting in four different states for each segment of resolution. Figure 1 shows the four different states of the quadrature output. A quadrature encoder with a resolution of 100 pulses per revolution would actually produce 400 different states for each revolution of the encoder. That’s why quadrature encoders are sometimes referred to as x4 (times 4) encoders. The pattern of A and B turning ON and OFF also reveals which direction the encoder is turning. The encoder diagram above has A = ON, then B = ON when rotated in the clockwise direction. If this encoder were rotated counter clockwise, B would turn ON first, then A would turn ON. Encoders may differ in their definition of direction based on quadrature pattern.

Z-pulse or the index channel Certain incremental encoders have another channel called the index channel or Z-pulse (zero position pulse). This output pulses once per revolution of the encoder, and 6

OUT A

Normal revolution (CW)

T(100%)

H OUT B

OUT A L

a b c d

H OUT B L

Time slice ‘a’: A=OFF and B=ON Time slice ‘b’: A and B both OFF Time slice ‘c’: A=ON and B=OFF Time slice ‘d’: A and B both ON

Time slice ‘a’: A=OFF and B=ON Time slice ‘b’: A and B both OFF Figure 1: The timing and diagram for a quadrature output shows A = ON, then B = ON Time sliceoutput ‘c’: A=ON B=OFF whenTime rotation in aA clockwise direction. sliceis‘d’: and B both ON

is used to indicate when the encoder disc crosses the fixed zero position inside the encoder (Figure 2). The Z-pulse can be used to reset a counter, or it can be used for very precise homing. For example, consider a servo drive that uses an incremental encoder as a feedback device. The servo can home to an external signal (a proximity switch, mechanical limit switch, etc) then proceed to the next occurrence of the encoder’s Z-pulse for extremely accurate positioning. Typically, the encoder’s Z-pulse is factory set and cannot be moved. However, several families of encoders offer servo-mounting clamps that allow the body of the encoder to be rotated, or ‘clocked’, after installation, so the Z-pulse signal occurs in the desired position relative to a machine function.

Gray code There is one more consideration when selecting single-turn absolute encoders: many don’t count in standard binary code. Table 1 shows an example of the way binary normally counts up. Notice the transition from decimal 7 to 8: all four lower digits change state at once. If the PLC is reading inputs when this transition occurs, a bad value could temporarily be decoded by the PLC (at least for one scan) since each output may not change state at the same instant (there could be nanoseconds of difference). Gray code was developed to combat this problem of reading multiple transitions simultaneously. It is a special kind of binary that only increments one bit at a time. Since only one bit changes with each transition, a PLC is much less likely to decode erroneous position data. The only drawback to Gray code is that it’s not very intuitive to recognise the value as the bits change state. However, the logic to decode Gray code is very straightfor-

ward and can be done with minimal ladder programming.

Electrical outputs for incremental encoders Incremental encoders offer several types of electrical outputs: line driver, NPN open collector, or push pull (totem pole). A line driver output is a differential signal and requires two unique output wires per channel (Figure 3). Typical wire designations are A, A- (A ‘not’), B, B- (B ‘not’), etc. When channel A is ON there’s a positive voltage between A and A-. When channel A is OFF, there’s a negative voltage differential between A and A-. The magnitude of the voltage differential will be greater than 2.5 V. The same happens for the B and Z channels. Line driver outputs provide a high-quality signal and are fairly immune to electrical noise. Line driver encoders are very straightforward to wire to line driver-equipped PLC or motion controller inputs. Each output (A, B, Z) requires two wires, plus two wires for power supply (usually 5 VDC). A second output type is an open collector (NPN transistor) output (Figure 4). NPN open collector encoders sink current from sourcing (PNP) PLC inputs. Sinking and sourcing inputs simply refer to the current flow in a transistor. An open collector encoder has A, B, Z, and 0 V wires (and a wire for +DC to power the electronics). NPN open collector (sinking) encoders require the master PLC or motion controller to have PNP (sourcing) inputs. Open collector encoders usually accept a wide range of voltage. The third type of encoder output is a push-pull circuit, also known as a totempole output (Figure 5). The push-pull output is a special circuit that can sink or source current to the PLC. The key to this

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Motion Control

Line Driver Output (VD)

A 26C31 or equivalent

Power supply 4.75-5.25 VDC OUT A+/B+/Z+

OUT A -/B-/Z+

Figure 2: This timing diagram is for a 5 PPR encoder. Notice that the Z pulse stays on for one entire cycle of output B.

Open Collector Output (BD)

Main Circuit

Protection

Figure 3: An incremental encoder line driver output requires two unique output wires per channel, and two corresponding inputs in the automation system I/O.

Totem Pole Output (RZWD)

Power supply 10.8-26.4 VDC Outputs A, B, Z (Protected against short circuit between each output and 0 V)

Power supply 4.75-30.0 VDC Main Circuit

Protection

Figure 4: An NPN (open collector) incremental encoder requires the automation system to have PNP (sourcing) inputs.

encoder’s circuit is the pair of transistors in the encoder. When one transistor is ON, the other is OFF. If the PLC supplies current (the PLC has sourcing, or PNP inputs), the pushpull encoder can sink current through the lower transistor. If the PLC sinks current (the PLC has sinking or NPN inputs), the encoder will source current through the upper transistor.

Speed limitations There are two speed limitations when it comes to rotary encoders: mechanical and electrical. The mechanical speed limit is a fixed rpm value for each encoder, which is the maximum speed that encoder can withstand without incurring possible damage. The electrical speed limit for each family of encoders is imposed by the maximum switching speed (frequency response) of the electronics inside the encoder. The electrical speed limit is determined by the formula: max electrical speed = (max frequency response/pulses per revolution) x 60 s/min. The maximum frequency response is a fixed number (in Hertz) for each encoder

Output A,B,Z (Protected against short circuit between each output and 0 V)

Figure 5: An incremental encoder with totem pole output can sink from, or source current to, the automation system.

family. This is how fast the electronics can physically switch from OFF to ON. Since the maximum electrical speed is dependent on PPR, each encoder’s resolution for a given encoder family has a different maximum electrical speed. For example, a 3 PPR encoder spinning at 5000 rpm produces pulses at 250 Hz, while a 1000 PPR encoder spinning at 5000 rpm produces pulses at a much higher rate of 83 kHz. The 1000 PPR encoder has a much lower maximum speed than the 3 PPR encoder. A mechanical limit on speed is typical for many encoders, but if an application requires high speed or high resolution, both the mechanical and electrical speed limits of the encoder need to be considered. The lower of the two maximum speeds is the fastest an encoder is allowed to go. For example, a certain encoder might have a maximum mechanical speed of 3000 rpm. The maximum frequency response (electrical speed) could be 100 kHz. Thus, the fastest speed that this encoder could spin based on the speed of the electronics is (100 kHz/100 PPR) x 60 s/min = 60,000 rpm, which is much higher than the mechanical limit of 3000 rpm. This encoder

should not be rotated faster than 3000 rpm (the mechanical limit). While the above information is mostly geared toward incremental encoders, the same calculations hold true for absolute encoders. One extra consideration for absolute encoders is that general-purpose DC inputs are not high-speed inputs, so the OFF-to-ON and ON-to-OFF response times of general-purpose DC input cards may limit an absolute encoder’s speed more than the encoder’s switching frequency.

Summary There are many different considerations when determining what type of encoder to use in a particular application. This article has examined some of the basic structures and types of encoders with the goal of differentiating among the various types based on encoder properties. Selecting the right encoder is not a difficult process, but it’s definitely worthwhile to take time up-front to ensure all the different application criteria are considered. Automation Direct Pty Ltd www.automationdirect.com.au

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Users have instant visibility to their measurements through a non-intrusive Wire-

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and UF20.481 by utilising electrochemical double-layer capacitors (EDLC), which can provide a backup time of up to 33 s for a 10 A load. One of the key features of the modules is a greater than 10 years operational lifetime expectancy and, unlike DC UPS systems which use batteries, no cabinet ventilation is required. With a short charging time compared to that of batteries the units are rapidly back in ready mode following a discharge. They also maintain a regulated output voltage in buffer mode of 22.5 V and are capable of providing full output power between -40 and +60Â°C and with quick-release spring clamp terminals it makes wiring quick and easy. Other features include a digital inhibit input that when activated turns off the output and buffering and provides unit status back to a control system using a relay output.

