FREE CONFIGURATION SOFTWARE with thousands of ready-to-use objects
NEW! CM5 Series High-performance HMIs
The NEW C-more CM5 HMI series o ers low-cost, high-performance HMIs in sizes from 4 inches (only $340.00) to an impressive 22 inches (only $2,299.00) With an amazing 1.6 GHz processor in the larger units (10” and above) and 43 Mbytes of memory, these HMIs provide better trending, extra data storage, faster communication, improved le types, and 16.7 million screen/object color options.
All CM5 panels have serial and Ethernet ports (dual Ethernet ports on 10” or larger models) that support many of the most popular industry protocols, including EtherNet/IP, MQTT, and Modbus. The included USB ports provide in-an-instant connections for keyboards, barcode scanners, memory storage, etc. and the embedded SD-card slot provides easy project transfers or up to an additional 2TB of data storage (depending on model) for important log les.
Plus, all C-more HMIs come with FREE, powerful, easy-to-use programming software and FREE technical support!
NEW!
Priced at $793.00 (FMR10-CAQBMVCEVEE2)
The Endress+Hauser FMR10 series pulsed radar liquid level sensor provides accurate, reliable non-contact liquid level measurement. Featuring a compact footprint, it is easily commissioned with the SmartBlue Mobile App, which allows simple, safe, and secure wireless remote access via Bluetooth - even in places that are difficult to reach.
Temperature Switches/Sensors
Starting at $21.50 (THMJ-B02L06-01)
• Optris infrared pyrometers
• Temperature switches and transmitters
• Digital temperature switches/transmitters
Temperature switches and sensors provide accurate and reliable feedback for temperature control and monitoring applications.
• Thermocouples, RTDs, and thermowells
NEW! SOLO Modular Temperature Controllers
at $79.00
Controllers
Starting at $79.00 (SLM1-C)
SOLO modular temperature controllers feature a compact, snap-together design that allows users to add additional controllers as needed. Each controller can be configured a different control mode and output type, making it possible to tailor a system to the application’s specific requirements. Stack up to eight controllers for a compact multi-loop control system.
SOLO modular temperature controllers feature a compact, that allows users to add additional controllers as needed. Each controller can be with a different control mode and output type, it possible to tailor a system to the application’s specific requirements. Stack up to controllers for a compact control system.
Pressure Switches/Sensors
Starting at $87.00 (QPSL-AP-42)
Pressure switches and sensors measure pressure at a specific point in the process and transmit the measured value or trip point to a control device. at a point in the process and transmit the measured value or to a control device.
• Pressure switches and transmitters
• Digital pressure switches/transmitters
• Differential pressure transmitters
• Winters pressure accessories: siphons snubbers, and isolation needle valves
Flow Switches/Sensors
Starting at $73.00 (FG1W-100PP-28)
Flow measurement devices monitor liquid media and provide reliable flow indication, detection or measurement.
• Mechatronic flow switches and transmitters
• Magnetic-inductive flow meters
• Thermal and vortex flow sensors
• Variable area mechanical flow meters
17 | Automation Fair 2023: Future of industrial operations; Four advances in future automation technologies; Sustainability requirements; Weftec: Advanced gas monitors. ONLINE: SPS, Shows
Digital instrumentation improves liquid analysis and process control
21 | Think Again: What you need to know about AI, people, automation research
ANSWERS
22 | Digital instrumentation improves liquid analysis and process control
26 | Are you measuring sustainability with reliable sensors, analytical instruments?
27 | Can you avoid clean-in-place delays, risks with a new flowmeter design?
28 | WEBCAST Q&A: SCADA, HMI features and functions
31 | What your peers identified as hot topics in late 2023
32 | PLC standards for the new-ish millennium
34 | MTP standard accelerates DCS and PLC integration
ONLINE, read more: From the digital edition, click the following headlines or search at www.controleng.com
COVER: Some processes require precise instrumentation. In whey processing, pH measurement and control enhanced with digital capabilities, is critical to prevent damage. Courtesy: Endress+Hauser
and
INNOVATIONS
NOVEMBER/DECEMBER 2023
u Control Engineering eBook series, now available: Winter Edition
60 | New Products for Engineers – See products in this issue.
High-resolution 5.7-inch touchscreen; Capacitive proximity sensors; D-shaped, compact cylindrical reed sensor; Electronic flow control for compressed air; Entry-level edge AI computing modules; Compact magnetic encoder; 24-V power supply; VOC gas detectors; transfer switches; Ultra-compact Industrial PC; Two-in-one analyzer; Multi-touch resistive touch screens; Cased pumps
See more products in the New Products for Engineers Database. www.controleng.com/products
63 | Back to Basics, Control Engineering Europe: How digitalization, digital transformation strategies are evolving
NEWSLETTERS ONLINE
Digital Transformation
• Unlocking efficiency: How digitalization transformed petrochemical manufacturing Process Instrumentation & Sensors
• Digital transformation, AI powering process manufacturing changes
IIoT Process Control & Automation
• Connected worker platforms help automation companies thrive
Digital transformation is a hot buzzword in manufacturing today, but what does it mean for manufacturers and what effect will it have for the present and future? Learn more in this 57-page eBook.
Applied Automation
AppliedAutomation
eBook demonstrates how automation, instrumentation and control techniques are applied to increase capacity, enhance design and production, improve efficiency, increase profitability and meet regulatory requirements.
Learn more at: www.controleng.com/ebooks
u Control Engineering digital edition
Useful links to more info, photos: In the digital edition, click on headlines to see online version with more text and often more images and graphics. Download a PDF version.
www.controleng.com/ magazine
LAPP networking technologies are the lifelines of automation systems, reliably transmitting the power and data that enable the seamless interaction of machines, devices and plants.
Using our in-depth expertise, we design powerful communication solutions that enable the most reliable connections on the market— meeting your toughest industrial requirements and keeping production lines running.
lapp.com/us
Online Highlights
INSIGHTS
u Table of contents for Control Engineering November 2023
Gary Cohen, Industrial Cybersecurity Pulse: In the 12th episode of the Cybersecurity Awareness Month podcast series, Madison Horn, CEO of Critical Fault discusses proactive cybersecurity, quantum computing. www.industrialcybersecuritypulse.com/podcast/cyber-awareness-ep-12-madison-horn-on-proactive-cybersecurity
u Are you using the unified OT data layer to bridge IT and OT?
Stone Shi, Control Engineering China: Five data layer functions. www.controleng.com/articles/are-you-using-the-unified-ot-data-layer-to-bridge-thenatural-gap-between-it-and-ot
u Automation mergers, acquisitions, capital markets analysis: October 2023 (B)
Clint Bundy, The Bundy Group: 21 automation transactions were reported. www.controleng.com/articles/automation-mergers-acquisitions-capital-markets-analysis-october-2023
u WEBCAST: Advice on SCADA software selection and best practices
David Miller, Control Engineering: Northwind Technical Services’ Andreina Lugo and Applied Control Engineering’s Mike Lennon provide tips and a use case. www.controleng.com/webcasts/scada-series-advanced-scada-applications
ANSWERS
u Accelerate EV battery manufacturing by integrating servo motors, robotics (C)
Jeff Willis, Yaskawa America Inc.: Electric vehicles (EVs) require more efficient manufacturing to meet increased demands and use of robotics and servo motors can help. www.controleng.com/articles/accelerate-ev-battery-manufacturing-by-integrating-servo-motors-robotics
u Choosing between discrete, continuous position sensors for an application (D)
Scott Rosenberger, Balluff: Discrete and continuous position sensors offer many benefits. www.controleng.com/articles/choosing-between-discrete-continuous-position-sensors-for-an-application
u Project lifecycle process safety reviews
Judith Lesslie, CFSE, CSP, aeSolutions: Care should be taken in project lifecycles to ensure the project aims are met while ensuring that process safety is built into the project. www.controleng.com/articles/project-lifecycle-process-safety-reviews
INNOVATIONS
u PRODUCT OF THE YEAR: Submit through Dec. 29, 2023 (E) www.controleng.com/events-and-awards/product-of-the-year
How AIoT leads innovation in the intelligent device industry
Artificial intelligence of Things (AIoT) is emerging, and it will enhance intelligent manufacturing.
Stone Shi, Control Engineering China
Online controleng.com
KEYWORDS: AIoT, Industrial PCs
LEARNING OBJECTIVES
Learn how can end-users enhance the intelligence of production equipment.
Understand what technologies will support upgrades to the intelligent device industry.
ONLINE
More details with this article online. Also see: www.controleng.com/ articles/how-the-aiot-makesfactories-smart
CONSIDER THIS
How can the implementation of AI make your operation more intelligent?
The global manufacturing industry is undergoing a profound transformation, and digitalization, networking and intelligent manufacturing are driving the trend. As industry embarks on this journey, the intelligence of production equipment will be a prerequisite for achieving more intelligent manufacturing overall. How can end-users enhance the intelligence of their production equipment? What technologies will be relied on to support and lead the upgrades required by the intelligent device industry? How can traditional automation technology and emerging IT technology empower the intelligent device industry? Control Engineering China interviewed Chen Yongcheng, deputy general manager of Advantech (China) industrial IoT business group, to explain how the intelligent device industry is navigating these challenges.
AIoT, intelligent equipment
Effectively meeting the requirements of intelligent manufacturing requires that end-users start with their production equipment. Using intelligent devices, various terminal devices can be interconnected, achieving intelligent perception and communication among devices and laying a physical foundation for intelligent manufacturing. As end-users move toward an intelligent manufacturing model, Yongcheng believes that the artificial intelligence of Things (AIoT) will play a key role. AIoT refers to the combination of artificial intelligence (AI) and the Internet of Things (IoT). It is a new technological system that connects and integrates physical devices, sensors and IoT to achieve intelligent interaction and data sharing between devices. This enables objects to perceive the environment, obtain information, automatically perform tasks and enable intelligent interaction between humans and machines.
The implementation of AIoT relies on the support
of multiple key technologies, which build the foundation for device interconnection, data exchange and intelligent control. These technologies include embedded systems, sensing technology, communication technology, data processing and storage technology, IoT security, artificial intelligence, machine learning, visualization, interactive human-machine interfaces (HMI) and more.
Previously, devices emphasized their own control functionality and increasingly needed capacity for networking, perception and data analysis. Driving upgrades of the intelligent device industry through AIoT is an inherent requirement for equipment intelligence. Yongcheng said AI and IoT in AIoT are akin to the human brain and senses. The senses are used to collect information from the surroundings and transmit signals to the brain for processing. Through this process, the combination of AI and IoT in intelligent devices can achieve higher efficiency, strengthen data management and analysis, and improve interaction among humans and machines. AIoT will improve intelligent manufacturing.
In Yongcheng's view, AIoT is particularly important in emerging intelligent device segments such as semiconductors, lithium batteries, energy storage, photovoltaics, 3C electronic manufacturing, electric vehicles and vehicle-road collaboration.
Compared to traditional rack mounted industrial control computers and GPU graphics cards, the compact industrial edge AI platform can achieve a maximum power consumption of only 150 watts, and its efficiency can still reach 60% to 70% that of the traditional approach. This efficiency can meet the needs of on-board, AGV and intelligent devices. In the next three to five years, it could become a trend for industrial edge AI platforms with AIoT characteristics to replace traditional industrial control computers. ce
Stone Shi, executive editor-in-chief, Control Engineering China. Edited by David Miller, content manager, Control Engineering, CFE Media and Technology, dmiller@cfemedia.com.
Impact of WEG, Regal Rexnord acquisition on motor market
In late September, the world’s second-largest low voltage ac motor manufacturer, WEG, announced it would acquire the industrial electric motors and generators business from Regal Rexnord for $400 million. The acquisition includes most of Regal Rexnord’s industrial systems segment (Marathon, Cemp and Rotor brands).
While Regal Rexnord will continue to operate its commercial motor business, this move represents a significant divesture from the low voltage motor market by the company. WEG, a company that has expanded its share within the low voltage motor market in recent years, adds hundreds of millions in revenue to its motor business through one of the most significant acquisitions in the market in a decade. WEG will gain ~2,800 employees across 10 factories in seven countries: Canada, China, India, Italy, Mexico,
the Netherlands and the United States. In 2022, the estimated net operating revenue of the included businesses was $541million, with an adjusted EBITDA margin of 9.5%. The transaction is expected to close in firsthalf 2024.
WEG’s president, Harry Schmelzer Jr., said, “The geographical distribution of these operations complements WEG’s current presence and will help achieve greater scale and cost efficiency as we integrate the new operations with the existing ones. With a long history in the market and a global presence, this acquisition will support the ongoing growth of the WEG Group ... through the incorporation of recognized brands and a product line that complements the Group’s current portfolio.”
Since the merger of Regal Beloit and Rexnord in 2021, Regal Rexnord has strug-
gled to maintain its competitiveness in the low voltage motor market, losing market share each year since the announcement. To Regal’s competition, it quickly became clear that the new company was not interested in expanding industrial motors business and instead focused on building capabilities aligned with HVAC/R and material handling. This led to market share being taken by competitors. This underperformance is demonstrated by a sale price of just $400 million. This would represent the second major acquisition by WEG for a price under the annual revenue of the entity being acquired. In 2022, WEG acquired Gefran’s motion control business for a price half of the entity’s annual revenue. ce
Interact Analysis is a CFE Media and Technology content partner.
Components in industrial robots market forecasting strong growth
THE GLOBAL MARKET for key components used in industrial robots reached $12.1 billion in 2022, a year-on-year increase of 14.7%, driven by production of collaborative and SCARA robots. The components market growth will likely slow as the robot market matures and stabilizes. The industrial robots components market is expected to grow at a CAGR of 8.8% from 2022 to 2027. Key components in market size statistics include motors, servo drives, precision gearboxes, encoders and sensors, robot controllers, end effectors, machine vision hardware and teach pendants used in industrial robots and collaborative robots.
More collaborative, SCARA robots
Demand for collaborative robots in industrial applications increased rapidly in the past two years; momentum is expected to continue to 2027. Growth is fueled by collaborative robots ease of use and the increase in human-machine industrial prodution collaboration. The market for high-payload collaborative robots is growing faster, competing with traditional robots. Production of SCARA robots is expected to have the second highest CAGR among five robot types. Weak semiconductor and consumer electronics sectors since 2021 created negative SCARA robot pressure. Demand from the surging new energy industry (lithium-ion battery manufacturing and photovoltaics) provided an offset.
Production of collaborative robots and SCARA robots
Production of collaborative robots and SCARA robots grows fastest. Courtesy: Interact Analysis
Interact Analysis is a CFE Media and Technology content partner.
6 AI motion control applications to improve OEE
AI offer end-users the ability to analyze information collected from machines or manufacturing lines to optimize operational performance. Below, see six common motion control applications that can benefit from AI.
Use of artificial intelligence (AI) is becoming more common in industrial applications. The ability to collect information from a discrete machine or from a manufacturing line and use this information to optimize operational performance, efficiency and consistency can be extremely beneficial for manufacturing companies striving for higher overall equipment effectiveness (OEE). Used effectively, AI can be useful for unlocking the potential of manufacturing equipment. Automation companies have built functionality into products to allow the user to access information from the automation products and from the equipment they are automating. Information can diagnosing issues that result in downtime and unlock untapped machine output potential.
1: The amount of useful data that can be collected from modern motion control equipment is considerable. The table above outlines some examples. All images courtesy:
1. Motor temperature
Servo motor operating temperature variances can indicate changes in machine mechanics. Servo motors draw as much current as is required for the application. Increases in servo motor temperature (which relates to the current draw) usually can be attributed to worn mechanical transmission components. This information is captured by the system controller and can be used in a preventive maintenance program where mechanical components get lubricated or replaced when efficiency starts to drop.
2. Vibration detection
Some high-end servo products incorporate accel-
eration sensors into the control board of the servo motor’s encoder assembly. These types of sensors can detect vibrations seen at the motor during a normal machine cycle. The system controller can monitor changes in these vibrations over time and recommend corrective action that could be taken. FFT (Fast Fourier Transform) analyzers in the system controller can provide a visual representation of what frequencies are present in a given set of machine data. These FFT “fingerprints” for each machine axis can help identify specific changes in machine mechanics over time.
3. Move profile information
Each servo axis on a machine has a unique move profile that is programmed for each application. The
actual position of each servo axis can be tracked during its move profile and this data can be recorded at the time of machine commissioning. The actual position of each axis can then be tracked while the machine operates over time. When changes to the actual position of the axis during the move profile are detected, the system controller will identify specific differences (ie: overshoot, undershoot, higher deviation from commanded position, etc) and recommend
FIGURE 2: Normal operation.
FIGURE 3: Change in mechanics (loose coupling).
FIGURE
appropriate action that can be taken. Slight changes to load inertia can affect system tuning and could contribute to significant changes in performance during the move. This issue could be remedied with adjustment of servo tuning parameters and/or rectification of load inertia changes (ie: maybe there is a disturbance to the load being moved during operation).
4. Life monitors
Life monitors on critical wear components of automation equipment can be used to predict failures. Machine operation can be optimized by scheduling component replacement prior to a catastrophic failure that could halt manufacturing. Motion control components typically come with life monitors. Other sensors can be added to a motion control system and monitored by the system controller. With a good set of AI algorithms, the system controller can use the data and predict future failure of machine components or monitor machine performance.
5. Energy consumption
Electricity consumption monitors can highlight inefficiencies in individual machines or entire manufacturing lines. This information could be used to
adjust machine cycles to minimize overall electricity consumption or to maximize energy consumption at times when energy is less expensive.
6. System communication errors
Most sophisticated motion control systems allow for monitoring of low voltage supply power to each motor’s encoder. Spikes in this power supply due to system electrical noise can cause momentary loss of position data which can result in disturbances to the move profile. The system controller can detect when
electrical noise is introduced to the system and how this noise affects operation. This information can be used to troubleshoot and correct the issue so the machine can run smoothly. System controllers can detect errors and loss of packets from the determin-
istic network being used (Such as EtherCAT, Mechatrolink, etc). Consistent network errors and loss of information can cause a variety of issues with manufacturing equipment. The system controller data logging capability troubleshoot machine issues.
AI tools: Organize, communicate
Information availability is important, but having a set of tools that organize the information and suggest actions for improvement can be just as important. Some automation vendors have created customizable toolboxes that display the types of information described and for statistics related to the efficiency and performance of the machine or manufacturing line. These toolboxes typically can be viewed on the piece of equipment’s human-machine interface (HMI) or from anywhere via a secure internet connection.
Tools such as this can be used for visualizing the operations of one machine, a manufacturing line or a factory. They can provide asset management information, predictive maintenance schedules, alarm forwarding and data management. They can exchange communications with external systems through OPCUA or other protocols. The tools are customizable. ce
Scott Carlberg, product marketing manager, Yaskawa. Edited by David Miller, content manager, Control Engineering, CFE Media and Technology, dmiller@cfemedia.com.
controleng.com
Keywords: AI, Motion Control
Learning Objectives
Understand how AI can be used to optimize operational performance, efficiency and consistency for discrete pieces of equipment and manufacturing lines. Discover six specific AI motion control applications. Learn how AI toolboxes that organize and display data can suggest actionable decisions to end-users. ONLINE www.controleng.com/ ai-machine-learning CONSIDER THIS What other metrics could AI be used to analyze?
FIGURE 4: Life monitor display from Yaskawa SigmaWin+ software.
FIGURE 5: Electricity consumption monitors display from Yaskawa SigmaWin+ software.
SPS 2023 PREVIEW:
Open automation platform applications
Expanded drive and servo motor lines, greater interest open automation, and discussion of a new modular, distributed motion control platform were included in an SPS 2023 preview.
TFIGURE 1: Cable space savings results with one-cable technology used in this 40-axes motion control application, demonstrating the Bosch Rexroth ctrlX Automation system. Images courtesy: Mark T. Hoske, Control Engineering
he Bosch Rexroth ctrlX Automation platform is the most open automation system, according to Dave Cameron, director of sales, automation and electrification solutions, Bosch Rexroth Corp. USA. Cameron explained expanded platform offerings, including drives and controls and software applications in the style of smartphone apps. Cameron and other automation platform experts provided media with a preview at the Hoffman Estate, Illinois, headquarters, Nov. 1 for products to be introduced at the SPS-Smart Production Solutions 2023 show in Nuremberg, Germany, Nov. 14 to 16.
Similar to a smartphone app store, ctrlX platform can expand as developers and Bosch Rexroth add capabilities to the xtrlX OS platform. As of Nov. 1, 27 additional developers are working on applications during 2023 with more than 90 developers now in 16 categories. More than 75 apps are available in the ctrlX Store as of Nov. 13; use cases exceed 150. More than 1,500 customers have purchased ctlX Automation in some way.
The Bosch Rexroth facility in Lohr, Germany, is tripling site capacity of its automated warehouse powered by ctrlX Automation with 2024 completion expected. Brnik, Slovenia, a new Bosch Rexroth ctrlX Automation servo motor production plant also is expected to be fully operational in 2024.
The ctrlX Automation offerings include motion controls, human-machine interfaces (HMIs), industrial PCs, safety I/O (input/output) devices, control platform, motors and motion controls, programmable logic controllers (PLCs), industrial Internet of Things, engineering software, operating system and services.
Part of the open functionality is that the ctrlX OS is hardware independent, industrial, based on Linux, has an app store with apps from many devel-
opers and includes services and a software development kit (SDK), Cameron said. Those using ctrlX as an embedded control system in their offerings include Dell, Nokia and Wago.
Drive line expansion
The ctrlX Drives expansion was explained by Joaquin Ocampo, drive product manager, Bosch Rexroth. The drives can be arranged in line, star or in groups. They can be air or liquid cooled. Single and double axis are available from 6 Amps to 54 Amps. The cabinet-free design (third generation in 15 years, with no air conditioning needed for heat dissipation) allows placement of the drives outside control cabinets (with IP65 rating), in smaller spaces, with easier cable management using 1 cable instead of 9 for 9 axes. Setup is faster and shipping is lower costs and easier, Ocampo said. It offers multiple Ethernet communications in the same device, multiple encoder and motor capabilities (synchronous, asynchrony, torque, highspeed, linear, rotary), I/O, safety and other functions.
Compact servos are available in the 0.05 kW to 1.5 kW voltage range, in three housing sizes. The low-voltage servo drive 24 V/48V slice I/O connections can be placed next to the drives. [Lower voltages mean that if they are located separate from higher voltage devices, no personal protective equipment (PPE) is required for access.]
Controls, software, easier use
Using and upgrading capabilities of ctrlX Controls and ctrlX Software is easier because of the app-store concept, noted Ed Polzin, product manager for controls hardware, Bosch Rexroth.
The ctrlX x3 low-range and x7 high-range controllers are available now, and the x5 ctrlX midrange controller will be available in 2024. All are modular with different processing capabilities, and all have multi-Ethernet capabilities without add-on communications cards or modules.
A new solid-state ctrlX controller drive is available for added storage.
FIGURE 2: Joaquin Ocampo, drive product manager, Bosch Rexroth, explains the drive line expansion in the ctrlX Automation platform.
The Hailo module for vision/AI includes algorithms to help machine vision systems learn more quickly with easier “teaching.” Mike Mueller, production management leader, factory automation, automation and electrification, Bosch Rexroth, said partners offer bin picking and other expanded capabilities.
Polzin said 22 new I/O modules are being added for a total of 50 I/O slices. Capabilities include analog and encoder feedback, compact safety controls and more I/O safety, among others. OPC UA Pub/ Sub is included for controls-to-controls communications over TSN. The ctrlX system is said to be hardware agnostic, and software can be updated without connecting an external PC by using a plugin card for machine-to-machine commissioning.
Hardware, software and engineering services partners number more than 90. Because apps are containerized (think app store), Mueller said, connectivity and adding functionality is easier, with less work to integrate and no to low code. Variables are set through a drop box; code doesn’t have to be run through a programmable logic controller (PLC).
Polzin said programming environment translation from existing CoDeSys is easy (perhaps 95%), though vendor-specific code libraries functions may require more attention. He noted it may be more efficient in the long run to abandon older code and use capabilities of the modern ctrlX platform.
An application validation team adds quality. Apps include cycle time optimization, throughput, energy optimization, vision, connectivity, safety, data harmonization, overall equipment effectiveness (OEE), manufacturing execution system (MES) integration and human-machine interface (HMI). Robotics solutions include Fanuc, Kassow Robots, Kuka with iiQKA and Robotic Republic. Seven partner solutions for robotics are available for download from the ctrlX Store, including sim-
ple programming and the integration of cobots and industrial robots and software for planning optimum palletizing algorithms.
Modular, distributed motion controls
For motion controls, Bosch Rexroth ctrlX Flow Smart Conveyance includes planar levitation technology with round disks as well as track-based systems offering high-speed linear motion. Powered by ctrlX Automation, the ctrlXFlowHS flexible topology tracks have embedded linear motors and sensors to minimize friction and maximum performance with in an integrated (cabinet free), modular design. Shuttles avoid collisions with precise positioning and can add functionality with third-party apps from the ctrlX Automation app store. Each carrier has 2.5 kg capacity and double configuration can be used for maximum 5 kg combined payload. A prototype will be shown at SPS; product is expected to be available in 2024.
Straight and curved segments and switches can be combined as necessary to create specific topologies, lengths and routes. With acceleration of up to 10 G and a speed of 5 m/s, the system allows quick movements. Compared to other solutions, the system has smaller movers and a product spacing reduced by 20% to just 40 millimeters. ce
Mark T. Hoske is content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com.
controleng.com
KEYWORDS: Automation, control systems, motion controls
LEARNING OBJECTIVES
Understand how more drive and servo motor products will be available next year. Learn how interest in the Bosch Rexroth ctrlX controls, software is growing. Explore capabilities of a new the modular motion control platform.
CONSIDER THIS
Would a more open automation and control system help?
ONLINE
See a Dave Cameron video, “App-based control system targets usability.” https://www.controleng.com/ articles/app-based-controlsystem-targets-usabilityexpert-interview-series-davecameron-bosch-rexroth/ Also see:
FIGURE 3: Smart energy control application using Bosch Rexroth ctrlX Automation was demonstrated in a press event Nov. 1, previewing SPS 2023 announcements. The demo includes a battery, ac to dc and dc to ac power conversion and energy monitoring.
Electrostatic motor: less copper, no magnets, ultra-efficiency
Demonstration models show enormous motor energy savings without magnets, using 90% less copper for the C-Motive ultra-high-efficiency, electrostatic motor, as shown at Automation Fair event by Rockwell Automation. See short video.
Most motors use magnets and a lot of copper; the C-Motive motor uses electrostatic principles instead in a motor design that uses 90% less copper promises 20 to 50 Nm torque at 0 to 300 RPM without permanent magnets, gearbox or pulleys, as demonstrated at the Automation Fair 2023 event by Rockwell Automation.
OF THREE MOTORS in the Automation Fair 2023
C-Motive demonstration, the electrostatic motor on the right wastes almost no energy in heat, uses 90% less copper and runs without magnets. Courtesy: Mark T. Hoske, Control Engineering
large region in Asia is responsible for a majority of copper, electrical steel and permanent magnets, used for traditional motor designs.
Design demonstrated: Automation Fair
Online controleng.com
KEYWORDS: High-efficiency motor design
LEARNING OBJECTIVES
Understand differences and energy savings in an electrostatic motor design comparted to traditional motors.
Learn how electrostatic motors use 90% less copper and tout 98% efficiency in most applications, compared to 84% for standard efficiency motor designs.
CONSIDER THIS
How would you apply a more efficient direct-drive motor?
ONLINE
Read more about motors and drives from Control Engineering.
https://www.controleng. com/motors-drives/
The low-speed, high-torque electrostatic motor design is said to have efficiency of greater than 98% in most applications, the company said; each 1 hp electrostatic motor saves approximately 2 metric tons of CO2 annually. [For comparison, a standard efficiency motor may be around 84% efficiency; an advanced design premium efficiency motor design can exceed 90% efficiency.] In a short video, Matt Maroon, chief executive officer, C-Motive, explains more about electrostatic motor design and benefits.
Design elements, benefits
The C-Motive motor uses voltage, printed circuit board plates and a proprietary dielectric fluid to create motive force, whereas a traditional motor uses more voltage, permanent magnets and a lot of copper or copper-wire windings to create rotating or linear force. In addition, electrostatic motors operate in audible silence, have extremely low torque ripple and run comparatively cool under load, requiring no active cooling and have much lower power draw (<0.2% full power) for zero speed holds, compared to traditional motor designs.
The electrostatic motor design may provide sustainability and supply chain benefits with copper demand expected to double by 2035 along with widely variable copper prices in world markets. A
In the Automation Fair demonstration, three motors pumped fluid at the same speed and flow rate to compare heat generated by the electrostatic design to permanent magnet motor and induction motor. The thermal imaging shows little heat generated by the electrostatic design and considerable heat (and efficiency losses) from the other motion system designs operating at 60% to 65% efficiency. C-Motive information said, “Electrostatic motors are significantly more efficient, require no added gearbox and generate less heat than motors that use magnetism.” Electrostatic motors run cooler and are said to perform especially well in “direct-drive, low-speed, hightorque applications.” It can operate fully submerged and is said to be able to scale to multi-megawatt size using the same design principles.
C-Motive, headquartered in Middleton, Wisconsin (near Madison), derived from research at University of Wisconsin-Madison about 10 years ago, has a team of 20 experts with experience that includes power electronics, chemistry and mechanical design. C-Motive, a venture-backed startup company, owns around 50 patents and applications, U.S. and international and is said to use a U.S.-based materials supply chain. The company seeks partners for demonstration opportunities and for industrial integration. ce
Mark T. Hoske is content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com.
How artificial intelligence may change cybersecurity, policy
The ISA Leadership conference: Generative AI, cybersecurity
While risk protection and industrial process optimization are among the benefits of artificial intelligence (AI), hackers also are using AI in cybersecurity attacks. These were among topics discussed at the International Society of Automation Leadership Conference was help in Colorado Springs, Oct. 3-7. The conference featured digital transformation, cybersecurity and career skills tracks to its attendees.
A keynote speaker, Mark Weatherford, spoke about how local and federal policies on cybersecurity and AI may impact security professionals and how they can prepare themselves for industry changes.
Weatherford has over 40 years’ experience working with in the public and private sector on information security. Beginning as a cryptologic officer for the U.S. Navy, he has most recently worked as the chief strategic officer for the National Cybersecurity Center.
Benefits, risks for industrial use?
Weatherford discussed the value and risk associated with generative artificial intelligence (AI) for industrial cybersecurity. He cited better risk prediction, easier monitoring and optimization industrial processes, increased automation of security tasks and the ability to analyze large volumes of data to detect patterns and prevent attacks as primary AI advantages. Generative AI also can be used as a tool helping hackers and cyber criminals. With obvious examples like deepfakes and synthetic media, generative AI creates a risk of more sophisticated adversarial attacks. As labor shortages continue in many positions in many industries, AI’s ability to work faster and more accurately than people for some applications may mean that certain jobs will be outsourced to AI.
“Businesses aren’t benevolent so if they can replace you with something cheaper and faster, they will,” Weatherford said. “If you’re sitting back and watching it happen passively, you’ll be left by the wayside.”