ZigSense and ZigCloud are business units of Conlab Pty Ltd 13/1020 Doncaster Road, Doncaster East, Victoria 3109 Australia Ph: +61 3 9842 7711 Fax: +61 3 9842 7511 www.zigsense.com.au Email: info@zigsense.com.au

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WIRELESS TECHNOLOGY MAKES EVERYTHING BETTER Wireless tank gauging enjoys many advantages over traditional wired gauging equipment, ranging from reduced costs to sheer convenience and efficiency…

L&J Engineering has offered the industry’s best level gauging solutions for over 35 years, and continues its tradition of innovation and superiority with wirelessready products.

S&J 92021 Mechanical Tape Gauge with MCG 2000 max Transmitter

S&J 94020/94040 Conservation Vent with MCG1097 wireless switch

L&J Engineering’s wireless communication option is an easy, simple solution for your plant. By integrating wireless communication with one of our level gauging devices, the gauge transmit a wireless signal back to the base station, for incorporation into your inventory/asset management system. S&J 94020/94040 Conservation Vent with MCG1097 wireless switch

S&J 92021 Mechanical Tape Gauge with MCG 2000 max Transmitter

•P rovides Pressure and Vacuum Relief to Tanks Under Abnormal Pressure • Ideal for Tanks Blanketed with Nitrogen or Other Inert Gases • Settings: 0.215kpa to103kpa Options: Closed Vent, Open Vent, • Vacuum Only, Pressure/Vacuum, Steam Jacketed • Sizes 2’’ through 12’’

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ON WWW.PROCESSONLINE.COM.AU THIS MONTH

MULTIVARIABLE VORTEX FLOW METERS

The vortex multivariable flow meters from Azbil employ a vortex shedding velocity sensor, an RTD temperature sensor and a solid-state pressure transducer. AMS Instrumentation & Calibration Pty Ltd http://bit.ly/1mKTb0O

> PRESSURE CALIBRATORS Suitable for gas custody transfer applications, the Fluke 721 precision

pressure calibrator has dual isolated pressure sensors, allowing users to take simultaneous measurements. Fluke Australia Pty Ltd http://bit.ly/R2AuJJ

OIL CONDITION MONITORING The LDP100 optical particle monitor measures the degree of cleanliness or the level of contamination in mineral oils, ester oils and bio-

CAMERA-BASED CODE READER

degradable oils. ifm efector pty ltd http://bit.ly/1mPOWBm

The main strength of the LECTOR620 OCR is the reading of printed plain text and simultaneous identification of 1D and 2D codes.

Sick Pty Ltd http://bit.ly/1oG8Kcn

MINIATURE INFRARED CAMERA

The latest Micro-Epsilon miniature infrared camera, the TIM450, offers a high optical resolution of 382 x 288 pixels and features a detector with high thermal sensitivity. Bestech Australia Pty Ltd http://bit.ly/1jjDtsx

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Make the unpredictable totally predictable.

Swagelok® Pressure Regulators are now an even better choice for all your pressure regulator needs. Why? Well, alongside our proven experience and expertise, our range now covers sizes from 1/8 to 4 in. and all your regulator needs – high-flow capability, two-stage, back-pressure and vaporizing models. With our regulators you get accuracy, sensitivity and pressure stability. In short– total predictability. Exactly what you would expect. Visit swagelok.com/pressure.

NEW PRODUCTS

DATA LOGGER The DataTaker Series 3 logger is a low-powered, internet-ready platform, suitable for applications in remote environments. The device is available to rent. The DT80M logger features 5-15 channels, for measuring parameters such as voltage, current, resistance and frequency. Each channel is independent and supports one isolated 3-wire or 4-wire input, or two isolated 2-wire inputs, or three common referenced 2-wire inputs. The DT80M is generally used at sample rates of 1 Hz and slower. Storage is available for up to 10 million data points in userdefined memory, and the device supports 2G and 3G networks (GSM/GPRS/EDGE/WCDMA). Analog inputs support up to Âą30 V sensor inputs, and automatic data delivery can be scheduled. TechRentals www.techrentals.com.au

BULK STORAGE TANK RELIEF VALVE The Fisher Type 63EGLP bulk storage tank relief valve is designed to be used on 110,000 litre and larger propane tank applications. The Type 63EGLP offers multiple benefits over traditional multiport relief valves, including a 40% increase in relief capacity, a 20% weight reduction for easier installation, and reduced maintenance costs. The UL-certified relief valve is approved for bulk propane storage relief installations compliant with NFPA 58. The valve achieves significantly greater relief capacity than a traditional multiport relief by incorporating a highly accurate pilot controlling valve. This pilot controlling valve has been used for decades in petrochemical and natural gas applications and has proven to be both accurate and highly reliable. The 40% capacity increase translates into significant savings for tanks of 340,000 L or larger, requiring only two Fisher Type 63EGLPâ&#x20AC;&#x2122;s versus three traditional multiport relief valves. Installation is simplified due to a 20% reduction in weight and a reduction in overall size in comparison to multiport relief valves, along with an included lifting sling. The deviceâ&#x20AC;&#x2122;s dual-pilot design provides high accuracy relief and the ability to service one pilot while the other pilot controls the relief valve for uninterrupted relief protection, helping to minimise maintenance time and costs. Emerson Process Management www.ap.emersonprocess.com 12

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NEW PRODUCTS

TEMPERATURE CALIBRATORS Fluke has introduced two single-function calibrators for simulating process temperature sensors. For technicians who donâ&#x20AC;&#x2122;t want the complexity of multifunction test tools yet need highly accurate temperature calibration, the Fluke 712B RTD and 714B thermocouple temperature calibrators let instrument, process and plant maintenance technicians quickly and easily test process temperature instrumentation. The Fluke 712B measures and simulates 13 different resistance temperature detectors (RTDs) types and resistance, and the 714B measures and simulates 17 different thermocouple types as well as millivolts, to verify process sensors by direct comparison of measured versus reported temperatures. The calibrators also measure 4-20 mA signals

VOLUME FLOW SENSOR The Bulkscan LMS511 uses time-of-flight technology for non-contact measurement of volume flow on conveyor belts. Using multi-echo technology, the Bulkscan LMS511 can combine time-of-flight data with the belt speed to generate a reliable volume flow signal, regardless of the bulk materialâ&#x20AC;&#x2122;s properties or weather conditions. Aside from calculating total quantities and mass flow, the Bulkscan LMS511 can monitor the operation of the conveyor belt without coming into physical contact with it and promptly gives warning of any belt slippage. The integrated centre-of-gravity calculator can be used to detect uneven loading of the bulk material and avoid excessive belt wear. Its tough industrial housing is well suited to rugged operating conditions. An integrated heater also ensures safe operation at low ambient temperatures. Discrete signals as well

with 0.001 mA resolution while simultaneously sourcing a temperature signal with both readings displayed on the large, backlit display for easy transmitter calibration. They can scale the measured mA to the programmed 0 and 100% temperature settings to verify the 0 and 100% values scaled in a temperature transmitter. They also feature linear ramp and 25% step auto-ramp based on 0 and 100% settings. Settings at power down are saved for easy restart of tests when the calibrator is powered back up. Both calibrators have built-in magnetic hanging tools

as Ethernet TCP/IP can be used to connect the measuring

for easy mounting while taking measurements.

system to a host communication system.

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NEW PRODUCTS

DIESEL AIR COMPRESSOR The compact Airman PDSF210SC-5C3 box-type diesel air compressor is particularly suited for mining contractors and mine maintenance teams who prefer to truck mount their compressors. The device features several unique benefits and smart design elements, including a built-in after-cooler, and a water separator that removes 65% of condensate, ensuring better-quality downstream compressed air. The compressor has an auto-shutdown system to provide added user safety, and a low engine idle rate of 1300 rpm makes the unit very fuel efficient and minimises component wear. The box type compressor has been designed with convenient access and storage in mind, incorporating cabinet-style doors mounted on the side. This design permits easy access for maintenance and also supports the unit being mounted on vehicles or stored in restricted spaces. An electric fuel and air bleed (EFPS) pump means that air is automatically primed and bled out of the system without opening injector lines should the compressor run out of fuel, resulting in maximised uptime and reduced service calls. The robust construction of the unit features a durable steel and powder-coated finish with stainless steel hardware. Power transmission is optimised as the Yanmar 4TNV98T-ZNHK Tier 3 engine is direct coupled to the airend. The company says the air compressor is exceptionally quiet, with noise levels of 67 dBA (at 7 m), and the device comes with a comprehensive range of standard and custom build options, including an environmental containment base, lockable battery isolator, emergency stop button, exhaust spark arrestor, fire extinguisher, and air-hose reel. CAPS Australia Pty Ltd www.capsaust.com.au

ETHERNET SWITCHES Optimised and designed for use in harsh industrial environments, unmanaged Ha-VIS eCon Ethernet switches equally enable the cost-effective expansion of existing network infrastructures, as well as the development of new industrial networks. The compact, cost-effective, plug-and-play switches can be easily and quickly put into operation. Two different compact, space-saving housing designs guarantee the best possible use of available space in the switch cabinet. Power over Ethernet Plus (PoE+), full Gigabit Ethernet and an industrial temperature range of -40 to +70째C broaden the wide product range with additional functionality. Due to their approval for use in industry as well as the maritime market and transportation technology, the switches can be optimally selected for each application. HARTING Pty Ltd www.harting.com.hk

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CASE STUDY

Snack food maker’s drive to integrate A quick check of the local supermarket shelves gives a clue as to the complexity of the snack-food manufacturing process. The variety on display is enormous. Everything from high-energy breakfast alternatives and morning pick-me-ups to chips and party foods is readily available. Imagine then, the logistical exercise of continuously moving all these different snack foods through a clean manufacturing plant, where hygiene, energy efficiency and reliability are the priorities. To achieve the tight production schedules, all these items must be boxed in their various manufacturing zones and moved along sophisticated conveyor lines to the appropriate packing and despatch areas. Design of the conveyor systems and the motors and drives that power them is of critical importance in this environment. According to Jason Thompson, Director of Contech Engineering, there was no need for compromise when designing the drive system for a recently installed snack-food conveyor system in Sydney. While the multivendor, mix-and-match approach had worked well in the past, the opportunity to source suitable drives and electronics from a single supplier produced the optimal result at the snack food manufacturing plant. The layout of the snack-food plant called for a complex set of conveyor lines, feeding into the dispatch area like a multitude of tributaries flowing into a major river. From the manufacturing line, each snack-food carton is placed on a conveyor that joins other lines before moving at a steady rate to an upper level in the manufacturing plant. To achieve this, and to keep the snack-food production targets on track, the design incorporated a number of high grip and inclining conveyors. At the upper level, these lines feed into a single conveyor that carries the cartons to the distribution area. Thompson had a clear goal in mind when planning the project. “We were looking for a reliable and integrated system of drives to keep the conveyor belts moving,” says Thompson. “We wanted simple drive operation and decentralised installation, to save on space and cabling costs.” To accomplish this goal, Thompson deployed 34 SEW-Eurodrive Movifit FC 0.75 kW variable speed drives. “The decentralised control units of the drive systems required less cable and fewer cabinets in the field, and that was where we made most of the space savings,” he says. This reduced the design complexity and overall costs, while allowing for easy diagnostics and maintenance. The simplified design also reduced possible sources of errors in the wiring-up stage. The decision to close couple the gear motors to SEW-Eurodrive decentralised motor controllers was a significant step says John

Gattellari, National Industry Specialist Food & Beverage, with SEWEurodrive. “The inclusion of our Movifit system, particularly suited for food-grade environments, provided a perfect match in terms of compatibility, and reduced the time required for installation and set-up. We provided some initial training and they did the rest. The system has run like clockwork ever since,” he says. Gattellari says that the Movifit solution allows for flexible topology, which simplified the design process for the snack-food conveyor system. This was aided by built-in local intelligence and local control functions. Isolators are also local, providing an important safety feature. Energy efficiency was another important consideration in the design of the snackfood conveyor system. “The energy efficiency of the drives reduces costs, while also complying with new energy efficiency laws,” says Thompson. Being modular and flexible, the Movifit drive control fulfilled Thompson’s important criteria for decentralised drive systems, with fewer components required in the system design. A decentralised electronics unit enables control of several drives, which reduces the number of units required in the system. The three versions of the unit available afforded his team the options they sought for the snack-food project. A flexible communication system was a major requirement. In this case the designers selected DeviceNet. The connection technology enabled quick installation and commissioning. With SEW-Eurodrive providing training from its Drive Academy, Contech Engineering only required two half-day sessions for one of their engineers in order to complete the project. Following this training, the installation and commissioning of the drives was carried out by their own staff. After the conveyors were built and tested they were disassembled in preparation for shipping to site. The entire project took eight weeks to complete, with the locally assembled drive units delivered within three weeks of the order being placed. Despite the complexity of the conveyor system, Thompson says that because of the system design and the equipment chosen, disassembly and reassembly on site were easily implemented. The integrated design approach, with all drives sourced from a single supplier, allowed Thompson’s team to reduce the complexity of the conveyor system by minimising the number of different components. At all phases of the project - planning, design and implementation - this approach proved to be cost effective and fulfilled all technical requirements. SEW-Eurodrive Pty Ltd www.sew-eurodrive.com.au

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NEW PRODUCTS

PRESSURE TRANSMITTER The WIKA UPT-20 is a HART pressure transmitter featuring HART 7 firmware and a large LCD 4½-digit 14 mm display. The main 14 mm display in accompanied by a second three-line display and a radial bar graph which mimics an analog display for immediate value recognition. Configuration and electrical installation can be done without tooling with range turndown up to 20:1. Pressure ranges on the UPT are available from 20 mbar up to 1000 bar with accuracy as low as 0.1%. Application has been made for IECEx, ATEX, FM, CSA and GOST hazardous approvals suitable for EX ia potentially explosive applications, expected later in 2014. The device has all stainless steel wetted parts with no O-rings, making it suitable for most harsh process materials. The UPT-20 can also be used with diaphragm seals of exotic materials extending its versatility. An integrated stainless steel flush diaphragm is available with the UPT-21 for applications where the process may block the pressure inlet. With a standard 4-20 mA/HART output signal and pro-

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gramming features displaying pressure, volume and level the UPT range of transmitters will be suitable for most liquid- and gas-monitoring applications and process control. WIKA Australia www.wika.com.au

ETHERNET TERMINATION TOOL Clipsal’s Actassi quick-termination tool has been designed to save time and money. Easy to use, it provides fast and reliable termination of cabling, saving approximately 15% on overall network cable termination time. The tool is ergonomically designed for comfortable repeat use and requires minimal force. Constructed from cast alloy, the tool is suitable for Actassi Cat6 and Cat6A UTP

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connectors. It features a locking handle for neat storage and its small size makes it easy to store in a tool box. Every tool is supplied with a spare cutting module, which provides up to 5000 terminations. Additional cutting modules can be purchased separately and they are easy to replace.

Schneider Electric Clipsal Partner www.clipsal.com.au

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NEW PRODUCTS

WATER INFORMATION MANAGEMENT SOFTWARE The Hach Water Information Management Solution (Hach WIMS) software helps users see the complete picture of a water or wastewater system so that money can be saved and operational decisions can be made with confidence. This water data management software secures data collection, streamlined reporting, user-defined alerts, and charting, graphing and mapping tools to make this possible. WIMS is suitable for managing and reporting data to the EPA, and state or other regulatory agencies. Process data is automatically (or manually) stored into a central, secure database for easy monitoring, analysis, reporting and predictive modelling. Data can be accessed locally or via a secured web interface, ensuring audit trails and historical records are safe and available for easy viewing. WIMS has over 100 industry-specific formulas and verification engines to quickly and accurately perform complex calculations with the click of a button. Such built-in equations help provide consistent results based on EPA requirements. Intelligent alerts and modelling tools help resolve, predict and prevent disruptions. WIMS data management software will flag problems so users know exactly where they occurred. Data and information is automatically verified and compared. Modelling tools allow the development of what-if scenarios and to perform search queries on the data. Preprogrammed EPA and state report templates create business and regulatory reports instantly. The water data management software enables automatically scheduled reports on-screen, printed or delivered via email. Personalised dashboards allow key data to be monitored and immediately shows the information needed. Hach Company www.hachpacific.com.au

www.processonline.com.au/white_papers/67247-Industrial-Ethernet-challenges-and-opportunities-an-eBook 19

ACI CONNECT: OPTIMISING INDUSTRY INAUGURAL CONFERENCE AND EXPO A SUCCESS

The strong line-up of speakers and exhibitors at the newest Australian conference and exhibition focused on automation, control and instrumentation was well received by all who attended.

CI Connect, Australia’s new automation, control and instrumentation-focused conference and expo, launched in Melbourne last month, receiving very positive feedback from attendees. Engineering leaders from around the country gathered to hear industry experts present on such hot topics as Industry 4.0, cyber security, the future of manufacturing, addressing the skills shortage and Ethernet in industry. Twenty-five leading vendors, including Siemens, Emerson, Weidmüller and Endress+Hauser displayed their latest products and solutions on the exhibition floor and two industry workshops on machine safety and instrumentation complemented the two streams of the main conference. ACI Connect is run by Westwick-Farrow Media, publisher of What’s New in Process Technology and ProcessOnline.com.au and developer of industry-specific events like the Industrial Technology Regional Roadshows and (Radio) Comms Connect - CommsConnect.com.au. The event was supported by industry bodies Engineers Australia and the IICA (Institute of Instrumentation Control and Automation), and full conference attendance earned delegates up to 10.5 professional development hours. The conference theme was ‘Optimising Your Industry’ and featured three dedicated streams. • Industry Workshops - presented by technical experts Frank Schrever (machine safety) and Steve McKay (instrumentation/ electrical). 20

• Technology@Work - local case studies and technical solution papers from a variety of leading ACI specialists. • Business & Engineering Connect - panels and papers on cyber security, Ethernet in industry, skills shortage, Industry 4.0 and more.