Workers will need to understand how to become an expert in using AI by asking the right questions,
generating useful reports out of mountains of data and helping companies apply AI effectively and safely. As companies and individuals become more aware of the power and danger of AI, it has become a big talking point in the government as well.
Four-day reporting SEC rule
Throughout his career in the public and private sectors, Weatherford has met with federal and local officials to educate them and begin to unpack the question of what the government’s role is in cybersecurity. Officials have begun to create new policy for cyber-attacks. A recent Security and Exchange Commission rule mandates reporting of a cyber account within four days of occurrence.
This rule is controversial within the cybersecurity industry because, while it represents government care, it also creates what Weatherford called time-consuming red tape for companies of all sizes. Weatherford cited a recent Clorox incident on Aug. 14. The initial report was issued that day, but updates were released every two to three days, until Sept. 18. Frequent reporting took time and resources away from resolving immediate details about the issue.
Much like the career issues that individuals may face, the policy issues can be addressed by more education and discussion between officials and experts. Weatherford urged the audience to speak up and connect with their C-suite and government officials. Weatherford said AI will restructure the workplace and cybersecurity. T o create safeguards and prevent attacks, cybersecurity professionals are responsible for understanding how to use and protect against new technologies. They also should make themselves available to officials and executives to ensure that public and private policies are as strong and helpful as possible, he suggested. ce
Anna Steingruber is associate editor, CFE Media and Technology, asteinbruber@cfemedia.com.
RECENT International Society of Automation Leadership Conference keynote noted the following benefits to AI applications for industrial use. Courtesy: Control Engineering with information from the 2023 ISA Leadership Conference
u
Online controleng.com
See Control Engineering cybersecurity topical page: https://www.controleng.com/ system-integration/cybersecurity See more from the CFE Media and Technology publication, Industrial Cybersecurity Pulse. https://www. industrialcybersecuritypulse.com
How to improve automation: What system integrators find in plant walk-throughs
System integrators discuss how to automate and the things system integrators look for and find during plant or facility walk throughs. It’s often during initial automation project design discussions when the most savings can be identified for the least cost. What don’t you know?
AWEBCAST PRESENTERS
PRESENTERS for the Dec. 12 webcast, “Automation Series: What system integrators look for in a plant walk-through” are Jeff W. Buck, PE, CMSE, vice president of engineering, Automation NTH, and Eric Sahakian, senior industrial programmer, Vertech. Courtesy: Control Engineering for the 12 “Automation
KEYWORDS: System integrators, automation system integration savings
LEARNING OBJECTIVES
Explore what system integrators look for in a plant walk through. Meet and ask questions of the system integrators teaching the course on system integrator walk-throughs.
CONSIDER THIS
Are you sure you’re taking advantage of the most practical plant automation opportunities?
ONLINE
Register for the webcast, archived for a year, here. www.controleng.com/ webcasts/automationseries-what-systemintegrators-look-for-in-aplant-walk-through Online controleng.com u
common cliché in automation and controls is to pick the low-hanging fruit first, meaning automate the easiest and most accessible applications as the first step. A Dec. 12 Control Engineering webcast, “What system integrators look for in a plant walk-through,” aims to answer the following questions. Are you able to really see what may be done in an application that’s ripe for automation? Does the team need a fresh set of eyes to see old processes anew?
System integrators discuss how to automate and the things system integrators look for and find during plant or facility walk throughs. It’s often during initial automation project design discussions when the most savings can be identified for the least cost.
Find improvements in a walk through
In the webcast, the following are learning objectives. Experts aim to:
• Examine how, with the rate of technology advances, opportunities for automation advancement have changed in recent years.
• Understand what control system integrators look for when they do a plant for facility walk through, seeking automation opportunities for potential clients.
• Review why system integrator expertise (coupled with plant-specific domain expertise) can add value in the design and planning phase of any project.
• Learn best practices for identifying automation projects that can deliver high return on investment.
Presenters in the webcast are:
Jeff W. Buck, PE, CMSE, vice president of engineering, Automation NTH, www.automationnth.com, leads the engineering team at Automation NTH and is responsible for recruiting and developing engineers, resourcing projects and providing technical leadership to projects. He is a registered professional engineer in Tennessee and Certified Machine Safety Expert, and he created and leads “NTH University,” the company’s training program for engineers. Buck graduated with a M.S. in Mechanical Engineering, Automation and Robotics and a B.S. in Mechanical Engineering. Eric Sahakian, senior industrial programmer, Vertech, www.vertech.com, has a B.S. in Mechanical Engineering from Arizona State. He has focused on solid system function and user experience (UX), building long-term Ignition and enterprise solutions for dozens of clients over the past nine years. His comprehensive and custom manufacturing executive systems (MES) and supervisory control and data acquisition (SCADA) systems for Four Roses Bourbon provided full production tracking and overall equipment effectiveness (OEE) functionality. Those listening live have the opportunity to earn a PDH credit. The webcast includes an audience poll question and a question-and-answer session. ce
Mark T. Hoske is content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com.
Automation Fair 2023: Building the future of industrial operations
uRockwell Automation’s 32nd Automation Fair in Boston is focused on highlighting the future of industrial manufacturing operations and helping people what the future can and should be. The theme, “Discover what’s possible,” was emphasized in many forms throughout the keynote on Wednesday. Blake Moret, chairman and CEO of Rockwell Automation, said of the event, “We’ve grown in attendance, the number of exhibitors and the breadth of what we’re offering. But always at its core, Automation Fair, has been a training event.”
Training and learning and collaboration, Moret said, is key to the future. “Even with all the capabilities Rockwell has, we can’t do it alone. We have partners every step of the way. That ecosystem is what sets us apart,” he said.
Moret said future success is about connecting the imaginations of people with the potential of technology. “We want to combine the technology and expertise to create outcomes to help customers be more resilient, agile and sustainable,” he said.
That resiliency and strength isn’t just about technology, Moret said. The future of industrial operations depends on empowering people on the plant floor.
“We want to drive efficient upskilling and provide support to your frontline.... A winning hand is having enabled, energized people who are comfortable interacting with the technology that gives them superpowers. It’s so important, especially when you are dealing with workforce shortage critical to project completion. When you have scarce resources, making them comfortable and successful is the difference between a successful and unsuccessful project.”
Sustainability, digital twins
Sustainability is many things to many companies. For Moret, he described sustain-
ability as, “Being more an efficient steward of the inputs you have. Limit the amount of energy, water and other resources.”
Sustainability is about speeding production and capacity and expansion and doing it with the same set of tools used for the control systems and tying everything together efficiently. Using digital twins and digital transformation is tied into sustainability, Moret said, by allowing companies to simulate what will happen without wasting physical materials in trial and error.
“We can use digital twins to simulate processes and commissioning and model those operations and gamify potential changes to the layout. We’re able to move faster to debottleneck and improve capacity,” he said. Tying sustainability and digital twins can help accelerate the speed to market as well as give manufacturers and their customers the ability to respond to market.
Generative AI, manufacturing
Judson Althoff, CCO, Microsoft, talked with Moret about artificial intelligence’s (AI) role in manufacturing and the impact it’ll have. He said AI was considered a novelty in late 2022. During the rise of OpenAI’s ChatGPT in early 2023, excitement mixed
with fear about what AI could do and what it would mean for jobs.
“Today,” Althoff said, “companies have 100 big ideas of what they can do with generative AI, and it’s an education process. Generative AI has the potential to impact many ways people learn. We can accelerate learning curves and make it more inclusive. We’re also using generative AI to build generative AI capabilities, which gives us a time-to-market advantage.”
Generative AI can produce various types of content, including text, imagery, audio and synthetic data. This is not a new technology, but the rise of machine learning (ML) algorithms that are more responsive and human-like in their thought processes, combined with developing technology, has made generative AI a major potential force in manufacturing. AI is becoming more commonplace in manufacturing and can enhance workers’ jobs and bring them greater joy, Althoff said, because their tasks are more rewarding and less manual. Generative AI can allow them to do their jobs better, and it’ll get to the point where workers will not want to be at companies that do things the old way. Another key to helping people accept AI as part of their jobs, Althoff said, is the power of the prompt. “Frontline workers hold such a golden wealth of expertise on how things actually get done. You see how things really get done. There’s a complexity into frontline workers to make their work more efficient.” Generative AI can help by helping workers troubleshoot on the spot with easy prompts. “Everyone should be thinking how AI changes employees, customer interaction business processes and bend the curve on innovation.” ce
Chris Vavra, web content manager, CFE Media and Technology, cvavra@cfemedia.com.
Judson Althoff (left), CCO of Microsoft, discuss manufacturing trends and themes with Blake Moret, chairman and CEO of Rockwell Automation. Courtesy: Chris Vavra, Control Engineering
Four advances in future automation technologies for industries
uExpanding human possibility is how we should look at innovative technology applications for industrial use, explained Cyril Perducat, Rockwell Automation senior vice president and chief technology officer in the Nov. 9 keynote presentation at Automation Fair, by Rockwell Automation. Every technology consideration needs to start with people, he suggested. When talking about artificial intelligence (AI) or robots or other automation, Perducat said, it’s not about removing people, but using technologies to help people do their jobs. It’s not just about technologies, but creating the right experiences with technologies. There’s no way to invent the future without involving people and making technology usable.
“You always want to start with people,” Perducat said. “It’s about expanding human possibility and never about removing people from the equation.”
Now versus the future
Changing demands, such as evolving a medicine to help a specific human, or other product designs intended for a specific set of functions, are changing how innovative automation is applied, Perducat said. The world is changing to meet supply chain demands, resource and sustainability needs, resiliency requirements, as well as people and workforce considerations.
1. Supply chain volatility. For the past few years there’s more demand to deliver the right product at the right time for the right person for the correct application. Customers want speed and agility to quickly change setup. Flexible machines that enable fast changeovers are moving to reconfigurable manufacturing systems that simplify updates. Digital twins for machine
logic controllers and data analysis to optimize production and resources.
3. Industrial resiliency. Supply chain optimization moving to adaptive supply chains and integrated ecosystems. Users can identify, protect, detect, respond and recover. They are moving to a zero-trust architecture with threat detection. Cybersecurity needs to increase interconnections and lower risk of cyber intrusions.
and line design are moving to digital product lifecycle integration enabling constant evolution. Digital elements will be renewed and optimized with an understanding of relationships of connected data. Machine, robots and people can coexist to improve solutions.
2. Resources and sustainability for industry. Renewable energy sources are moving to full integration of renewable energy, carbon capture and viable energy models. Now we have machine learning and analytics, moving to modern AI for closedloop optimization. People need to analyze and oversee. “If you have a manual step in the process, you lose visibility,” Perducat said. “Integrating material movement is not just about removing that task from people, but it’s about improving the overall transparency and visibility." AI gives a person opportunity to focus on most difficult business cases. Using signals from drives to provide information not previously possible creating multi-dimensional closed-loop scenario. AI integrates with automation, programmable
4. Automation interaction with and support for people. Predictive maintenance systems moving to a natural language interrogation of systems. Users are enabled by having a co-pilot in design tools moving to AI-enabled code sharing and verification. Companies have automated mobile robots and intelligent conveyance moving to robots for all material movements.
“How do we really help people with the right technology and experience so they can do extraordinary things?” Perducat said. If done successfully, he said, it will help make manufacturing more attractive to a more diverse workforce.
AI changing the way we work
Nicholas Thompson, CEO of The Atlantic, discussed more about AI and how it will and is changing the way people work, interact and behave as machines are showing greater capabilities. “There is a moment of exponential growth where things take off and become crazy. I think we’re at that point,” Thompson said. An ideal world creates spheres of humanness and AI-ness to bring out the best in the other. ce
Mark T. Hoske is content manager, Control Engineering, mhoske@cfemedia.com; Chris Vavra, web content manager, CFE Media and Technology, cvavra@cfemedia.com.
The world is changing to meet supply chain demands, resource and sustainability needs, resiliency requirements, as well as people and workforce considerations, explained Cyril Perducat, Rockwell Automation senior vice president and chief technology officer, at Automation Fair 2023 by Rockwell Automation. Courtesy: Chris Vavra, Control Engineering
Advanced gas monitors signal technological change is in the air at Weftec 2023
GAS MONITORS are crucial safety devices in industries such as chemical manufacturing, oil and gas, mining and wastewater treatment. Used to detect the presence of potentially harmful or toxic gases in the environment, gas monitors play a vital role in ensuring the safety of workers, preventing accidents and easing the process of compliance with various codes and regulations. Moreover, as with many other field instruments and industrial devices, new trends such as remote access, intelligent sensors and cloud integration continue to shape their development. At Weftec 2023, MSA Safety exhibited its Ultima X5000 gas monitor, which capitalizes on several of these technologies.
Remote access: Through the use of Bluetooth wireless technology and MSA Safety’s X/S Connect app, end-users’ mobile phones can be used as human machine interface (HMI) screens to check gas monitor statuses, receive alerts, modify setpoints and alarms, initiate and monitor sensor calibrations, and reduce overall setup time. According to Angela Sauceda, marketing communications manager at MSA Safety, remote access through the X/S Connect app can allow for easier interaction with gas monitors that are mounted on ceilings or in hard-to-reach places.
LED display: Building from technology absorbed through MSA Safety’s acquisition of General Monitors, the company’s gas monitors also feature large, bright LED screens that display instrument status indicators such as power, fault and alarm notifications. The screens aim to help operators identify status changes at a glance more easily, even if they are doing so from a distance, Sauceda says.
Self-calibrating, intelligent sensors: The X5000 also features dual sensor technology that allows it to monitor two different types of gas at once. In addition, the product uses a process called diffusion supervision to warn users if a sensor has become blocked and is unable to detect gas. Using an on-board acoustic microphone and software algorithms, the sensors can measure the amount of sound moving across the surface of their inlet. If a sensor is blocked by a material such as ice or dirt, the microphone is able to detect a difference in sound and alert users that accurate gas detection is being obstructed. MSA Safety also exhibited its Sentry IO controller, which enables seamless integration with the company’s other products by pre-populating the details of HART-enabled gas and flame detectors.
David
Miller is Control Engineering content manager.
Click headlines in digital edition to see more online. See page 7 for more.
Coverage online includes the LNS IX2023 The Industrial Transformation Event from LNS Research and announcements from ODVA and Siemens at SPS-Smart Production Solutions 2023 and more from Automation Fair 2023.
Safety standard for industrial mobile robot systems and applications available: A3 www.controleng.com/articles/safety-standard-for-industrial-mobile-robot-systems-and-applications-available SHOWS, CONFERENCES
Jan. 15-17, A3 Business Forum, Orlando, www.automate.org/events/a3-business-forum-2024
April 15-19 , CSIA Executive Conference, Dallas, www.controlsys.org/events
April 22-26, Hannover Messe, Hannover, Germany, www.hannovermesse.de/en
May 6-9, Automate by A3, Chicago, www.automateshow.com
INSIGHTS
Sustainability efforts require measuring and control tools, system integration
uMaturity level is often applied in technology adoption applications, and four energy readiness maturity levels were offered to manufacturers and facility engineers Nov. 8, at Automation Fair 2023 by Rockwell Automation in the session “Discovering what’s possible: Calculating your energy readiness for net zero.”
Sinethemba Zulu, sustainability technology architect, Rockwell Automation, and Alex West, senior principal analyst, Omdia, discussed measurements and tools, challenges and successes related to industrial sustainability efforts.
Automation manages energy
They cited many motivators for energy management related to the energy “trilemma” of cost, security and sustainability. An industrial power outage can cost millions of dollars per hour, depending on the application, proven by recent climate concerns linked to wildfire expansion of intensity and frequency, and by rolling blackouts required to maintain grid balance during extreme weather events. Industries need regular, reliable access to energy.