Attendance The inaugural ACI Connect conference and expo was attended by engineers, systems integrators, EPCs, OEMs, consultants, project managers and plant and manufacturing management from a broad range of industry sectors, including food, mining, oil and gas, manufacturing, utilities and infrastructure. Attendees to the conference and exhibition included senior engineering staff from Bulla Dairy, Worley Parsons, Patties Foods, BP, Melbourne Water, ExxonMobil, Wood Group, Nestlé, Lycopodium, K L Ballantyne, Qenos, Orica and GlaxoSmithKline to name just a few. ACI Connect will move to Sydney in 2015 and will take place at Sydney Showground on 22-23 April.

A needed conference User feedback for this first-run event was very positive. John Immelman, Chairperson Sydney Branch, IICA, was impressed by the professionalism of the organisers. “The professionalism and efficiency demonstrated by the organisers mirrored these same characteristics found in most ACI technologists - the industry is about measurement and manage-

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Quotes:

ment,” he said. “The visual impact of the customised booths at the exhibition was a reminder of how much the industry has missed an event of this magnitude. Everyone I have spoken to is already looking forward to ACIconnect Sydney in 2015.” When asked whether there is a need for such an event on the annual engineering sector calendar, a senior control technician from Nestlé said: “What we do is extremely important and we definitely need to expand knowledge in good process control practice, to maintain the viability of industry in Australia.” A process engineer from Patties Foods said: “The variety and quality of topics presented was of a very high level and the combination between conference and exhibition was great.”

“I would like to express my warm thanks for you all for allowing me to attend the conference. Both my work colleague ... and I enjoyed the openness, technical atmosphere and faultless organisation ... “I hope we will meet again soon.” Systems Engineer, Land Engineering Agency “I just wanted to send a quick thanks for the opportunity to upgrade my pass to the Full Conference Status. I attended both days in full and really appreciate the value I received from the upgrade. “I found that the whole thing was very well run, and it was really worth being there. “Thanks again to you and the rest of the team that helped me out.” Control Systems Engineer, Industrial Control Technology

Keynotes and panel discussions Interesting, relevant and topical keynote and plenary addresses included ‘Engineering and manufacturing - where to now?’ presented by Professor Alex Baitch, National President, Engineers Australia; ‘Greybeards and ‘Playstationers’ - how to address the skills shortage’ by Bruce Kendall of RMIT; ‘Industry 4.0 - what is it, and what does it mean for us’, presented by Chris Vains of Siemens; and ‘Cyber security in a nuclear context’, by Mitchell Hewes and Nick Howarth of ANSTO. Panel discussions on Industrial Ethernet and on industrial cyber security were well attended, with the cyber security panel generating extensive discussion and audience participation. The general conference presentations covered many topics including: • Cloud-based predictive maintenance • Control room design • Data mining for asset management

• Functional safety • Machine vision • MES and operational intelligence • Pervasive sensing • Preventive maintenance • S88 batch control Many of the presentation and training presentation slides can be downloaded from the ACI Connect website at http://aciconnect. com.au/pages/speakers-topics.

Looking forward to 2015 Following the success of the inaugural event in Melbourne, ACI Connect will be in Sydney in 2015, and we hope to see you there. ACI Connect www.aciconnect.com.au

www.processonline.com.au/white_papers/67247-Industrial-Ethernet-challenges-and-opportunities-an-eBook 21

NEW PRODUCTS

UPDATED SCADA SYSTEM Honeywell Process Solutions has launched its latest version of Experion PKS Orion, featuring capabilities that allow industrial plants to implement automation projects faster and more efficiently, while making it easier to manage daily operations. Experion PKS Orion makes use of approaches such as virtualisation, universal channel technology and using the cloud to design projects remotely. The project workflow, when implementing process control and safety systems, can be adjusted to shorten schedules and minimise risk through every phase of the project. Experion Virtualization Solutions and remotely configurable Universal I/O cabinets allow for late-stage design changes and better hardware management. Capabilities like Experion Collaboration Station and Experion SCADAâ&#x20AC;&#x2122;s HMI provide teams with the ability to share information across geographically dispersed locations and simplify operations over thousands of assets. The universal channel technology enables instant, remote configuration of both process and safety I/O, without additional hardware - permitting the use of standardised cabinets. Universal I/O modules reduce equipment requirements and footprint, and can be quickly configured for multiple channel types. The version also uses blade server technology for advanced virtualisation capabilities. Leveraging virtualisation, upfront hardware requirements can be delayed so hardware is more current when the project is handed over. With the Experion Collaboration Station, users can display both business and process information in a common view supporting faster resolution of routine or abnormal situations. Additionally, the company has incorporated Abnormal Situation Management (ASM) Consortium principles in its SCADA design for superior HMI and situational awareness. Honeywell Limited www.honeywell.com.au

LEVEL SWITCH

The Besta BLS frequency sweep level switch offers a compact alternative to vibrating tuning forks. A single sensor will detect a wide range of different applications including bulk goods/grains and liquids (high or low viscosity) - even with sticky or pasty media. Typical installations include petrochemical, pharmaceutical, food and beverage and general industry (for lubricants and coolants). With no moving parts, this rugged design sensor is immune to shock and vibration (IEC 60068-2-6, GL test 2). It can be mounted in any orientation under tough process conditions (-40 to 115Â°C, up to 100 bar) and is immune to foams and suspended particles. The BLS has a fast reaction time of less than 100 ms, but can be factory set to include switch damping (0-10 s). Control Components Pty Ltd www.controlcomponents.com.au

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Everyday Price SmartPAK (10) $69.00 ea Web Managed switches IES608 series (8 port 10/100M Industrial Ethernet switch, WEB managed Everyday Price $339.00 ea Everyday Price SmartPAK (10) $349.80 ea

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NEW PRODUCTS

ULTRASONIC LEVEL TRANSMITTER The non-contact Hawk MiniWave is a cost-effective, loop-powered ultrasonic level transmitter designed for reliable, continuous measurement of liquids up to 8 m. It provides effortless and intuitive operation with its refined, industry leading, automatic echo detection and control software. The 2â&#x20AC;ł PVDF transducer offers high chemical compatibility, which makes the MiniWave suitable for multiple applications in all industries. Easy and flexible mounting along with the pushbuttons on the front face simplify the installation and configuration of the MiniWave. A four-line backlit graphic display allows for easy level indication and configuration. The MiniWave with powder-coated cast aluminium housing is robust and also has a glass window for easy viewing of the display. The unit also comes with a HART 4-20 mA output as standard. Hawk Measurement Systems Pty Ltd www.hawkmeasure.com

CELLULAR REMOTE I/O The Moxa ioLogik W5340-HSPA is a wide-temperature cellular remote I/O device for remote monitoring applications over mobile networks. With support for the advanced High Speed Downlink Packet Access (HSPA) technology, the W5340-HSPA reduces the response time for I/O status acquisition and control communications. The increased performance also provides enough bandwidth to perform data logging and email alarms. The ioLogik W5340-HSPA is equipped with a cellular interface that supports both fiveband UMTS/HSPA+ and quad-band GSM/GPRS/EDGE functionality, and features four analog I/Os, eight digital I/Os, two relays, an Ethernet RJ45 port, a 3-in-1 serial port and an SD storage socket. It is also available in a rugged wide-temperature W5340-HSPA-T model with a wide operating temperature range of -30 to 70Â°C for deployment in harsh environments, such as facilities without air conditioning or roadside cabinets. Patented active communications technology and IPSec/ VPN functionality allow easy use of the dynamic and private IP addresses provided by most cellular data plans. By using active communications, the Moxa Active OPC Server and DA-Center free software packages are also efficient in pushing data from the ioLogik W5340-HSPA to the SCADA system or IT database quickly, without consuming very much bandwidth. Together, the ioLogik W5340-HSPA, Moxa Active OPC Server and DA-Center deliver highly efficient event-driven SCADA connectivity, database/Excel conversions and analysis. Moreover, the W5340HSPA flexibly supports both IT and IA applications due to compatibility with the Modbus/TCP industrial standard as well as the IT-oriented SNMP v1/ v2c protocol. Madison Technologies www.madisontech.com