Zulu said common challenges customers mention about sustainability efforts include regulatory reporting and compliance; achieving net zero and environment, social and governance (ESG) criteria; water stewardship; and material efficiency and circularity. He added that energy accounts for at least 5% of an average manufacturing company’s cost, and energy saving measures could save 10% to 30% of energy costs. Rockwell Automation products and service brands that can help include Allen-Bradley, FactoryTalk, Lifecycle IQ Services, Maverick Technologies, Kalypso, Fiix and Plex, Zulu said. West, citing research on energy, ESG and the economy, said 39% of compa-
In mid-2024, a Rockwell Automation-Fork Farms partnership will grow produce at the Rockwell Automation headquarters in Milwaukee, said Sinethemba Zulu, sustainability technology architect, Rockwell Automation at Automation Fair 2024. Courtesy: Brian Gross, CFE Media and Technology
nies have energy accounting for greater than 15% of their costs and 69% of energy reduction efforts are strongly influenced by ESG efforts and goals. Significantly, a year after setting sustainability targets, more companies are behind than ahead on emissions targets and transitions to renewable energy sources.
Cost, security, sustainability
An upgraded energy management calculator was mentioned as a resource.
Looking at maturity level of industrial sustainability efforts, 7% are in stage 1, where they use energy management software (EMS) but are not integrated; 21% are in stage 2, where they’re evaluating EMS integration, 51% are in state 3 with partially integrated EMS; and 21% are in stage 4 with EMS fully integrated with other plant or factory software tools.
West said data has to be refined into information to make effective decisions.
Looking at energy management maturity, devices and metering are most basic, followed by collaboration, EMS integration, data collection and use, energy audits and process optimization at best. By 2025 many companies will need to report and demonstrate progress toward targets and tools such as machine learning and analytics and advanced process control solutions can help.
There’s a shortage of green skills sets, required to help, including auditing and monitoring, reporting, lifecycle assessment, regulatory compliance, operational improvement and energy management.
Energy and emission savings potential for industrial sustainability
Zulu said in water and wastewater industry the Eastern municipal water district (EMWD) cited 2,200 kWh savings per day. Less energy use and less chemical use totaled more than $100,000 savings per month. AI used machine learning to adjust proportional-integral-derivative (PID) coefficients and improve dissolved output (DO) setpoint tracking.
In a Sibanye Stillwater mining ventilation application, Energy Drive Co. installed optimized variable-speed drives (VSD) to optimize fans. Previously, the application ran one fan at a time. With VSDs applied, both fans could operate at the same (lower) flow rate with greater energy efficiency. Energy saved in first shaft was 62% with 48% saved in the second with 379,000 tons of annual carbon savings.
In a tour of the Automation Fair sustainability booth, Zulu said a new vertical farming partnership installation at the corporate Rockwell Automation office in Milwaukee (ClockTower Farms) is expected to grow 150 tons of produce a year. ce
Mark T. Hoske is content manager, Control Engineering, mhoske@cfemedia.com.
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Mark T. Hoske, Control Engineering
What you need to know about AI, people, automation
Nervous about artificial intelligence? Here’s what I’ve heard lately about AI, including at Automation Fair.
How’s artificial intelligence changing how people integrate industrial automation and controls in manufacturing automation? It’s another tool to help people more quickly and effectively automate, optimize operations and solve big challenges, such as meeting sustainability targets. Will what I’ve heard lately below help you think again about how you’re integrating AI into manufacturing operations and other automation applications?
AI in industrial automation
Future success is about connecting the imaginations of people with the potential of technology, according to Blake Moret, chairman and CEO of Rockwell Automation. “We want to combine the technology and expertise to create outcomes to help customers be more resilient, agile and sustainable,” he said. Cyril Perducat, Rockwell Automation senior vice president and chief technology officer, explained that it’s not just about technologies, but creating the right experiences with technologies. There’s no way to invent the future without involving people and making technology usable. The world is changing to meet supply chain demands, resource and sustainability needs, resiliency requirements, as well as people and workforce considerations, he said.
Generative AI helps
While AI dates back to the 1950s, new applications are emerging daily. An Automation Fair session called, “Harnessing AI for automation system design and troubleshooting,” Rockwell Automation said it is beta testing generative AI (spoken-word instructions) to generate sample code in the next version of Rockwell Automation’s FactoryTalk Design Studio. Citing cus-
tomer security concerns, the AI prompts from customers will not be used to train the model. The AI feature is expected to be included in an upcoming version of the software at no extra cost, said Adam Gregory, platform manager, and Tony Carrara, business manager, both for FactoryTalk Design Studio, Rockwell Automation. Nick Kwiecien, data and AI cloud senior solution architect manufacturing for Microsoft, affirmed the value of generative AI integration, saying that when Microsoft used AI in its GitHub Copilot, 88% of developers using it reported faster code was completion, 87% spent less mental effort on repetitive tasks and 60% said they were more fulfilled in their jobs.
Why AI is important
As Control Engineering noted in October, citing its own “Artificial Intelligence in Industrial Automation” research, “When asked what factors are considered when deciding whether or not to implement AI-based automation solutions in industrial processes, the leading responses were: Operational efficiency gains; cost and return on investment (ROI); and availability and quality of data. Other important factors (about half or more of respondents also checked off) technological infrastructure as well as workforce impact and skill requirements.”
How are you applying AI to help automation, controls and instrumentation implementations? ce
See other Automation Fair coverage at www. controleng.com and in this issue.
See more on industrial AI and machine learning from Control Engineering.
https://www.controleng.com/ai-machine-learning
Thomas Chirdo, Endress+Hauser
Digital instrumentation improves liquid analysis and process control
Modern instruments employ advanced digital technology to enhance accuracy, reliability, and ease of use in liquid analysis applications.
Liquid analysis has become increasingly important in many process industries, including but not limited to water/wastewater, food and beverage, dairy, chemicals and pharmaceuticals. Monitoring — and responding to changes in — relevant parameters is essential for improving product quality, optimizing yield, and ensuring safety as well as regulatory compliance and environmental protection.
In the past, online process liquid analytical measurements were made using basic analog instruments with limited diagnostic and measurement quality parameters, but today, digital communi-
cation protocols and smart instrumentation have significantly expanded sensor functionality and user-friendliness.
Analog sensor limitations
Before digital protocols were developed and deployed at scale, liquid analysis was typically conducted using basic analog instruments, each comprised of a sensor, cable, and transmitter, to make online process measurements. The measured process variable from each instrument was then sent to a supervisory, control, or other host system via a 4 to 20 mA analog signal.
These instruments were often cumbersome to work with, requiring meticulous reagent setup, for instance.
The analog transmission between sensor and transmitter was susceptible to moisture ingress at connection points, in addition to corrosion, salt bridge formation, and electromagnetic interference — all of which could adversely affect the raw signal received by the transmitter, before even sending the scaled value to the host system via a 4 to 20mA current signal.
On top of environmental factors, sensor cables and transmitter idiosyncrasies could degrade a measurement value, so these nuances had to be included in calibration procedures. These issues preclude calibration in a laboratory setting, instead requiring technicians to transport calibration equipment to the field site and perform calibration in potentially difficult or hazardous conditions.
FIGURE 1: Laboratory calibration with Memosens provides convenience and substantial time savings as compared to field calibration. All images courtesy: Endress+Hauser
Calibration in the field also typically took much longer than in the lab. For example, calibrating a single pH loop can take 40 to 60 minutes and often requires more than one technician.
Basic analog sensors are not only challenging to calibrate, but they also are complex to commission and difficult to maintain due to the lack of instrument health diagnostic indicators. As a result, plant personnel inevitably spend a great deal of time and resources on configuration, troubleshooting and maintenance.
Inductive digital instruments burst the analog bubble
To address these and other issues, inductive digital sensors digitize measured values and relay signals to their transmitters via non-contact connections. Digital signals are unaffected by the aforementioned environmental factors, and galvanic isolation between the sensor and transmitter eliminates potential interference signals.
This type of digital sensor technology also makes laboratory calibration viable because digital communication removes the effects of sensor cables and analog signal transmission on values received by the host system. Key sensor data, including calibration information, is stored in the sensor head, so sensors can be easily exchanged in the field following lab calibration. Having calibrated sensors ready to go minimizes downtime due to device failures because staff can replace a problematic sensor in minutes. Calibration is typically valid for twelve
2.0 chlorine sensor provide precision measurement accuracy, even at low concentrations.
months prior to field deployment, providing a long shelf life for pre-calibrated replacements.
Compared to the hour or so required for field calibration, a digital pH sensor can be lab-calibrated in under ten minutes, while simultaneously eliminating the need to transport calibration equipment to the field. Meanwhile, switching out a questionable sensor on the plant floor with a precalibrated replacement requires only a few minutes (Figure 1).
Initially developed for pH measurement, inductive instrument technology has grown into a wide-reaching platform for many liquid analysis qualities, including conductivity, ORP, dissolved oxygen, turbidity, disinfection properties, UV/Vis, spectrophotometry measurements, and more. These sensors are capable of driving further improvements in reliability, process management, and predictive maintenance with a host of additional instrument and process information stored (Figure 2). Such parameters include programmable CIP cycles, load matrix of pH and ORP probes, a distinction between calibration checks and adjustments, digital sensor labels, operating hours, and electrolyte consumption monitoring for amperometric disinfection, conductivity, and dissolved oxygen sensors.
Improving sensor accuracy and maintenance in gold processing
In gold mining, cyanidation is a common process for extracting gold from low-grade ore. Cyanide is extremely toxic, and safe cyanidation
‘ Basic analog sensors are complex to commission and difficult to maintain, lacking diagnostic indicators.’
controleng.com
KEYWORDS: process instrumentation, liquid analyzer
LEARNING OBJECTIVES
Understand how digital analytical instruments for liquid analysis can help improve digital transformation.
Learn about the role process sensors can play in gathering and synthesizing data for engineers.
ONLINE
See additional process instrumentation and sensor stories at www.controleng.com/ process-instrumentationsensors/
CONSIDER THIS
How can digital analytical
FIGURE 3: The Endress+Hauser CYA27 Flow Assembly and CCS51E Memosens
FIGURE 2: The cycle of Memosens sensor operation, cleaning and calibration.
ANSWERS
requires accurate and reliable pH measurement.
A Finnish mining company was experiencing measurement accuracy issues, and staff were spending too much time and too many resources on calibration. Unsatisfied with its current process instrumentation, the company sought to improve safety and efficiency, while reducing maintenance efforts, with new solutions.
The mining company performed a yearlong trial in which they compared instrumentation and services from multiple vendors. Working in close collaboration the selected vendor, the team installed inductive digital pH sensors and transmitters throughout the facility to solve the technical challenges.
‘ New, more accurate pH sensors increased process safety and efficiency, reducing the consumption some chemicals by up to 50%. ’
Using the aging, previously installed instrumentation, sensor cleaning was difficult, inconvenient and time-consuming, and it had to be conducted manually in the field, which was unpleasant during the winter months when temperatures fell as low as -40 °F. By contrast, the new instruments perform automatic self-cleaning, improving efficiency and staff satisfaction.
Altogether, instrumentation calibration and maintenance efforts were cut by nearly 90% from 2,200 to only 240 labor hours per year after the switch. Decreasing the amount of demanding field maintenance reduced costs and improved worker safety and convenience. In addition, the accuracy improvements provided by the new pH sensors increased cyanidation process safety and efficiency, reducing the consumption of chemicals such as sodium metabisulphite by up to 50%.
High-precision chlorine measurement in vegetable wash water
In food production, cleaning vegetables with a hypochlorite wash improves consumer safety by killing harmful pathogens. Higher chlorine concentrations translate to faster and more powerful disinfection, but before wash water is disposed, chlorine must be neutralized to stringent regulatory limits — potentially as low as 0.2 mg/L. However, many chlorine sensors have trouble measuring at such low concentrations, often entering a sleep mode when chlorine levels remain this low.
To meet the low concentration requirements demanded in this application, one processor installed a cabinet-mounted solution with inductive digital chlorine and pH sensors, a flow assembly, and transmitter. The chlorine sensor is designed to measure trace levels of chlorine, and it can be configured to avoid sleep mode, even at low concentrations (Figure 3).
With precise chlorine measurement, bisulfite dosing for chlorine precipitation can be executed with high efficiency, reducing operational costs. Chlorine measurements are transmitted by the installed a transmitter to regulate the bisulfite pump, using a proportional-integral-derivative (PID) controller to maintain a chlorine setpoint of 0.08 mg/L, safely below the 0.2 mg/L discharge requirement.
pH monitoring prevents damage in whey processing
The process of separating whey protein from lactose and minerals uses polymer or ceramic filtration membranes that can be easily damaged in unsuitable pH conditions. During polymer membrane cleaning in particular, pH must be carefully monitored and controlled to prevent such harm
FIGURE 4: Whey processing membranes must be routinely cleaned, but pH control is critical to prevent damage during this process.
The ceramic membrane cleaning solutions contain enzymes that break down organic materials in the membrane pores, as well as chemical buffers used to maintain safe pH levels. However, inaccurate pH measurements can quickly compile and cause problems because these systems are frequently cleaned, as often as four times each day.
Unlike polymer membranes, ceramic membranes are cleaned with a caustic solution that does not pose the same risk. However, monitoring is still important during regular operation to prevent damage and ensure effective separation.
A whey processor installed inductive digital pH sensors at the inlet and outlet of each of their process skids to monitor the separation process and prevent damage to its membranes. On separators with polymer membranes, the processor installed sensors inline, which are therefore cleaned during every cycle. For the other application, sensors on the ceramic separators were installed in a retractable assembly to avoid exposure to the caustic solution used during cleaning. These sensors must be removed and cleaned separately.
The setup has remained effective over time, without any noticeable sensor degradation after 300 cleaning cycles, and the low calibration frequency of every six to twelve months is very manageable for the processor.
Digitalization propels liquid analysis
Modern instrumentation with digital data transmission resolves many of the issues with analog sensors, including susceptibility to environmental conditions, lack of instrument diagnostics, and required field calibrations.
These advanced digital instruments help plants continue their digital transformation improving production safety, process efficiency, and product quality, while maintaining regulatory compliance and optimizing operations in liquid analysis applications. ce
Thomas Chirdo is the national product marketing manager for liquid analysis at Endress+Hauser. Edited by Chris Vavra, web content manager, CFE Media and Technology, cvavra@cfemedia.com.
Insightsu
Process instrumentation insights
uTraditional analog sensors for liquid analysis were prone to environmental interference, required meticulous calibration, and were challenging to maintain, leading to significant time and resource investments.
uDigital sensor technology revolutionizes liquid analysis by eliminating environmental vulnerabilities, enabling lab-calibration, and drastically reducing calibration and maintenance time, ultimately enhancing safety and efficiency in various industries.
•
• High resolution graphics and glass panels
• Support of all six IEC PLC programming languages
ANSWERS
Are you measuring sustainability with reliable sensor, analytical instruments?
Detecting greenhouse gas emissions such as methane requires accurate industrial analytical measurements.
Sensors used for industrial analytical measurements also help with detecting global emissions of methane and other greenhouse gas emissions from space. Advances in electronics, sensing methods, packaging and industrial design allows monitoring of multiple natural gas contaminants from one device.
controleng.com
KEYWORDS: Industrial analytical measurement devices and systems
LEARNING OBJECTIVES
Learn that the ABB factory in Quebec, Canada, established in 1973, manufactures industrial analytical measurement devices and systems, including the ABB Sensi+, which monitors multiple natural gas contaminants in one device.
Understand that optical sensors built by ABB in Quebec help with detecting methane and other greenhouse gas emissions from space.
CONSIDER THIS
Have you considered measurement reliability?
ONLINE
Read more on process instrumentation and sensor from Control Engineering. https://www.controleng. com/processinstrumentation-sensors
Established in 1973, the ABB factory in Quebec, Canada, manufactures industrial analytical measurement devices and systems.