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NEW PRODUCTS

PRESSURE AND TEMPERATURE TRANSMITTER The STS PTM/RS485 programmable pressure and temperature transmitter has dual outputs for RS485 and 4-20 mA (pressure and/or temperature). The PTM/RS485 is available in any range from 1-15000 psi and various output signals. It is made of stainless steel or titanium, making it a rugged and reliable transmitter for harsh industrial or field applications. The pressure measuring range is 100 mbar to 1000 bar, with a turndown ratio of 4:1 and an accuracy of less than ±0.15% FS. The temperature measuring range is -25 to 85°C, and there is a compensated temperature option for -40 to 85°C. Automated Control Pty Ltd www.automatedcontrol.com.au

VISUALISATION APP The Visu+ mobile visualisation app brings system visualisation to smartphones or tablets. This enables flexible operation and monitoring concepts, with the option of universal access to the system at any time and from any location. The app meets the growing demand for flexibility in controlling and monitoring tasks by allowing users to use popular consumer devices such as smartphones and tablets. Traditional SCADA functions, including charting of trends and alarm handling, are thus possible on mobile devices. The app is a flexible add-on to the Visu+ visualisation software. The Visu+ web server required for the app is pre-installed on many devices like the touch panels from Phoenix Contact. To use the app in conjunction with Visu+, the only step necessary is to add the web Visu+ licence option to industrial PCs. Fully expanded, up to two clients can be operated using a touch panel or up to 100 clients using an industrial PC at the same time. The HTML visualisation screens for the app are generated in the development environment of the Visu+ visualisation software. In addition, the software can be easily installed via the Google Play Store or Apple App Store. Phoenix Contact Pty Ltd www.phoenixcontact.com.au

www.processonline.com.au/white_papers/67247-Industrial-Ethernet-challenges-and-opportunities-an-eBook 25

CASE STUDY

Success is sweet for Sunshine Sugar

Sunshine Sugar manufactures raw sugar from sugarcane supplied at its mills in the Northern Rivers region of New South Wales and also operates the Manildra Harwood Sugar refinery (MHS) in a joint venture with Manildra Group. All of Sunshine Sugar’s raw sugar production is sold to MHS, which has the capacity to process all the raw sugar produced by the three mills. The NSW Sugar Milling Co-operative was formed when cane growers purchased the three NSW sugar mills from CSR in 1978. The mills are located at Condong on the Tweed River, Broadwater on the Richmond River and Harwood on the Clarence River. Sunshine Sugar’s centrifugal drive system was aging and in need of replacement, and after considering all the options, the company chose a Siemens AC drive-motor combination for the upgrade. The decision to replace the 298 kW DC centrifugal drive system with a 184 kW AC motor-drive combination was not an easy one, but Siemens was determined to prove the value of the solution. Plant manager Stephen King explained how Siemens supported the company in its decision making, which ultimately led to the upgrade of the centrifugal drive system on time and even under budget. “Siemens drew on their 1200 worldwide reference sites with successful centrifuges operated by AC drives. They also provided detailed analysis of their success with reducing the size of motors and drives by controlling the switching rate of the insulated-gate bipolar transistor (IGBT). And they even sent out a global expert on drives from their Sugar Competence Center in Germany to reassure us that this was the right solution,” said King.

Brian Jackson, Sunshine Sugar’s senior electrical superintendent, was also impressed: “We were convinced by the 184 kW drive system when we learned about the Active Front End technology, which is a standard feature in Sinamics drive systems. This allows us to reduce the size of the motor and drive without losing power, achieve harmonics of less than 1%, and consequently reduce our energy costs significantly.” AC drives are particularly well suited for centrifuges, as they can provide the performance required. The largest centrifuge available can handle 1200 kg of massecuite in a single charge. Variable-speed AC drive systems require very little maintenance. They are robust and durable, can operate continuously, and offer much better reliability than variable-speed DC drives. The technology used as a standard feature in the converters of centrifugal drives also provides several important benefits. The use of self-commutated converters with IGBTs, and a clean power filter in the input, means that sinusoidal currents and voltages are maintained, with no mains-typical harmonics and thus absolute minimum mains pollution on the line side. Compensation and filter circuits are no longer needed and an overall unity power factor is achieved. There is also no conduction-through with fuse tripping in response to mains undervoltage or failure in generator mode, thanks to active tripping; this makes the solution especially suitable for weak or unstable systems. Compensation of mains undervoltages is achieved by a voltage step-up mode. Sunshine Sugar installed the Sinamics AC drive and motor solution, and it was commissioned and optimised locally by Siemens. Siemens also provided an I/O device to interface to the existing Bailey distributed control system for bidirectional communication. Since the commissioning of the new drive, Sunshine Sugar has achieved a substantial reduction in power consumption. “Power recordings have confirmed a reduction from 1.7 to 1.0 kWh per ton of massecuite, despite the recording being made prior to optimising the drive. So we’re planning to undertake further analysis soon to determine the final savings,” says Jackson. Due to the success of this solution, Sunshine Sugar has placed a second order with Siemens to upgrade the drive and motor of a second centrifuge. Siemens Ltd www.siemens.com.au

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NEW SCADA SOFTWARE Schneider Electric has announced an updated release of StruxureWare SCADA Expert ClearSCADA, its open software platform for management and optimisation of remote assets in critical infrastructures. SCADA Expert ClearSCADA is scalable for large enterprise environments and

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PRODUCTS

effective for small systems alike. Distributed system architectures provide high performance and availability as well as disaster recovery capabilities, while the integrated historian facility and open standard interfaces allow long-term storage and analysis of data. Historical field data is made available to local and remote users via integrated clients and third-party data management applications. The major update features include a refreshed interface, updated functionality and enhanced multimonitor capabilities. These functionalities are embedded in a ribbon-style framework that is the current standard for other Windows applications, while still providing the familiar core SCADA Expert ClearSCADA functionality. Users will also notice improved security and protection of system information, with restricted access to sensitive IP address and node name information (including servers, clients and other IP-connected devices) and logging of unsuccessful user logons. It also offers enhanced operational intelligence, due to a new advanced OPC driver, 3D trending and integration with Aquis (Schneider Electricâ&#x20AC;&#x2122;s software for water network modelling). SCADA Expert ClearSCADA is designed to allow users to turn field data into actionable business information that is instrumental to improving their efficiency. It is suitable for demanding telemetry applications in the oil and gas, and the water and wastewater industries as it eliminates the need for additional software to collect data from remote devices. Schneider Electric Industry Business www.schneider-electric.com

www.processonline.com.au/white_papers/67247-Industrial-Ethernet-challenges-and-opportunities-an-eBook 27

NEW PRODUCTS

OPC UA PROXY The MatrikonOPC UA Proxy has been designed to make it easy for companies to take advantage of the next generation Open Process Control (OPC) standard - OPC Unified Architecture (UA) - while continuing to use their existing OPC classic architectures. While the OPC UA standard is backward compatible with classic OPC from a data perspective, it uses different technologies to establish connections and transmit OPC data. Using the UA Proxy from MatrikonOPC, it is possible to maximise ROI on existing classic OPC technologies while being free to adopt the broad range of new OPC UA-based technologies. With the release of the UA Proxy, MatrikonOPC claims to provide the first easy, reliable way to seamlessly combine these two OPC technologies. Key features include a streamlined set-up workflow that allows for connection in minutes, and easy-to-use smart defaults requiring minimal user knowledge of OPC UA. The proxy eliminates traditional DCOM or firewall issues and operates on a Windows server system. MatrikonOPC www.matrikonopc.com

ENCODER RANGE EXPANSION Zettlex has announced a massive expansion of its IncOder range, which now offers more than 4 million versions. IncOders are high-precision, harsh-environment angle encoders which use a unique inductive technology to enable a low-height, large-bore, bearingless sensor. The form factor makes it easy for designers to accommodate through shafts, slip-rings, hydraulic pipes or electrical cables which can simply pass through the middle of the sensor. IncOders are popular with equipment manufacturers and system integrators because high precision is achievable without fine installation tolerances - and the need for environmental protection is minimal because the sensors are unaffected by most foreign matter. As well as the existing range of absolute digital outputs, the expanded product range now includes A/B pulse outputs; electrically duplex formats; resolution choices from 1k to 4M counts per rev and analog voltage outputs for all sizes from 25 to 200 mm bore. There is also an ‘extended range’ of products aimed at the aerospace and defence sectors offering features such as extended burn-in testing, conductive surface finishes, -60°C operating temperature and leaded solder. Motion Technologies Pty Ltd www.motiontech.com.au

www.processonline.com.au/white_papers/67247-Industrial-Ethernet-challenges-and-opportunities-an-eBook