Industrial analytical sensors
“In its 50-year journey, ABB’s Quebec factory has both pushed the boundaries of industrial analytical measurement and also reached for the stars, literally,” said Jean-René Roy, global business line manager, ABB Measurement and Analytics. The factory houses ABB’s largest measurement and analytics research and development group, with 150 engineers and scientists and more than 400 employees. Products and services sourced there include the following.
ABB Sensi+ analyzer monitors natural gas quality through one device for continuous and simultaneous measurements of gas contaminants (hydrogen sulfide, water and carbon dioxide), eliminating the need for multiple analyzers and numerous maintenance schedules while reducing hours of operator training and services.
The ABB suite of natural gas leak detectors have sensitivity 1000 times greater and speed 10 times faster than traditional equipment.
ABB designs and manufactures one of the largest portfolios in the world of laboratory, at-line and process FT-IR/FT-NIR analyzers. Used for quality control, these solutions increase productivity while lowering environmental impact in industries such as oil and gas, chemicals, life sciences and others.
Space-based sensors
The ABB Quebec factory offerings have served the global space industry since its inception, collaborating with major space agencies with services such as weather forecasting, climate analysis, earth observation, space exploration and astronomy.
In recent years, optical sensors built by ABB in Quebec have played a vital role in detecting greenhouse gas emissions from space. Space-based gas analysis enables reporting across jurisdictions, crucial to verifying climate commitments. ABB-built optical sensors offer 100-times higher resolution than comparable technologies, precisely identifying emissions sources. ce
Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com.
THE FOUNDERS of the ABB factory in Quebec are, from left to right: Garry Vail, Henry Buijs, a scientist in spectroscopy, and Jean-Noel Bérubé. Courtesy: ABB
Can you avoid clean-in-place delays, risks with a new flowmeter design?
Clean-in-place, sterilize-in-place requirements decrease when a Coriolis flowmeter uses a replaceable sensing tube: Automation Fair 2023.
As pharmaceuticals get more specific with smaller quantities produced, and as pharmaceutical manufacturers seek more flexibility, skid-based pharmaceutical production has increased. To avoid or reduce clean-in-place (CIP) requirements, a single-use Coriolis flowmeter with replaceable sensing tubes is under development from a process sensor and instrumentation manufacturer, as explained at Automation Fair 2023 from Rockwell Automation.
Sensing changes in life sciences
Key trends in life sciences industries include increased capacity and production schedule demands, continuous manufacturing, digitalization and Industry 4.0 initiatives, cost reduction pressures and new drug modalities. Drug designs are changing with cell and gene therapy (CGT) and messenger RiboNucleic Acid (mRNA)-based treatments, according to Bethany Silva, industry manager - life sciences and Lauton Rushford, product marketing manager – flow, both with Endress+Hauser, in the Automation Fair session, “Flowmeter instrumentation enhances reliability in the life science industry.”
With these changes, original equipment manufacturers (OEMs) and skid designers for life sciences and pharmaceutical manufacturing seek options for increased flexibility and faster changeover times along with avoiding hazardous and wasteful cross contamination. A skid or line requiring CIP or sterilize-in-place (SIP) processing can delay production for up to a week, they said.
Flowmeter applicationrelated specifications
Other OEM or end-user considerations in flowmeter application specifications include mass and volume flow accuracy, repeatability, wetted part materials, current good manufacturing practice (cGMP) calibration compliance, physical space and environmental needs, handling, pharmaceutical compliance, required certifications and approvals, communications abilities and design flexibility. Coriolis flowmeter designs include sensing elements, processor and analytics capabilities, a human-machine interface, and abilities to securely store and transmit data and information. Most modern Coriolis flowmeters, like some other modern process sensors, avoid the need for field calibration.
LIFE SCIENCE industry trends include increased capacity and production schedule demands, continuous manufacturing, digitalization and cost reduction pressures, said Bethany Silva, industry manager - life sciences and Lauton Rushford, product marketing manager – flow, both with Endress+Hauser, in the Automation Fair session, “Flowmeter instrumentation enhances reliability in the life science industry.” Courtesy: Mark T. Hoske, Control Engineering
controleng.com
The Endress+Hauser Coriolis flowmeter, Promass U 500 with disposable sensing tube is expected to be available in first half of 2024, they suggested. ce
Mark T. Hoske, is content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com.
KEYWORDS: Flowmeters LEARNING OBJECTIVES Understand trends in life sciences, flowmeter specs. CONSIDER THIS How can new sensors improve manufacturing workflow?
In an August 15 webcast on new SCADA features and functions, Avanceon’s Matt Ruth and Nicholas Imfeld discussed advances in SCADA technology—and how to justify investing in an upgrade. See unanswered questions from the live event below.
In the Control Engineering webcast SCADA series: New SCADA features and functions,”
Matt Ruth, president at Avanceon, and Nicholas Imfeld, operations manager at Avanceon, discussed current trends and innovations pertaining to SCADA technology. Courtesy: CFE Media and Technology
From its inception, Industry 4.0 has emphasized the pursuit of system-wide efficiencies and data-based decision making. As such, it’s no surprise that interest and investment in supervisory control and data acquisition (SCADA) systems has grown in recent years as companies seek to adapt. Human-machine interface (HMI) software and SCADA systems can provide end-users with a variety of benefits, including:
• Holistic visibility: Because SCADA systems provide a central platform for monitoring and visualization of entire operations, they can help endusers understand how different components and processes interact with each other.
• Data integration and analysis: By aggregating data from numerous sources, SCADA can help operators identify system-wide trends, patterns and correlations.
• Adaptive and predictive control and maintenance: Advanced analytics as well as artificial intelligence (AI) and machine learning can be applied to the large datasets SCADA systems provide to anticipate future system behavior. This enables proactive, rather than reactive adjustments to optimize performance and prevent production stoppages.
In an August 15 Control Engineering webcast, “SCADA series: New SCADA features and functions,” Matt Ruth, president at Avanceon, and Nicholas Imfeld, operations manager at Avanceon,
discussed current trends and innovations pertaining to SCADA technology. Questions submitted by the audience that were not answered during the live event are addressed below.
QUESTION: In what ways does the integration of virtual reality (VR) or augmented reality (AR) technologies enhance situational awareness and decision-making in SCADA environments?
I see these as different spaces. VR and AR are primiarly being used in the training space (that is, how work is done on the physical elements of a system), and less in the monitoring of the system. I would argue that using VR/AR in a SCADA system would run counter to the principles of situational awareness much the same way that the earlier SCADA trends of using 3D graphics and lots of colors worked against the simple/clean presentation of information which is highlighted by situational awareness display methodologies.
Q: How does offering a variety of access options impact the security, convenience and operational flexibility of SCADA systems?
Access options drive use and expansion of scale for operations resources. With more mobile and remote options, there is less reliance on staffing at each physical asset location. As a result, less operators can cover more assets. From a security perspective it is critical to consider a security approach that addresses verification on a physical basis (firewall, DMZ, etc.) as well as from a procedural perspective (allowing specific access only to operators allows you to know who should be online at any given time).
Q: What are the most common communications protocols for SCADA and IEDs?
Ethernet is the main protocol in today's modern factory.
Q: How does modern SCADA differ?
There are many technical innovations in modern SCADA (refined graphics, mobile form factors of interface, alarm segregation, historian integration, advanced navigation, etc.), but at the end of the day, the modern SCADA answers the following questions:
• It simplifies and streamlines the information and makes it easy for operators to access.
• It's accessible by everyone from anywhere
• It emphasizes having valuable information/knowledge rather than just large quantities of data.
• It is a platform for future expansion and advanced applications like MES, analytics and predictive maintenance.
Q: What are some advancements in SCADA technology to protect against extreme weather climates (excessive heat)? Are there new technologies to support the system in the event of localized power loss?
The main environmental impacts come from applying thin client technology and removing the non-solid state components from the hazardous area. Removing moving parts from PCs makes them more robust in the event of failure, as well as easier to change out in the event of failure. Additionally, the use of UPS and solar panels (for outside applications) has expanded the options on local power issues.
Q: Is the existing data on a SCADA system transferred to a new SCADA automatically?
Most SCADA platforms have an upgrade path that allows the data and screen content from the past to be migrated to the newer versions. There are implementation strategies that allow the old SCADA to be "wrapped" inside of the new SCADA, and allow the use of the old while still getting the value of the new.
Q: It seems that from a risk and complexity standpoint, rolling the new design out to smaller, less complicated systems
‘ Modern SCADA simplifies and streamlines the information and makes it easy for operators to access; information is available as needed for others and other systems.’
ANSWERS
‘ Rollout for the first plant development was one year with commissioning taking two months. Each successive plant is averaging about 10 to 15% less time than the prior.
and plant operations would have been a safer approach. Was this considered and discussed with the client?
This path was considered and discussed with the customer. In this case, the customer had a commitment to documentation and simulation for their process and, while more complex, the system was exercised for a significant period of time and verified by top customer operations before installation. Additionally, in this system there was an approach to use temporary PLCs for a hot cutover allowing a fall back path if needed or if issues.
Q: With the upgrade at the wastewater treatment plant (from the example) were the PLCs also upgraded, and what are the most significant lessons learned from the upgrade? Also, how much time did it take for the upgrades per plant including planning and integration?
In the SCADA upgrade project, the PLCs were also upgraded. Some of the biggest consideration were the approach to naming convention and the development of tightly integrated PLC/SCADA standards where the functionality could be developed, tested and then relied upon for rollout in multiple instances.
Rollout for the first plant development was one year with commissioning taking two months. Each successive plant is averaging about 10 to 15% reduction in time over the prior. ce
Edited
by David Miller, content manager, Control Engineering, CFE Media and Technology, dmiller@cfemedia.com.
controleng.com
FOR MORE ON THIS TOPIC, SEE: Aug. 15 Control Engineering webcast, “SCADA series: New SCADA features and functions.” www.controleng.com/webcasts/ scada-series-new-scada-features-and-functions Control Engineering SCADA and HMI pages www.controleng.com/control-systems/ dcs-scada-controllers www.controleng.com/control-systems/hmi-oi
Mark T. Hoske, Control Engineering
See these Control Engineering hot topics for late 2023
People at Control Engineering, like you, measure to help optimize. Below are 3 articles on controller programming, 2 on engineering careers, and 1 each on motion, smart manufacturing, advanced controls, products and machine vision, along with date of posting and links to the articles. Notice the diversity of automation and control topics. Most read Control Engineering articles posted mid-May through mid-November, 2023, follow.
1. PLC programming language fundamentals for improved operations, maintenance, July 18
Learn about five programming languages and how they’re used. www.controleng.com/articles/ plc-programming-language-fundamentals-for-improved-operations-maintenance
2. Control Engineering Career and Salary Survey, 2023, May 15
Leading-edge automation technologies are helping solve workforce shortages and economic challenges by adding efficiency. www.controleng.com/articles/ control-engineering-career-and-salary-survey-2023
3. Manufacturer opens packaging and logistics headquarters, June 8
ABB Robotics’ dedicated Packaging and Logistics facility in Atlanta will develop AI-enabled robotic skills to help U.S. customers remain competitive. www.controleng.com/articles/manufacturer-opens-packaging-and-logistics-headquarters/
4. Is Industry 4.0, smart manufacturing working for you?, July 13
2023 marks a dozen years of Industry 4.0. Control Engineering asked an Industry 4.0 expert how companies can tell if they’re moving quickly enough toward smart manufacturing and digital transformation. www.controleng.com/articles/is-industry-4-0-smart-manufacturing-working-for-you
5. How to create PLC ladder logic code with Excel, May 22
Programmable logic controller (PLC) ladder logic code can be mass produced with Microsoft Excel to generate repetitive logic like I/O mapping and alarms. www.controleng.com/articles/ how-to-create-plc-ladder-logic-code-with-excel/
6. Beyond PID: 6 advanced strategies to add value to modern process control, Aug. 28
Six strategies can simplify PID applications. www. controleng.com/articles/beyond-pid-6-advancedstrategies-to-add-value-to-modern-process-control
7. 2023 Control Engineering Product of the Year winners announced, June 1
Winners of the 36th annual Control Engineering Product of the Year awards have been announced www.controleng.com/articles/2023-control-engineering-product-of-the-year-winners-announced
8. Are you making the most of PLC programming standards from PLCopen?, July 4 www.controleng.com/articles/are-you-making-themost-of-plc-programming-standards-from-plcopen
9. What makes an engineering trailblazer? Read about the 2023 leaders here, Sept. 11 www.controleng.com/articles/what-is-an-engineering-trailblazer-read-about-the-2023-leaders-here
10. Framework advances computer vision with pixel processing, June 24 USC Viterbi researchers proposed a framework for computer vision that increase processing speed. www.controleng.com/articles/framework-advances-computer-vision-with-pixel-processing ce
Mark T. Hoske is content manager, Control Engineering, mhoske@cfemedia.com.
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Related Control Engineering hot topic articles include: Control Engineering hot topics, October 2023 www.controleng.com/articles/ control-engineering-hot-topicsoctober-2023
Top 5 Control Engineering content: Nov. 6-12, 2023 www.controleng.com/articles/ top-5-control-engineeringcontent-november-6-12-2023
Hot topics in Control Engineering for 2022 www.controleng.com/ articles/hot-topics-in-controlengineering-for-2022
ANALYTICS
Traffic ranking and compilation at www.controleng.com
Google Analytics were by Chris Vavra, web content manager, CFE Media and Technology, cvavra@cfemedia.com.
ANSWERS
Frank Burger, Avanceon
PLC standards for the new-ish millennium
PLC standards have greatly changed since the 1980s. Learn how modern programming tools have greatly improved PLC development.
The topicof programmable logic controller (PLC) standards for both programming and hardware has been on the mind of the industry nearly as long as the PLC itself. Throughout this time, the industry and its professionals have experienced great success and several setbacks.
and the next generation needs to cover a wider array of technologies, which dilutes focus and prevents investment in initiatives with longer term payback.
Online controleng.com
KEYWORDS: PLC programming, standards
LEARNING OBJECTIVES
The world is a vastly different place than it was in the 1980s. Back then, we had only recently put away our slide rules, enticed by the lurid glow of the seven segment displays on our digital calculators. We had yet to experience upheavals such as the mass retirement of skilled workers, the Great Resignation and the globalization of the workforce. There have been profound changes in the technological landscape as well. Aside from the magic of air fryers and streaming TV, we’ve got the Industrial Internet of Things (IIoT), the cloud and accelerated development via object-oriented programming.
Learn about the challenges facing organizations that wish to develop in-house PLC standards to improve operations.
Discover how lightweight standards can help retain resources and achieve more effective implementations.
Explore considerations to be made when working with a third-party vendor, OEM or system integrator to develop PLC standards.
How can you use these strategies to develop PLC standards that best suit your organizations needs?
Creating PLC standards
PLC standards are a lot like playing the guitar or speaking a second language. It’s great to grab your six-string acoustic and play campfire songs, but it requires hours and hours of grueling lessons to get you to the point where that’s a possibility. Similarly, creating a comprehensive set of PLC standards is an undertaking that fewer and fewer companies are equipped to undertake. The old guard of PLC pros has one foot out the door,
From an engineering perspective, creation of standards is the fun part. Who doesn’t enjoy a company sponsored lunch while arguing with your colleagues over whether or not to nest your UDTs? Long-term stewardship, including training, enforcement and continual improvement efforts, can be more of a drain, literally and figuratively. Certainly, if resources weren’t available to create standards in the first place, there’s unlikely to be enough excess horsepower for ongoing maintenance efforts.
Apart from workplace changes, one of the arguments in favor of standardization has traditionally been that it enables accelerated design and deployment. If we planned to copy/paste our standard logic a thousand times, some up-front design and testing effort would be more than justified, as would the documentation effort to ensure that the standards were implemented properly in various situations. Modern programming tools take off quite a bit of the pressure here. With userdefined function blocks or add-on instructions, the instantiation process is much faster than copy/ paste, and we now retain the link between template and instance, so that all is not lost if we discover a change that needs to be made after roll-out has started. This is undoubtedly a positive development but erodes one of the drivers for implementing standards.
If the industry has a smaller pool of less experienced resources who have less time and less incentive to devote energy to creating and maintaining
standards, what is the path forward? There are at least two, and they can work well in conjunction.
The programming pathway forward
Industry supported standardization efforts, such as IEC 61131-3, help define the tools in our toolkit, and simplify the learning curve inherent in switching between hardware brands. This early example has been a real success story—quietly changing the “normal” way we get our jobs done. This value is also seen in ISA 88 for Batch Control and TR88.00 (PackML), among others.
These standards, made available to the industry as a whole, will obviously change the way we approach specific projects and applications. However, what is more important is that they will change our collective mindset about the way we should go about things over time. Manufacturers and engineering companies would do well to embrace the standards put forward by industry, and to engage in the ongoing dialogue around these standards.
The other element that will help to forge a pathway forward is migrating to a more lightweight mindset. Standards consisting of a large amount of documentation and ancillary materials are problematic in several ways; they require a large amount of initial effort to create; face the likelihood of becoming outdated due to resistance to modification; and create barriers to usage due to struggles with up-front reading and comprehension. Instead, a cohesive sample code that follows a common set of rules can present a much lower cost of entry and usage. When taking this approach, it is important to provide guidance in the form of training so that the programmers leveraging these lighter standards don’t fall into traps that the more lightweight approach might expose them to. This combination of better training and more lightweight standards can often be more professionally fulfilling than blindly following terser and more rigidly developed standards, and could lead to improved retention of resources.
Shopping for standards versus building them in-house
If you find yourself shopping for these standards rather than building them in-house, there are a number of potential resources, including PLC manufacturers, OEMs and systems integrators. The best
advice is to identify a solution that truly fits your business, so that programmers will feel enabled, rather than burdened, by the standards. This may involve an internal search for running applications that are well regarded by the maintenance and support teams, and then reaching out to the supplier. You may also prefer to start the search externally. Either way, it’s important to consider the entire life cycle of the code that will be written. This life cycle includes not only streamlined development
‘ A cohesive sample code that follows a common set of rules can present a much lower cost of entry and usage. ’
and robust code, but maintenance and easy
and robust code, but simple maintenance and easy future upgrades, along with your own, more custom requirements.
As we think about future states, the lightweight approach accepts that there’s unlikely to be a world in which every one of your systems follows the same standards. There’s usually limited value in replacing an application that’s non-standard, unless it’s letting you down in a bigger way. The lightweight approach invites an increased pace refinement over time, which should be viewed as a win-win. Incremental improvements can be leveraged, and the process is more organic such that you don’t suddenly wake up one day 10 years in the future with a heavy investment that has become obsolete.
ce
Frank Burger, principal engineer, Avanceon. Edited by David Miller, content manager, Control Engineering, CFE Media and Technology, dmiller@ cfemedia.com. Avanceon is a Control Engineering content partner.
CORRECTION: This article was scheduled to run in October on page 30 of the printed edition. The issue printed with a prior article repeated. Though it was corrected at www.controleng.com/magazine, here it is for those who subscribe to paper only.
Insightsu
PLC Standard Insights
uUpheavals such as mass retirements, the great resignation and the globalization of the workforce coupled with strained internal resources have made it more difficult than ever for organizations to develop in-house PLC standards.
uWhile creating PLC standards is challenging, maintaining them is even more difficult.
uRelying on pre-established industry wide standards such as IEC 61131-3, ISA 88 and TR88.00, and adopting a lightweight mindset can help to ease the process.
Keith McNab, Emerson
MTP standard accelerates DCS and PLC integration
NAMUR MTP is a standardized configuration and communication method to facilitate PLC and DCS integration, while cutting the cost, time and risk of doing so.
WOnline
controleng.com
KEYWORDS: MTP, Interoperability
LEARNING OBJECTIVES
Learn how to use module type package (MTP) to bridge the gap between DCS and PLC control systems to more fully integrate plant assets.
Understand how NAMUR NE 148 establishes the concepts and specifications of MTP.
ONLINE
More graphics with this article. See more on standards, benefits:
https://www.controleng. com/articles/unifiedenvironment-for-controlsystem-integration-benefits/ CONSIDER THIS
How could you benefit from more complete plant-wide integration?
hile modern process manufacturing operations are usually heavily automated, they are often not as thoroughly integrated. This persistent problem has been characterized as “operational silos” or “islands of automation.” Certainly, both large and small plant areas can be well-automated, but if they are not completely integrated, then significant performance, efficiency and even safety improvements remain left by the wayside. This situation exists for many reasons. Most units in a typical production process are controlled and monitored by a large distributed control system (DCS). But there are many skids, utilities and other
OEM equipment—including product finishing and packaging systems—more appropriately controlled and monitored on a localized basis using programmable logic controllers (PLCs) and human-machine interfaces (HMIs). Both operating units and associated equipment can vary dramatically depending on their role and may be supplied by many different vendors, each of which standardize on a variety of automation platforms, complicating any integration efforts beyond the most minimal functional interfaces. Traditional integration methods have involved manual data mapping, custom code and “handshakes” and hardwiring. Even these efforts may still require operators to consult many different control interfaces throughout a plant, instead of having clear and transparent top-level visualization in the control room. Fortunately, modern system convergence and connected manufacturing initiatives have resulted in a new solution to make it easier and quicker to integrate DCS, PLC, and HMI systems. The technology is called Module Type Package (MTP), recommended by NAMUR to modularize process plant automation.
1: Traditional manual PLC/DCS integration methods (upper diagram) are time-consuming and may involve multiple iterations for complete implementation. MTP integration automates and simplifies the task. All images courtesy: Emerson
FIGURE
FIGURE 2: Each piece of equipment within the PEA layer is described using a library of standard MTP objects. These are exported and then imported to the POL using an MTP utility embedded in the DCS.
Traditional integration challenges
As an example of why integration is important, consider a typical pharmaceutical facility using a DCS to control and monitor the primary processes, with many specialized PLC-controlled centrifuges forming part of a subsequent production step. A bare-bones approach might simply have the DCS command each centrifuge to run when needed, and then monitor whether the equipment is actually running.
A centrifuge has significantly more running, performance, tuning and diagnostic data, and perhaps other modes such as cleaning. Live data is important, but so is historized information. Without a more sophisticated interface, control room DCS operators have no visibility into any of this detailed operation, unless they visit the individual HMI for each centrifuge. This is difficult if there are just a few centrifuges, and it becomes increasingly impractical as the quantity of PLC-controlled equipment grows.
Traditional solutions required systems integrators (SIs) and control systems engineers to develop bidirectional communications between the DCS and PLCs of interest, and to then create DCS graphics, alarming, historical logging and other associated functions as needed. This type of work can be complex and expensive, and it also requires additional testing and commissioning. Suppliers and OEMs of the PLC-based equipment may object to providing open access into their systems due to concerns that performance could be compromised, along with issues related to protecting their intel-
lectual property. Any changes must be manually performed on both ends, and then retested.
Delivering benefits
A more workable alternative is to create an environment where native and standard mechanisms exist to support the necessary integration and subsequent communication. PLC-controlled equipment, even complex examples, can supply the required integration configuration information via an export, and a DCS can interpret it via in import, so that users need only connect the two elements.
NAMUR NE 148 establishes the concepts and specifications of Module Type Package (MTP), which is designed specifically as a vendor-neutral description language for performing data, visualization and functionality integration between a main process control system and associated automated equipment systems. MTP lets users easily configure their PLCs with the right “hooks” needed for interacting with a DCS, and it provides a mechanism for joining the two, reducing integration duration and risk by eliminating many of the prototyping and integration steps required by traditional integration methods (Figure 1).
FIGURE 3: Emerson’s MTP-capable DeltaV DCS and PACSystems RX3i PLCs are examples of products which meet basic vendor-agnostic NAMUR NE 148.
MTP is not an industrial communication protocol such as OPC UA, Modbus TCP, or Profinet. It provides a means for presenting PLC-based information in a consistent way, concentrating on process control, safety and security, alarm management, HMI graphics and maintenance diagnostics.
NE 148 defines two layers. The first and “lower” layer is the Process Equipment Assembly (PEA), where PLC-based skids and other subsystems live. MTP is used to export PLC configurations from the PEA and import them into the second and “upper” layer, which is the Process Orchestration Layer (POL), consisting of the DCS or other higher-level process automation host system (Figure 2).
Each PLC is called a Module, or a Package Unit. Once the export/import has taken place, each Module communicates with the DCS over a standard Ethernet architecture network using secure OPC UA to present their process data, HMI information, and more.
The standardized MTP library of data objects provides an easy and extensible way for developers to establish sophisticated integration, without the need for writing specialized code, or perform-
Insightsu
MTP Insights
uEven if many areas of a plant are well-automated, if they are not effectively integrated together, performance efficiency and safety gains may not be fully achieved.
uModule type package (MTP)is a technology recommended by NAMUR to modularize process plant automation and enable communication between DCS, PLCs and HMIs from different vendors.
uMTP is designed specifically as a vendorneutral description language for performing data, visualization and functionality integration between a main process control system and associated automated equipment systems.
ANSWERS
ing extensive research and testing. Besides reducing integration risk, an important result is that the effort to perform the integration can be reduced by half or more, and any required changes after commissioning are greatly simplified.
Integration advantages
MTP provides clear advantages for end users seeking to break down barriers among operational silos. These users now have an economical and reliable approach to designing new installations or upgrading existing operations. This approach provides integrated control and visibility, helping operators to be more effective.
‘ MTP can break barriers among operational silos. ’
MTP opens doors by supporting other data-driven efforts, such as analytics and connected manufacturing.
Skid and machine builder OEMs can leverage MTP to deliver futureproofed solutions, making them a preferred supplier for their end-user customers. OEMs generally prefer standardized automation designs, but they often must invest effort to produce customizable or fully bespoke systems tailored to individual customer specifications. Solutions based on MTP provide a way for OEMs to focus on the performance of their equipment, while enabling easy integration with any customer automation system.
Controls engineers and SIs tasked with integrating PLC-based equipment with a DCS will appreciate how MTP streamlines this work, while promoting quality and consistency, and reducing the likelihood of human error. A technology cutting the time of integration by half in many cases,
and minimizing the overall cost, is a major win for all parties involved.
Although MTP is a vendor-agnostic and cross-platform technology, some PLC and DCS suppliers have taken an additional step to support customers by incorporating platform-specific extensions (Figure 3). Standard MTP functionality is preserved, but when one supplier can provide all the DCS and PLC platform elements, additional efficiencies can be built-in to provide additional advantages for end users.
One example is that when PLC data structures are imported into the DCS, they can be handled in a way that optimizes the signal assignments within the DCS. This is because these automation platforms are already tested to work together right out of the box, over and above the basic NAMUR NE 148 requirements, and can therefore deliver additional consistency and capabilities.
One chemical manufacturer launched a program to build a new manufacturing unit. To expedite construction, the design called for many packaged subsystems, such as filtration skids, chemical injectors, natural gas-fired heaters with NOx suppression and a spray dryer. Instead of pursuing a costly and lengthy traditional integration approach, the team specified MTP-enabled automation systems across the board, predominantly from one supplier (Figure 4). Integration within modern production plants is imperative to provide operational efficiencies, while enabling other advanced capabilities like analytics and proactive maintenance. MTP is an innovative breakthrough to reduce the time, cost and risks associated with integrating PLC equipment with a plant DCS.
Greater modularization leads to increased flexibility, and standardized interfaces simplify development and operation. MTP-capable systems help users eliminate complex prototyping, while shortening the highly critical integration, testing, startup and commissioning steps. End-users, OEMs, and SIs will find additional benefits when they can select PLC and DCS platforms that are not only MTP-enabled, but are also provided with optimized extensions to streamline the effort. ce
Keith McNab, director, control and automation software, Emerson. Edited by David Miller, Content Manager, Control Engineering, CFE Media and Technology, dmiller@cfemedia.com.
FIGURE 4: DCS and PLC integration based on MTP delivers many execution benefits, including speeding the time-to-market for new and retrofit projects.
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Case studIes
Case studies provide valuable discovery of challenge situations, recommended solutions, and implementation actions to solve specific real-life issues.
Control Engineering magazine
invites you to explore the pages to follow while you learn and benefit from the case study success stories and project details shared by the following companies:
Advanced Micro Controls Inc.
ANDRITZ Automation
Hargrove Controls + Automation LLC
Lafert North America
Beckhoff Automation LLC
DigiKey Electronics
Endress+Hauser Inc.
Eosys
Gray solutions
Motion
NKK switches
omlox
Patti Engineering
Premier Automation
Holdings Inc.
Quantum Design Inc.
Real Time Automation
skkynet Cloud systems
Trihedral Engineering
Velta Technology
Vertech Industrial systems, LLC
Wunderlich-Malec Engineering
yokogawa UsA
CaS e S tudy
AMCI DuraCoder Reduces Cost, Saves Time and Keeps Railway Grinders on Track
Challenge: Unlike most industrial applications, railway track grinders operate across an incredible range of conditions and temperatures, requiring an equally rugged encoder.
Solution: Harsco Track Technologies discovered AMCI’s DuraCoder™. Although other analog rotary sensors exist, none of them could match the DuraCoder’s industrial strength, construction and operational excellence.
ReSult: Harsco’s presence within the railway track maintenance industry continues to grow and AMCI is a proud partner in their success. AMCI’s deep understanding of control applications, combined with world class engineering, make it easy for customers to specify solutions that save their companies time and money, while improving quality.
SummaRy: Harsco Track Technologies is a chief global supplier of railway track maintenance equipment and services, providing track maintenance services to major railroads, short lines, and transit systems.
The company designs, manufactures and sells five of the world’s most successful railway track grinding machines; including the sophisticated RGH-8-C and RGH-10-C. These machines remove surface irregularities and restore the profile of the rail to extend track life, reduce wear on rolling stock and track components, and cut fuel consumption. These rail track grinders use independently adjustable grinding heads to efficiently grind critical track sections such as switches, turnouts, and road crossings. These grinding heads run along railway tracks and manage their position using rotary encoders. The operating environment for these rotary position sensors is extremely heavy-duty and Harsco’s engineering team needed a “bullet-proof” solution.
All AMCI DuraCoders meet IP 67 Ratings, enabling these sensors to reliably perform in applications that would render conventional encoders useless. Featuring an integrated NEMA 4 housing, the AMCI DuraCoder leverages a brushless resolver sensor absolute over a single turn. The resolver was originally developed for military applications and has benefited from more than 50 years of continuous use and development. By combining the time tested reliability of a resolver with advanced electronics, AMCI enables accurate rotary position feedback in virtually any application.
• 860-585-1254 www.amci.com
CaS e S tudy
Process optimization at the Haile Gold Mine in South Carolina, US
Challenge: In 2015, OceanaGold planned Haile Gold Mine in South Carolina, seeking a gold plant for optimal recovery and low operating costs. ANDRITZ, with expertise in gold plant operations, secured the contract for their proven solutions.
Solution: Leveraging its gold industry expertise, ANDRITZ provided innovative services, including simulator-based operator training, advanced process control, and Digital Twin technology for OceanaGold’s Haile Gold Mine. These solutions ensured a faster, safer start-up and efficient operations.