NEW PRODUCTS

SAFETY HINGE SWITCH With the Tesk series of safety hinge switches

EMC-PROTECTED CONNECTOR HOUSINGS

from Schmersal, the switching angle (the

Phoenix Contact has now added EMC-protected

hinge angle at which the safety-related signal

versions to its line of Heavycon EVO heavy-duty

is initiated) is freely adjustable over the whole

industrial connectors. The cable glands with a

of the working range. The user can select dif-

bayonet locking mechanism make both lateral and

ferent contact configurations with up to four

straight cable outlet directions possible in a single

contacts and the option of cable connection

housing. This enables a large number of ECM hous-

or plug connection.

ing and cable gland variations to be created with

The special construction of this safety

just a few components.

switching device allows it to be mounted on

The cable outlet can also be subsequently adapted

the hinge side of the rotating guard. This

on-site. The housing material is corrosion resistant,

replaces a conventional hinge and at the same time takes over monitoring

and all seals are electrically conductive. This pro-

the position of the guard.

vides a shield attenuation of approximately 40 dB,

Safety hinge switches offer high protection against tampering as the safety

which is sufficient for industrial EMC applications.

switch is not visible to the operator, being an integral part of the guard. Ad-

The IP65/66-compliant housings are available in the

ditionally, the machine builders benefit because their machines and enclosures

B6, B10, B16 and B24 formats with a single- or

can be constructed with the commercially available aluminium profile systems.

double-locking latch. The housings can be purchased

The safety hinge switch is suitable for the position monitoring of protection

individually and are available in stock as complete

doors on design-oriented machines, including double swing doors

plug-in connector sets with push-in contact inserts.

Control Logic Pty Ltd

Phoenix Contact Pty Ltd

www.control-logic.com.au

www.phoenixcontact.com.au

Looking for a high-performance vision sensor that is simple to install and configure? The new OsiSense™ XUW Vision Sensor assists with quality, selection, position and orientation control in packaging and manufacturing processes. Key features include: • compact size enables easy installation when space is limited • easy configuration; only three simple steps • up to 64 simultaneous checks on a part (XUWAA version) • the configuration interface offers you five tools with “unrestricted” usage. The configuration interface, installed on your PC, guides you by offering predefined parameters. With the aid of interactive online help, setting up your vision sensor doesn’t get any easier.

www.processonline.com.au/white_papers/67247-Industrial-Ethernet-challenges-and-opportunities-an-eBook 29

TROUBLESHOOTING REMOTE SITE NETWORKS Simon Lee, Vice President of Sales - Asia Pacific, Fluke Networks

With the increasing use in industry of common IT networking technologies such as Ethernet, Wi-Fi and WANs, there is an increasing need for the ability to effectively monitor and troubleshoot these technologies in industrial settings.

anagement and remote site employees at industrial plants expect the same level of network service as the headquarters site. However, when network engineers are faced with limited resources to support remote site networks, the applications, services and performance at those sites are not as robust as they should be. Although server virtualisation, consolidation and the move towards web-delivered applications have business benefits, optimal productivity can still only be achieved when the same levels of services are available across the organisation. Unfortunately, even the best-planned deployment may leave remote offices and users vulnerable to performance degradation and availability issues. This creates additional challenges for network engineers in maintaining remote site performance, availability, security and visibility. It also creates challenges for workers in industrial plants in delivering on time, on budget and maintaining safety. Effective troubleshooting helps avoid or reduce additional hardware expenses, purchasing excess wide area network (WAN) capacity and unnecessary investment in outsourced troubleshooting. In the headquarters environment, when remote users complain about poor performance or VoIP quality, network engineers must be able to determine the root cause of the problem and correct it quickly. Remote office network outages and slowdowns are made 30

far more difficult to solve because of the challenges presented by distance, travel time and the need for tools that may not necessarily be available at the remote location. Organising the necessary tools and dispatching staff to remote locations for troubleshooting is both time-consuming and expensive, and the time spent contributes to delays or stoppages in critical work. With the right information and tools, technicians can understand and resolve issues quickly and efficiently. Adding the appropriate level of visibility, technicians could even identify remote network degradations before they become significant problems at that site. This strategy means proactive action can be taken to eliminate congestion, latency and other problems that could affect remote users and interfere with operations. Additionally, the ability to resolve problems from the headquarters site avoids the need to dispatch staff, resulting in time and travel expense savings, increased network availability, more time for mission-critical projects and fewer delays.

Best practices for remote site troubleshooting: baselining, assessment and documentation To gain efficiency later on, a proactive first step must be taken to establish a baseline of the existing remote site network, so that network engineers know what they are dealing with. The first task

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Industrial Ethernet

levels or individual critical switch port traffic has exceeded what are considered to be normal levels. Many management tools (network management systems or NMSs) are capable of monitoring individual switch ports and WAN interface traffic and provide a method to determine when specific traffic thresholds have been exceeded on those interfaces, either by error rates or use rates. This will alert network engineers to potential network degradations before they become significant problems at that remote site. However, due to their primary purpose of providing long-term monitoring and trending, most management systems take samples that are too coarse for effective troubleshooting. When trying to determine the presence of intermittent or ‘spikey’ bandwidth-hogging events, an analyser with granular sampling rates is essential for problem detection and isolation. Additionally, seemingly minor problems such as incorrect subnet masks, duplicate IP addresses etc should also be reported. It is also necessary to monitor the protocols in use, which is especially important for the traffic traversing the WAN link.

Reactive tasks

is a comprehensive discovery and documentation of the remote site network. This entails not only what kind of equipment exists but also identifies the users and how and where they are connected to the network. Discovery must include information on hardware inventory, servers, access points, switch and router configurations, and network connection paths. Updated maps are an essential element of ‘knowing’ the remote site and are needed for reference when future problems emerge. The next necessary step is to understand what normal traffic levels are at the remote site. This provides a reference to work from when determining abnormal activity and compare against when validating problems in the future. Technicians must evaluate current network performance, including traffic patterns with protocol and application usage, bandwidth use, internet/WAN connectivity performance and potential network vulnerabilities.

Next steps: proactive, reactive and maintenance tasks Proactive tasks Once up-to-date network configuration diagrams are available and traffic levels and performance have been baselined, it is necessary to automatically alert headquarters staff when overall traffic

When remote users complain of a slow network, network engineers must follow a consistent process and have access to the necessary data to identify the problem domain to identify and prove who or what is at fault. First step: Testing connectivity and response times For most network engineers, the first step in troubleshooting a problem is to ping the remote site; either the machine of the complaining user, a local server or other reliably ‘on’ device, providing that ICMP (the layer 3 protocol used by ping) is not blocked. If ping has worked in the past, but is not working now, then an examination of port status along the path is required. In the absence of ‘down’ ports or links, an unsuccessful ping means troubleshooting from the bottom of the stack and moving up. Unfortunately, physical connectivity issues may require staff to travel to the site for troubleshooting but do not rely on ping alone for making that determination; it may be blocked. A successful ping at least assures physical connectivity and can give an inexact estimation of network round trip time. But ping is not a reliable measurement method for determining packet loss and, being symmetrical in nature, provides no insight into asymmetrical link problems. Also, no user application uses ICMP, so whether the protocols used by a particular application can traverse the network, and the speed at which they do so, must be measured a different way, such as opening a port. Initiating the SYN/SYN-ACK/ACK ‘three-way handshake’ of a TCP port provides a far more reliable test of layer 3 connectivity. Even better than a port connect, which validates network connectivity and network response times, conducting and measuring an application transaction provides a more reliable method of application connectivity and response times. Certain tools can target a local or remote web server and execute and measure an HTTP GET command as a way of measuring performance of a web-based application, for example.

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Industrial Ethernet

Second step: Examining network usage It is very common for performance slowdowns to be caused by overuse of network bandwidth. While most LAN connections exceed the available WAN or internet bandwidth by some multiple, it is not impossible for a local LAN connection to become overloaded, particularly if configurations are not achieving maximum throughput. Many a network engineer has been surprised to find 10 Mbps half duplex links in operation where 100 Mbps full duplex or Gig was expected. SNMP or flow-based data can be examined to determine interface utilisation. Granular measurement can indicate when spikes of usage are occurring, with flow data providing evidence of who is doing what. Third step: Testing network quality A unique method for testing the available bandwidth is to conduct a performance test from the HQ to the remote site. Software agents are available that can be deployed on remote PCs and then targeted by an analyser at the HQ. ‘Layering on’ a stream of test traffic to/from the remote site provides instant insight into the quality of packet transmission, revealing issues with latency, loss and jitter that could be impacting application performance. Fourth step: Packet analysis Still operating from the HQ, the network engineer can place their analyser inline with the traffic feed from the remote site (either using an analyser capable of inline analysis, or via a SPAN port or a network tap). Keep in mind that hardware-based tools are essential for zero packet-loss analysis. The worst waste of an engineer’s time would be to capture only parts of the traffic to/from the remote site, and (at best) be left guessing or, even worse, to mistakenly troubleshoot ‘lost packets’ when the loss was actually caused by the analyser itself. With capture files of traffic to/from the remote site, the engineer can examine delta times between frames and distinguish between network transfer time and client response time, thereby validating whether there really is an issue with performance to the remote site or whether the issue is with the client or the HQ side. Analyser at the remote site Despite these best efforts, and as pointed out already, testing from the HQ can only go so far and is only providing test information from the point of view of the HQ site. At some point, measurements must be taken from the remote site, from the point of view of the affected users. While remote desktop (RDP) can be used to take control of a remote PC and conduct various command line tests (such as ping or tracert), these have their limitations. The ideal

WITH THE RIGHT INFORMATION AND TOOLS, TECHNICIANS CAN UNDERSTAND AND RESOLVE ISSUES QUICKLY AND EFFICIENTLY.

scenario is to have a dedicated network analyser on site for local testing but control that analyser remotely from the HQ, eliminating the need for travel to the site.

Maintenance During network maintenance times, ensure that the internet/WAN links to the remote sites are capable of supporting the allocated bandwidth and providing quality transmission of application traffic. In order to perform this task, a network performance test (NPT) should be run between an analyser at the remote site and a similar analyser at the headquarters site. The test needs to be performed at various traffic rates and different frame sizes to determine if the WAN link is capable of handling the traffic, to determine packet loss and, more importantly, in which direction the packets are being lost. If there are dropped packets, or the link will not support the advertised data rate, the analyser needs to have features available to diagnose the source of the problem. Testing for throughput and loss is only one dimension of network quality. Latency and jitter must be measured, and jitter must be measured asymmetrically if one is to understand its impact on streaming applications. Also, QoS must be tested by passing traffic at various QoS settings to ensure proper traffic prioritisation and prevent improper discarding or throttling of application traffic.

The business benefit Effective troubleshooting not only reduces time and travel expense but, done properly, can help avoid or reduce additional hardware expenses, purchasing excess WAN capacity, unnecessary investment in outsourced troubleshooting or having persistent problems that suck time and money from the entire organisation. Importantly, in industrial plants, effective troubleshooting eliminates delays and costly outages and improves user safety. Fluke Australia Pty Ltd www.fluke.com.au

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NEW PRODUCTS

MANUFACTURING AND SUPPLY CHAIN PLANNING Aspen Technology has launched aspenONE Manufacturing and Supply Chain V8.5 software. This release is described as another step forward in collaboration across planning, scheduling, and manufacturing operations. By using the aspenONE Process Explorer, aspenONE PIMS Platinum, and Aspen Petroleum Scheduler, users can improve efficiency and profitability. The release includes aspenONE Process Explorer, designed to drive manufacturing execution with breakthrough visualisation and analysis of plant operations data; aspenONE PIMS Platinum formulated to compare refinery plan and schedule side by side for the first time; and Aspen Petroleum Scheduler, specifically configured to integrate refinery scheduling and dock scheduling. aspenONE Process Explorer and aspenONE PIMS Platinum are both built on the HTML5-based aspenONE web and mobile architecture, providing a user-friendly interface with touch interaction, intelligent search, and secure access from any web browser on a desktop, laptop, or tablet. aspenONE PIMS Platinum lets new users get up-to-speed quickly and advanced users reduce analysis and reporting time using customisable dashboard templates. By integrating Aspen Petroleum Scheduler, both the plan and the schedule can be seen together. aspenONE PIMS Platinum increases collaboration with management, process unit managers, and schedulers. Qualified aspenONE customers can upgrade to the new version for no additional cost. Aspen Technology Australia Pty Ltd www.aspentech.com

When There’s No Room for Error When it comes to measuring humidity in harsh manufacturing environments, you don’t want to cut corners. The Vaisala HUMICAP® Humidity and Temperature Transmitter Series HMT330 is an uncompromising transmitter you can depend on for years of trouble-free performance. • Credibility that speaks for itself – close to 80,000 installations worldwide and counting • A wide range of options and configurations • Built for extreme environments • Support and service you can count on Your customers choose the best. Why would you choose anything less?

More information: www.vaisala.com/HMT330 TIA-AU-WNIPT-May-2014-180x135.indd 1

Tel. 03 9815 6700 Email: sales.melbourne@vaisala.com 16.5.2014 14.42

www.processonline.com.au/white_papers/67247-Industrial-Ethernet-challenges-and-opportunities-an-eBook 33

NEW PRODUCTS

PORTABLE GAS FLOW METER

PANEL PC The P1197E-861 from Axiomtek is a

The GE Panametrics TransPort PT878GC

ruggedised 19″ expandable industrial

offers a portable solution for ultrasonic gas

touch-panel computer. It supports Intel Core

flow measurement in pipes. The system

i7, i5 and i3 processors, as well as Celeron

operates on the transit-time principle and

and Pentium processors in an LGA1155 socket

clamps on externally for unobstructed

with Intel H61 Express chipset.

internal flow. Compatible with metal or plastic pipes

The touch-panel PC is equipped with a 19″ SXGA TFT LCD with high-brightness LED

with sizes between 20 and 300 mm, the

backlight (350 nits), and has an IP65/NEMA 4-compliant front panel. Built around

meter can be used for applications in-

user convenience, the touch-panel PC adopts a slim industrial-grade panel unit,

volving compressed air, natural gas and

supporting complete expandability features, including a dual-display interface,

most other gases, without the need to cut

one expansion slot, eight USB 2.0 ports, four COM ports and Wi-Fi connectivity,

pipes. Readouts for flow velocity, actual or

making it suitable for kiosk, factory and automation.

standard volumetric flow, and mass flow are

The 19″ industrial touch panel PC features built-in speakers for kiosk application

available in numerical or graphical format.

to display multimedia content program. It also supports WLAN module antenna

The PT878GC features internal logging

(optional) for wireless network connectivity.

for 100,000 flow data points and has an

The all-in-one panel PC also supports two 2.5″ SATA HDDs with convenient

infrared communications port to interface

side-access trays, and the ‘less-screw’ design, with only three screws on the back

with a PC or printer. The rechargeable bat-

chassis, allows users to quickly remove it and install with ease, saving time and

tery provides 8 h of continuous operation.

maintenance cost, and increasing work efficiency.

TechRentals

Braemac Pty Ltd

www.techrentals.com.au

www.braemac.com.au

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NEW PRODUCTS

DUAL SENSOR MAGMETER The FPI-X Dual Sensor electromagnetic flow meter from McCrometer is designed to deliver accurate and repeatable measurement under extreme flow conditions, said to be unachievable with other technologies. The flow meter reliably achieves Âą0.5% accuracy under the most severe swirling flows. Designed for use in close proximity to cascading or multiple pump arrays, the meter delivers the advantage of accurate measurement where no flow meter previously could serve. Whether installed near pumps, valves, elbows, headers, or any other equipment that makes it impossible to create a symmetrical velocity flow profile in the pipe, the device is claimed to outperform traditional mag meters. The mag meter provides measurement in difficult sites that otherwise require multiple meters in various locations, saving users both money and installation time. The FPI-X also eliminates the expensive flow conditioners and piping modifications necessary with other meters. A dual-sensor configuration designed with multiple electromagnetic coils installed throughout both sensors produces a magnetic field across the complete cross-sectional area of the pipe. Placing voltage sensors in two planes across the pipe compensates for differences in velocity caused by severe flow disturbances. More velocity sensors results in a more accurate measurement. Multi-point sensing technology makes the mag meter suitable for cramped, retrofit and new construction pumping stations or in any constrained space areas with limited straight pipe run availability. The sensorâ&#x20AC;&#x2122;s body is hermetically sealed and protected by NSF-certified, 3M fusion-bonded epoxy coating. AMS Instrumentation & Calibration Pty Ltd www.ams-ic.com.au

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CASE STUDY

Thickener modelling improves efficiency

A 25-year project on thickener modelling that has already delivered huge value for the mineral processing industry has now entered a new phase. Water is used in processing most minerals to metals, ranging from simply washing away waste solids to leaching of target metals with acidic or basic solutions. Having done this, how are the solid and liquid phases then separated quickly and efficiently? Gravity thickeners (large tanks) are used widely for this and the addition of flocculants and suspensions assists in producing a clear liquid stream from the top of the tank, as well as a thick sludge of settled solids, which is discharged from the bottom. However, despite their importance and widespread use, thickeners can be erratic and inefficient. Researchers from CSIRO are advancing the science and modelling of thickeners using mathematical and computational fluid dynamics, with great results. According to an independent assessment, their work has already delivered well over US$500 million in value to end users. “Thickeners suffer from limited throughput, poor solid-liquid separation, operational difficulties and high consumption of expensive flocculants,” said CSIRO Project Leader Dr Phillip Fawell. “In tailings applications, for example, they frequently fail to deliver the desired solids concentrations, leading to the waste of water and the need for excessively large tailings disposal dams that can cause environmental issues.” In response, Dr Fawell and his team are creating the world’s first three-dimensional full thickener model as part of the existing multifaceted AMIRA International project. AMIRA International Ltd is a member-based organisation of minerals companies and suppliers which develops, brokers and facilitates collaborative research projects, through which companies can jointly fund research and jointly share the benefits. “We are applying the models to systematic studies of different designs and operating conditions (changing solids concentration, volumetric flows, dosages) to establish best performance guidelines,” he says.