ReSult: Thanks to ANDRITZ collaboration, OceanaGold achieved a swift and smooth start of operations with trained operators and advanced control. Through innovations like Digital Twin and ACE, they increased throughput, enhanced efficiency, and continue to receive ongoing support for operational improvement.
SummaRy: OceanaGold partnered with ANDRITZ to optimize the start-up of their Haile Gold Mine in South Carolina. Facing the challenge of maximizing recovery and minimizing operating costs, ANDRITZ employed simulation-driven engineering, integrating IDEAS process simulation, Digital Twin technology, and Advanced Control Expert (ACE).
This comprehensive approach provided OceanaGold with a powerful predictive tool, enhancing accuracy and efficiency in plant operations.
With simulator-trained operators and advanced process control, OceanaGold achieved a rapid and smooth start to operations, increasing throughput from 250 to over 430 tons per hour by 2017. The Digital Twin and ACE technologies empowered operators to supervise processes more effectively, fostering continuous improvement.
ANDRITZ remains a supportive partner, regularly on-site to enhance operational performance with additional ACE systems.
CaS e S tudy
Automated Welding System Nearly Triples Speed of Production
Challenge: Welding automation company had to modernize and go beyond the traditional “bolt on” approach for welding equipment.
Solution: Beckhoff PC-based control technologies and the EtherCAT industrial Ethernet system
ReSult: A 63% reduction in arc time, a 90% reduction in weld clean-up time, a 10% reduction in rework, and a 39% reduction in filler metal spend.
SummaRy: LJ Welding Automation, an engineering company in Edmonton, Alberta, has transformed its approach to welding equipment, moving away from traditional bolt-on methods to embrace integrated solutions. Recognizing a rapidly advancing technological landscape, LJ Welding Automation adopted an integrated strategy that enhances the aesthetics and functionality of their welding systems.
Their Pipe Titan pipe welding system, optimized for 2- to 24-inch-diameter pipes, exemplifies this shift. To meet the demands of Cleaver-Brooks, a global provider of boiler room solutions, LJ Welding Automation utilized Beckhoff’s PC-based control technologies and EtherCAT. The system consolidated functionality into a centralized control architecture and provided a flexible, fully integrated solution.
The Pipe Titan achieved impressive results, significantly improving performance metrics for Cleaver-Brooks. The implementation of TwinCAT 3 automation software, EtherCAT, and other Beckhoff technologies reduced arc time by 63%, weld clean-up time by 90%, rework by 10%, and reduced filler metal spend by 39%.
Leveraging the advantages of PC Control, LJ Welding Automation plans to enhance connectivity for analytics and continuous improvement in the next phase, ensuring their machines remain at the forefront of the welding equipment industry. The flexibility of Beckhoff technology allows LJ Welding Automation to offer unique, highly differentiated solutions to a diverse range of industries.
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DigiKey Delivers Automation Efficiency in New Product Distribution Center Expansion
Challenge: After years of record growth, DigiKey needed to expand its product distribution center in Thief River Falls, Minn., while also reducing the delivery cycle time.
Solution: The largest component of the newly automated system is the KNAPP Order Storage and Retrieval (OSR).
ReSult: Last year, after five years of building and planning, DigiKey opened its state-of the-art warehouse expansion. The automation systems in the new facility allow the company to pick, pack and ship nearly three times the previous daily average of 27,000 orders to customers in more than 180 countries around the world.
SummaRy: The new Product Distribution Center expansion, or PDCe, is nearly fully automated; DigiKey has developed many proprietary systems to aid in ensuring customers get the right part in the right quantity every time. The implementation of a KNAPP OSR system provides the right parts to the picker, eliminating walk time and providing an ergonomically appropriate environment for the picker.
This high level of automation improves efficiency by up to 35% for picking and improves packaging quality and efficiency.
The PDCe features two primary sorting systems to provide redundancy in the case of a breakdown and to enable future growth. Creating a team-friendly work environment while also planning for scalability and growth were top of mind in the plans and design of the building. There are over 27 miles of automated conveyor belt in the facility, and an average order will travel more than 3,200 feet inside the building.
Sustainability was also an integral part of the planning and construction of the facility. DigiKey specially designed a conveying system that maximizes energy usage and efficiency.
DigiKey has released a video series called “Revolutionizing Automation,” which takes you behind the scenes of the PDCe. Visit digikey.com/revolutionizing-automation to learn more about the future of automation at DigiKey.
sales@digikey.com 1-800-344-4539 www.digikey.com
CaS e S tudy
Efficient cooling for CO2 - neutral energy concept
Challenge: Monitoring and creating efficiencies in an advanced heating cooling system for one of the most advanced ice hockey rinks in Europe.
Solution: Endress+Hauser offers a complete package for determining the efficiency of the cooling system – including flow, pressure, temperature and data measurement technologies.
ReSult: Efficient cooling thanks to accurate and reliable monitoring.
SummaRy: The Swiss Life Arena is a multifunctional sports and event arena. It is considered one of the most advanced ice hockey rinks in Europe, and with that advancement comes a unique set of challenges. The energy center in the basement produces cooling for multiple operations from creating ice to moderating temperatures in nearby office space. And, excess heat from the from the refrigeration system is used in the hot water system or is transferred to a local energy network. With all the activity, they require utmost efficiency in their operation – so they turned to Endress+Hauser.
“For us, one of the big challenges is coordinating and optimally aligning the building technology components whilst integrating the arena into the Altstetten energy network… For this purpose, we need highly accurate measured values for cooling capacity and have found the ideal partner in Endress+Hauser,” says Matthias Eckerle Project manager, ewz Swiss Life Arena.
Endress+Hauser was able to help by offering a complete package for determining the efficiency of the chiller including solutions for flow, pressure, temperature and data measurement.
As a result, the Swiss Life Arena has highly accurate and reliable monitoring of cooling capacity for greater efficiency and optimized resources.
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CaS e S tudy
Renewable Energy — Trash to Gas to Cash
Challenge: Operator of a renewable energy business, landfill gas-to-electricity, needed a standardized control system solution to scale their business, enabling expansion to multiple sites.
Solution: Control hardware, Rockwell PlantPAx 5.0 software, and engineering for the base control system using the modern Rockwell CompactLogix P controller with a FactoryTalk View SE operator station.
ReSult: The end-of-life PLC and HMI systems were replaced. Network switches were added to the plant network. Physical chart recorders were replaced with data log configurations in the HMI for automatic data collection. A framework for a remote historian was established.
SummaRy: A renewable energy company that operates landfill gas-to-energy assets required a more robust and scalable control system solution. This company captures and repurposes methane emitted by landfills to provide an alternative to fossil fuel resources and helps businesses reduce greenhouse gas emissions. The operation included four remote sites and one central site from which operations aimed to have connectivity to all five sites. Data collection was being done manually using the existing systems that had been in service for over 15 years. The manual data collection process was labor intensive and created opportunities for errors and irregularities in the data provided.
To achieve this goal, EOSYS upgraded the control systems, in this case to a Rockwell Automation based control hardware and software solution. Each site required a uniform solution that could easily connect to the central system, making data collection and visualization possible from the central site. In addition, the industrial network required upgrades to meet the requirements for robustness and security. The network improvements came with improved visibility of network performance, making troubleshooting easier.
For over 30 years, EOSYS, a Rockwell Platinum Partner, has specialized in industrial controls, information systems, panel fabrication, and OT network services. The EOSYS Group, Inc. 615-355-7200
www.eosysgroup.com/contact
CaS e S tudy
Smart Cameras, Smarter Packaging
Challenge: Precision variability in laser code engraving led to high false positives, impacting operations for a global food and processing manufacturer aiming to enhance recall efficiency and transparency.
Solution: Gray Solutions introduced a Matrox Iris GTX Series camera with integrated AI and a vast font library, mitigating false positives without adding a PC. A user-friendly interface and integration with Rockwell-based systems streamlined quality control.
ReSult: The new vision system enabled cost-effective code inspections, ensuring compliance, preserving product quality, and safeguarding brand reputation in a competitive market while enhancing recall efficiency and transparency for the manufacturer.
SummaRy: Food manufacturers understand the importance of production dates and batch codes on packaging to swiftly pinpoint affected products during recalls, reduce losses, and enhance brand loyalty through transparent date information.
So when it came to packaging, this global food and processing powerhouse set the bar high by employing laser technology for code engraving. However, they faced challenges with laser precision variability, resulting in high false positives and operational inefficiencies. To address this, Gray Solutions developed a new vision system that utilized a Matrox Iris GTX Series camera from Zebra with an integrated algorithm which addressed the challenge while eliminating the customer’s concerns about bringing a PC into the mix.
Cl IC k here or scan QR to read the full Case Study online.
This smart vision system incorporates an exceptional AI algorithm with a vast font library, enabling the camera to rapidly decode diverse characters, significantly reducing false positives and ensuring efficient packaging processes.
Gray Solutions created a user-friendly visualization system for the operators and developed software that talks to the Rockwell-based automation system. This datadriven process streamlines quality control and directs packages based on inspection results. This solution provides a cost-effective means to enhance code inspections, ensuring compliance with food regulations and maintaining product quality and brand reputation in a competitive market.
DCS Migration Gives Incinerators New Lease on Life
Challenge: Due to the facility’s capacity, a hot cutover was completed while the plant was running with one incinerator down. In addition, the client required a turnkey solution with Process Safety scope.
Solution: A comprehensive cutover plan was developed. Through strong communication, the execution of the cutover was designed to eliminate and/or minimize surprises like unplanned downtime.
ReSult: The project was completed on budget with zero safety or environmental incidents. The cutover was executed as planned with no unplanned downtime to the rest of the site. The legacy system was decommissioned, and the incinerator was restarted flawlessly. Reliability and availability have increased.
SummaRy: A leading American provider of vinyl products had obsolete control equipment in one of their manufacturing facilities. The facility produces vinyl chloride monomer (VCM), an industrial chemical and building block for other products to be used in multiple industries. In addition to obsolescence, acquisition of spare parts for maintenance was very difficult and costly.
The objective of this project was to migrate two incinerator controls from legacy to modern hardware—Honeywell TDC 3000 to C300 Experion and Schneider Triconex Version 10 to Triconex CX.
This project was a turnkey solution that included detailed design, configuration, graphics, cutover planning, construction, and startup & commissioning. Particular care was required in the cutover planning because the facility was designed to run on three incinerators. Therefore, cutover needed to be completed as quickly as possible to maintain the site’s capacity.
After consultation with all stakeholders, a documented cutover plan was developed and executed with no unplanned downtime to the rest of the site. As a result, Honeywell will support the modern DCS for 20+ years, and the reliability and up-time availability of the system have increased.
info@hargrove-epc.com 877.388.8356
hargrove-epc.com
CaS e S tudy
Hydropool Revolutionizes Aquatic Fitness with Executive Trainer Swim Spas Powered by Lafert PM Motors
Challenge: Develop a new swim spa delivering the best swim quality and strongest swim resistance current in the market.
Solution: A complete redesign of the traditional swim current system to eliminate mechanical flow control and implement true variable-speed capability with Lafert HPS Series permanent magnet motors and Invertek Optidrive E3 drives.
ReSult: The Hydropool Executive Trainers are the only jetted swim spa in the market with a true variable-speed swim current system. Lafert permanent magnet motors power the adjustable current and support an unparalleled swim experience which delivers the strongest swim resistance and lowest operating costs of any Hydropool swim spa.
SummaRy: Hydropool Hot Tubs, industry-leading Canadian manufacturer of hot tubs and swim spas and Jacuzzi company, was seeking a partner to support their development of next-generation technologies for a top-of-range swim spa. Lafert Group, long-standing manufacturer of permanent magnet motors for air and water movement equipment, started working with Hydropool to develop and integrate a proof-of-concept variable-speed swim current system.
The proof-of-concept eliminated swim current turbulence introduced by mechanical flow controls used in most swim spas, and the adjustable output could challenge worldclass triathletes or deliver a gentle current for young children at play. The value of the motor technology at the core of the proof-of-concept was apparent from the first test swim, and Hydropool engaged Lafert to support development of their new swim spa, the Executive Trainer.
The Executive Trainer swim current system is powered by two customized Lafert HPS Series permanent magnet motors, which are highly efficient at all speeds and exceed the IE5 “Ultra-Premium” standard for efficiency. The motors are about half the weight and volume of an equivalent-power induction motor and were engineered for reliable operation in the high-temperature, high-humidity environment of the swim spa enclosure. HPS Series motors are available to be customized for a broad range of machine applications up to fifty horsepower.
+1-800-661-6413 • lna.info@shi-g.com lafertna.com
Deep learning and machine vision solve complex advanced inspection for foil seal, tamper-evident packaging
challenge: The FDA, following a malicious product contamination incident in the 1980s, mandated tamperevident packaging for all pharmaceutical OTC products. Capping processes impact the formation of a complete and robust seal resulting in damaged/under formed seals which are hidden under a plastic cap.
solution: The seal is induction heated, making it adhere to the bottle rim. A thermal camera acquires an image of the foil thermal signature through the plastic cap in the post induction heating process. Some defects are clearly defined in the thermal images, while others are more difficult to quantify. The successful inspection solution is accomplished by combining analytical vision tools with deep learning in a “hybrid” imaging analysis.
Result: The system accurately captured important seal defects while maintaining a minimal false failure rate. Based on saved defect seal data, key areas of improvement identified resulting in improved cap torquing. This resulted in improved seal integrity and lower reject rates.
summaRy: This application shows how a hybrid inspection system may be developed and deployed successfully in the field utilizing analytical machine vision and deep learning technologies. To achieve high detection accuracy for both the clearly defined defect features and the poorly defined defect features, the system’s strengths are effectively combined. One such system for diverse products was effective in deploying it to numerous places. The technology maintained a low false failure rate while accurately detecting significant seal flaws. Finding variations in cap torque based on seal integrity and completeness was a crucial area for process optimization. The cap torque was changed to achieve tighter seals and decrease product rejects using the continuing process data.
Liquid on the cap and bottle, which could cause issues with later operations like labeling, was also discovered using thermal imaging. As a result, the overall quality was raised. Additionally, even uncommon flaws like fractured caps that would have gone unnoticed were effectively recognized by the system.
This program skillfully integrates cutting-edge imaging methods and analytical tools to significantly improve a crucial industrial process. The use of tried-and-true industrial thermal imaging techniques and an original combination of deep learning and discrete vision tools are essential to the solution. The outcome is a comprehensive solution with broad application in industry.
info@ai.motion.com • 800-AUTOMATE • ai.motion.com
L-R: 2D thermal images of a good seal, a bad seal containing an underheated section (magenta), and a bad overheated seal.
Gas Systems Used in Conscious Sedation Procedures Gets an
Alarm System Redesign
challenge: Dental equipment needed to be overhauled due to its overly complex assembly. The panel was developed in-house and had not been updated since the invention of the device. Belmed wanted to reduce the time and money that was spent on manufacturing.
solution: Belmed and NKK Switches worked together to create a streamlined design for the new alarm system with the LB Series illuminated pushbuttons with connectors. They could be soldered directly onto NKK’s simplified PCB.
Result: Belmed was able to reduce vendor count, cut costs, and save assembly time by utilizing NKK’s engineering department’s design. Their suggestions prevented a full panel redesign.
summaRy: Belmed manufactures both a wall mounted and a desk alarm manifold that is used with a medical gas device. The manifolds deliver a consistent gas supply to a dental facility at a constant pressure rate and monitors the pressure that is left in the gas cylinders. This system lets the dental office know when there is a low pressure reading coming from the tanks and notifies them when they need to either switch to new, full tanks or schedule a gas delivery. This is vital to ensure that there is always an uninterrupted gas (O2 and/or N 2O) supply during conscious sedation procedures.