“Our team expects to deliver control strategies for dealing with specific issues or performance targets. “We’re also developing a new test that will give the parameters needed to characterise the settling and consolidation of a flocculated feed for process or control modelling from a series of simple cylinder tests.” Dr Fawell believes this could end up being a new standard method of all such testing. The project, or series of projects, which has been running for over 25 years, has been strongly supported by the Australian and international minerals industry with sponsorship funding of over $20 million since inception. Sponsors benefit from the sharing of key information and technology from each of the projects, including online resources such as a knowledge base, a thickener self-appraisal tool and process models and training presentations. They can also engage the research team to work on their sitespecific problems. This has resulted in significant improvements to the performance of more than 150 thickeners. “What has impressed me is how CSIRO has been able to pass on to sponsors their broader understanding of how flocculation should be done in gravity thickeners,” said Gray Bailey, program manager from AMIRA International. “There’s no better feedback than hearing from sponsors who have gone back to their sites, looked at their thickeners and said, ‘Now that makes sense!’” The Minerals Down Under Flagship of Australia’s national science agency, CSIRO, is one of the largest minerals research groups in the world and has a proven track record of working with industry to deliver innovative solutions. Through targeted research, CSIRO addresses the industry’s challenges, driving sustainability, productivity and innovation for its collaborative partners and clients. CSIRO - Manufacturing, Materials and Minerals www.csiro.au

This story first appeared in resourceful: www.csiro.au/resourceful.

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NEW PRODUCTS

PLC WITH HMI The Unitronics Vision350T PLCs with onboard HMIs have a flat fascia that makes these models suitable for the food and pharmaceutical industries. With their IP66/IP65/NEMA4X rating, these units are suitable wherever spray/wipe down applications apply. Their PLC + HMI advantage gives users the opportunity to operate on a minimum of budget, programming time and wiring. With a wide variety of onboard and expandable I/O options, these units are capable of supporting up to 512 I/O. These configurations include digital and analog inputs and outputs, high-speed I/O, PT100/thermocouple capabilities and weight measurement. The I/O can be mounted locally or remotely, up to 1000 m from the controller. These power-PLCs are equipped with recipe capabilities, Micro SD card memory storage for data logging and backup, and complete PLC cloning. The Vision350T units can support 24 autotuned PID loops to control temperature, level and pressure, while the 16-bit, 3.5″ 320 x 240 QVGA colour touch screen displays data, colour trend graphs and alarm screens. More than 1024 user-designed screens are possible, and up to 250 images per application. Internal memory holds 1 MB of application logic, plus 512 KB for fonts and 6 MB for images. Communication options include Ethernet, cellular and industrial protocols such as Modbus, DF1 slave, J1939 and CANopen. In addition, the Vision350T units can be ‘taught’ to communicate via almost any ASCII protocol. The controller is also capable of time-based and immediate interrupts, making it suitable for ‘rapid response’ applications such as packaging machines. Micromax Pty Ltd www.micromaxsa.com.au

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

MANUFACTURING GLOOM AND THE CONTRARIAN

’ve been in love with watching stuff being made since childhood factory tours. Cheese was the first date, the ‘Rotolactor’ turntable milking machine the engagement and ice-cream wrapping lines the wedding. At age seven I knew I wanted to be around machinery. The motion of industry still excites me, and the best part of my job is visiting new sites and getting to watch the genius of manufacturing design at work. The next generation of industrialisation - ‘Industry 4.0’ as coined by the Germans won’t be so visually stimulating, however. Embracing the ‘Internet of Things’, it conceives of a highly automated and integrated supply chain construct of inventory, schedules and resource management to achieve the next transformation of productivity. This Industry 4.0, or the fourth industrial revolution (after the mechanisation, mass production and digital revolutions), is certainly coming, but we’re far from finished with exploiting the current version, and the diminishing Australian manufacturing sector still has much life left in it, albeit not without changes. For example, the Australian uptake of robots is only marginally above the global average of 50 robots per 10,000 manufacturing workers (source: International Federation of Robotics). This figure is comparable with the UK, but ignoring the robot-rich automotive manufacturing sectors of South Korea, Japan and Germany (figures over 250), we are still well below other industrialised nations. Historically, robots are seen as a tool for the big boys with big budgets, but the global uptake of robots has provided the necessary scale, and the price of robots has fallen so far as to now be within the reach of even boutique manufacturers. With limitless gripper options, they can be less expensive than customised single-purpose machinery and provide the flexibility to perform multiple tasks. Further, the development of compact units, safe human interaction and assisted lifting mechanisms has extended the range of applications that small manufacturers can exploit. Unlike the disruption of replac-

ing a whole production line, robots can be introduced one cell at a time, so that the benefits of the first cell fund the next one. They enable a business to be rebuilt and transformed little by little - akin to the way the business originated. From the headlines, you might think governments don’t care about manufacturing. There are, however, a number of government grant and export trade programs at both state and federal levels that encourage innovation and diversification, and with the fast ROI that robots typically provide, a business could be literally transformed within 12 months. Small manufacturers in food, agriculture, fabrication and materials processing are removing bottlenecks, improving consistency, eliminating hazards and reducing costs with the adoption of robots for picking, placing, packing, lifting and welding operations. The gloom for Australian manufacturing is well documented - the very high returns, however, of the investment in robotics are not so prominent. Add to this the government support, speed of implementation and a payback often measured in months rather than years and the next wave of casualties could be avoided. In the ’70s, automation was accused of displacing workers. This fear didn’t materialise - 40 years later the unemployment rate is no worse despite significant population growth. More recently, robots have met the same opposition. The truth in both cases, however, is that they shift jobs but protect businesses, and the world has fallen in love with robots while Australia is still just flirting.

Mark Elrick is an Electrical Engineer with experience in the manufacturing, infrastructure, OEM, distribution and systems integration sectors. He consults in the area of industrial automation and networks with Integrated Automation.

Wahroonga NSW 2076 AUSTRALIA ph: +61 2 9487 2700 fx: +61 2 9489 1265 www.westwick-farrow.com.au Editor Glenn Johnson wnipt@westwick-farrow.com.au Chief Editor Janette Woodhouse Publisher Geoff Hird Art Director/Production Manager Julie Wright Art/Production Tanya Scarselletti, Odette Boulton, Colleen Sam Circulation Manager Sue Lavery circulation@westwick-farrow.com.au Copy Control Mitchie Mullins Advertising Sales National Sales Manager/NSW/QLD Nicola Fender-Fox ph: 0414 703 780 nfender-fox@westwick-farrow.com.au VIC/SA/WA - Lachlan Rainey ph: 0402 157 167 lrainey@westwick-farrow.com.au NZ - Mark Ryu ph: 0800 44 2529 mryu@westwick-farrow.com.au Asia - Lachlan Rainey ph: +61 (0) 402 157 167 lrainey@westwick-farrow.com.au Subscriptions For unregistered readers price on application. If you have any queries regarding our privacy policy please email privacy@westwick-farrow.com.au

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Printed and bound by Bluestar Print +61 2 9748 3411 Print Post Approved PP100007403 ISSN No. 0819-5447 All material published in this magazine is published in good faith and every care is taken to accurately relay information provided to us. Readers are advised by the publishers to ensure that all necessary safety devices and precautions are installed and safe working procedures adopted before the use of any equipment found or purchased through the information we provide. Further, all performance criteria was provided by the representative company concerned and any dispute should be referred to them. Information indicating that products are made in Australia or New Zealand is supplied by the source company. Westwick Farrow P/L does not quantify the amount of local content or the accuracy of the statement made by the source.

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