The alarm system’s board was in dire need of an improvement. Belmed enlisted the help of NKK Switches’ engineering team, who were instrumental in updating the product with a new streamlined behind panel design, preventing a full redesign. This was done by replacing incandescent switches that required a wire harness to new LED switches that are now mounted via sockets to simply be soldered in.
In addition, NKK was able to provide them with a PCB assembly that included everything but the switches and the front panel. This saved time spent on labor because the recommended switches were easier to install as there was no more crisscrossing wires from the old switches.
Scan QR code to learn more
CaS e S tudy
omlox Installation at MANN+HUMMEL Speeds Order Fulfillment
Challenge: Finding the right goods in the warehouse is a challenge and takes time. Sometimes parts are missing or not loaded correctly.
Solution: 15 omlox satellites were mounted on the hall ceiling. In parallel, a stand-alone LAN cabling based on PPPoE was installed. Furthermore, five omlox tags were integrated into scanners to find and retrieve ordered products.
ReSult: Because the standardized omlox interfaces don’t create data silos, they allow data exchange across the organization speeding up the order fulfillment process.
SummaRy: One of the first users of an omlox installation is Mann+Hummel, a global manufacturer of filter systems. At its production facility in Speyer, Germany, the company manufactures filter systems for industrial and off-road applications — mostly small batches. Finding the right goods in the warehouse is a challenge and takes time. Sometimes parts are missing or not loaded correctly.
The requirements were clear. The pallets and individual boxes to be located should be easy to find and the pallet positions should be displayed in a layout. Finally, this should be visualized on a mobile frontend device. For this purpose, 15 omlox satellites were initially mounted on the hall ceiling. In parallel, a stand-alone LAN cabling based on PPPoE was installed.
Furthermore, five omlox tags were integrated into scanners. The scanner can record the location of the pallet and can be used to retrieve this location at a later time. Since the locating tag is integrated in the scanner itself, the scanner navigates to the stored drop-off location.
This one installation saved over 600 hours of search time. So as a next step, Mann+Hummel plans to connect to the ERP system for automatic, optimal loading when the truck arrives.
e S tudy
Seamless Integration Success: Patti Engineering Upgrades Automotive Leak Test Systems to Siemens Standard
Challenge: An automotive manufacturer required three leak test systems to align with their stringent software and hardware standards. The OEM lacked expertise in converting their Allen Bradley template to the manufacturer’s Siemens standard, further complicated by a new software version.
Solution: The manufacturer engaged Siemens Certified Solution Partner Patti Engineering, who structured the software from the Allen Bradley reference, writing code from scratch where necessary. Collaboration with the OEM’s engineer ensured the code met system requirements.
ReSult: Upon successful completion, Patti Engineering transferred ownership of the software, trained the OEM team and validated the system on site.
SummaRy: An automotive manufacturer purchased three leak test systems from an OEM. The OEM’s systems follow a turnkey, plug-and-play methodology where the equipment is completely standalone except for a few basic interlocks to the surrounding equipment. To reduce the upfront development, the OEM uses a standard template and only makes minor adjustments to sell to their different clients. However, this manufacturer wanted to use their own meticulously maintained software and hardware standards.
Overview of device configuration
While the OEM was well versed in their Allen Bradley software template, they did not have the background to convert their template into the manufacturer’s custom Siemens template. To ensure that the software development ran smoothly, the manufacturer recommended their trusted Siemens Certified Solution Partner Patti Engineering to bridge the gap between the OEM and the plant’s standards.
After software development, Patti Engineering trained the OEM team on the new code’s functionality and completed validation testing before the systems were packaged for delivery to the manufacturer. The OEM then took over ownership of the software and installed all three systems. At the end of the project, Patti Engineering maintained their status as a trusted advisor to the manufacturer and became a dependable, welcome Siemens resource for the OEM.
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Overall Leak tester Status Screen
CaS e S tudy
A steel manufacturer’s pipeline speed mismatch damages fresh steel, requiring frequent equipment repairs for tube production.
Challenge: A steel manufacturer specializes in tube production. Their process involves hot steel passing through a narrowing pipeline, gaining speed as it meets waiting rollers. Unfortunately, the motors controlling the rollers couldn’t keep up, resulting in damage to the steel and constant repairs.
Solution: To address this, Premier Automation introduced an innovative measurement system. Traditional sensors weren’t viable due to the heat of steel. Instead, engineers monitored electrical current spikes caused by the steel’s movement. Using this, they reprogrammed the equipment, synchronizing roller speed with the steel.
ReSult: This reprogramming reduced damage, saving the manufacturer repair costs. Premier Automation’s calibration eliminated issues and lowered expenses.
SummaRy: A large steel product manufacturer faced a problem with their seamless tube production process. Hot steel passing through a pipeline was moving at a different speed than the rollers designed to catch and move the steel.
This speed mismatch caused damage to the steel and required frequent equipment repairs. The solution was provided by Premier Automation, which developed a system to measure the steel’s speed by monitoring electrical current spikes required to move the steel due to the hot steel’s temperature.
They used this data to reprogram the customer’s Siemens PLC and drives, synchronizing the speed of the rollers with the steel.
As a result, Premier Automation’s solution significantly reduced the risk of damaged equipment and product. The frequent equipment repairs, which were costing the manufacturer thousands of dollars per week, were minimized. By properly calibrating the mill’s equipment, Premier Automation eliminated product quality issues, reduced downtime, and lowered repair costs.
CaS e S tudy
Quantum Design
Control Systems Retrofits a Plating Line Upgrading PLCs, HMIs, and More
Challenge: PLC5 controls and HMI are discontinued making it risky to continue running lines using those controls. Replacement parts are not readily available and customers resort to Ebay for replacement parts. Some parts may never be available and many companies can’t afford lengthy downtimes.
Solution: Quantum replaced the PLCs with a single Rockwell Compactlogix PLC, and the HMI with a new Rockwell Panelview Plus 7 Performance color HMI. A new Ethernet Network was added for communication between the HMI and PLC, lasers, and VFD.
ReSult: These upgrades have made the system more operable and reliable. Quantum also offers valuable after-market support and builds long-lasting relationships with customers.
SummaRy: Quantum Design knew the only option was a full retrofit on the existing line. The plant was having difficulty finding spare parts, and the risk of keeping the line outdated was growing daily.
The customer also requested better control on the barrel rotation motors and better hoist location feedback. Quantum moved the motors on to a VFD and two lasers were added to the system for position feedback, one for each hoist.
The existing PLC’s were replaced with a Rockwell Compactlogix PLC, and the HMI replaced with a Rockwell Panelview Plus 7 Performance color HMI. Quantum eliminated the Remote I/O connection putting in an Ethernet Network for communication between the HMI, PLC, lasers and VFD. A VFD packaged in a new Fiberglas enclosure with main disconnect ready to be mounted and wired to the existing motors was also added.
Twenty-nine barrel rotation motors were put on the VFD with individual overcurrent protection. Quantum installed a Sine Wave Filter on the output of the VFD to correct the wave shaping to not damage any of the motors. Using the VFD allows the operator to set the speed the motors run at to maximize the rotation for better plating.
The largest benefit seen by the plating line is updated technology, parts readily available and continued support resulting in less and shorter breakdowns.
CaS e S tudy
Tiny Module, Big Impact: Streamlined Design, Faster Development—Proof in Every Byte, Simplifying Protocols
Challenge: A conveyer/motor company enlisted a contract design manufacturer (CDM) to spec a new motor. The CDM needed a solution that leveraged existing Modbus RTU (board interface) communications to EtherNet/IP. With footprint and time being a big factor.
Solution: The RTConnect™ module from RTA features connectivity from Serial ASCII and Modbus RTU to Modbus TCP, EtherNet/IP or BACnet IP allowing the CDM to eliminate code development, redesign and overall shortened development time.
ReSult: Within 2 weeks the data models were established with board design and integration were supported. With some minor communication tweaks in the RTC module, the CDM was able to deliver proof concept to their client in under a month.
SummaRy: With an ever-growing list of technologies that need to be incorporated in the world of automation, industry 4.0 and robotics. It’s forcing device manufacturers to evolve quicker, get innovative products to market, and seamlessly integrate with existing equipment (oh yeah and be cost effective).
Having leveraged our protocol communication products in the past, the CDM tapped us on the shoulder for this project. They needed to leverage the clients’ existing Modbus RTU board interface and get communication in the device converted to EtherNet/IP. After discussing the full list of project parameters with the CDM from software stacks, gateways and the RTConnect module. RTA’s recommendation was the RTConnect module.
Both agreed, the RTConnect module was the right fit for this project and reduced many risk factors in the development cycle by removing front loaded licensing with source code, being fiscally responsible for a couple hundred units yearly and allowing the ability to make modifications/customizations in the comms to work with the customers original data modeling.
From receiving existing data modeling and supporting CDM testing, the process took about 2 weeks to get communications aligned and in under a month the CDM had a proof of concept to deliver.
Our CDM was ecstatic that they had proof of concept to deliver to their client rapidly and know that they have our Enginerd® support for modifications and conformance testing when the time comes.
CaS e S tudy
Keeping production running yields huge cost savings
Challenge: Changes to DCOM security enforcement were causing serious bottlenecks. Minor disruptions in the control system that used to take a few seconds to resolve were now shutting down whole production lines for up to five hours.
Solution: OPC DA tunnel/mirroring allowed engineers to network OPC DA securely, without using DCOM.
ReSult: Cost savings are significant. Security log-ins no longer require re-synchronizing across multiple machines, reducing shutdown times to a bare minimum. And engineering staff can now identify problems much faster than previously.
SummaRy: A large pharmaceutical manufacturer in the European Union faced a production bottleneck due to recent security changes in Microsoft Windows. Minor disruptions in their control system which used to take seconds to resolve began shutting down entire production lines for up to five hours, resulting in significant costs and operational disruptions.
The problem stemmed from Microsoft’s initiative to enhance security standards for data networking in Windows software, impacting the plant’s IT systems closely integrated with manufacturing processes. The plant systems use OPC DA, which relies on DCOM for networking. New, stricter DCOM security settings, mandated by a Microsoft security patch, created complications for the plant’s automation team.
To address this challenge, the team implemented OPC tunnelling using Cogent DataHub software. This solution allowed the pharmaceutical plant to establish secure connections between OPC clients on networked PCs and the OPC server on the main controller, without the need for DCOM. The result was a streamlined and more reliable system, reducing production downtime and making it easier to diagnose and resolve connection issues.
The successful implementation of Cogent DataHub tunnelling resolved the production bottleneck, resulting in substantial cost savings. It also improved system stability. The pharmaceutical manufacturer expanded this solution to multiple production lines, leading to enhanced operational efficiency and reduced downtime.
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CaS e S tudy
VTScada helps a South African ferrochrome smelter increase efficiency by providing a unified furnace
interface
Challenge: Bright Alloys was struggling to effectively run a battery of smelting furnaces built with different combinations of monitoring hardware and software resulting in low efficiency and a costly burn through.
Solution: Their integrator ElectroMechanica used VTScada software to create a scalable application that could communicate with their diverse array of PLCs and provide a unified operator interface for all furnaces.
ReSult: The completed VTScada application helped Bright Alloys achieve a one third reduction in natural gas consumption, a 10% increase in furnace availability, and vastly improved feed accuracy.
SummaRy: Bright Allows serves customers in Indonesia, China, and North America. “Our plant and furnaces were built in different times with different technologies,” says Andrii Denysiuk, Engineering Manager for Bright Alloys.
“So, one of our targets was to standardize.” Another goal was to eliminate operator blind spots that contributed to a burn through the year before. “We took weeks of downtime and loss of production,” says Denysiuk. Bright Alloys worked with integrator ElectroMechanica (EM) to select SCADA software that would solve these issues and provide advanced redundancy and scalability.
Timothy Kleinschmidt, Product Manager at EM recommended VTScada software by Trihedral. Built-in device drivers allow VTScada to communicate with their broad array of RTUs. EM used the drag-and-drop screen development environment to create a standardized interface for all furnaces. This, together with High Performance Widgets, Rate of Change Tags, and remote alarm management, provides the situational awareness to identify hot spots and prevent failures. VTScada’s integrated design and native historian allowed them to configure robust multi-server redundancy with automatic bi-directional synchronization.
“VTScada has changed our company culture completely,” says Denysiuk. “The way we manage faults and process requirements has changed drastically. We are now able to monitor our furnace operation online from wherever we are and apply changes immediately. I would recommend working with ElectroMechanica and VTScada.”
High-Stakes
Industrial Cybersecurity:
Precision Protection Prevents Costly Shutdowns
Challenge: The manufacturing client needed to improve OT cybersecurity amid increasing threats like lack of asset visibility, uncontrolled remote access, and lack of tailored tools.
Solution: The client partnered with and adopted Velta Technology’s OT Continuous Monitoring for real-time visibility, OT Secured Remote Access to control connections, and Velta Technology Lifecycle Services to implement an ongoing OT cybersecurity program.
ReSult: Following unauthorized external network access from a phishing attack, enhanced visibility and cyber protection measures protected against a cyber breach, allowed quick confirmation of no impacts to operations, and avoided a potential costly shutdown. Proactive resilience makes the difference when attacks occur.
SummaRy: The client’s manufacturing process uses multiple levels of automation to manage dangerous, high-pressure production of flammable chemical and fuel products. Process safety, precision, and resilience are paramount. The company engaged with Velta Technology to improve its OT cybersecurity amid increasing threats.
Key challenges included lack of visibility into OT assets, uncontrolled third-party remote access, and absence of tailored OT cybersecurity tools. To address these, Velta Technology and client implemented the following Velta Technology OT Cybersecurity Adoption methodology:
• OT Continuous Monitoring to provide real-time asset visibility down to the firmware level, detecting anomalies and threats.
• OT Secured Remote Access to control and audit all remote connections to the OT environment, enforcing MFA.
• Velta Technology Lifecycle Services to tune and maintain solutions, building an OT cyber program suited to the environment.
In the second year, an employee fell for a phishing email that resulted in unauthorized external access into the client’s network overnight. Thanks to enhanced visibility, the response team quickly confirmed:
• No OT network access or anomalies
• No data theft or ransomware
The proactive solutions avoided costly shutdowns, theft and damage. When attacks inevitably occur, preparation and resilience provide digital safety for operations. The program continues to evolve risk reduction in a cost-effective manner.
• No need to halt production
CaSe Study
Enterprise-Level SCADA for a Remote Solar Operations Center
Challenge: SB Energy needed a way to monitor and control their six national sites from their remote operations center. The new software’s performance needed to stand up to the sheer amount of data flowing in, while also providing a seamless and beautiful UI for ease of use.
Solution: Using Ignition, the Vertech team created an enterprise-level SCADA in the form of a single-platform, multi-site management software application.
ReSult: A robust, beautiful, and easy to use SCADA system that gives SB Energy real-time visibility and control of its sites, assets, and energy production performance.
SummaRy: This enterprise-level SCADA project involved designing an Ignition solution that could integrate with six solar sites to acquire, consolidate, and validate data from all the sites in real-time—while also providing site monitoring and performance analysis with clear industry relevance.
Vertech also designed their system with a standardized data model and dynamic screens, so SB Energy can easily expand the system as their needs grow.
Read below about some more of the innovative features built into this project.
Nuisance Alarm Filtering - Improved the alarming logic across the fleet to prioritize alarms and consolidate repeat alarms into one action.
Built-in Alarm Hierarchy and Dependencies - User-defined dependencies can be added to alarms—prioritizing upstream device alarms, and shutting off downstream device alarms. This enables the client to solve the root cause of the problem, rather than responding to hundreds of subsequent alarms.
Power and Revenue KPI’s - The system displays KPI’s from both business and operations, giving decision-makers a clear understanding of what’s happening across the entire portfolio.
Weather Forecast Integration - Open Weather Maps and Windy.com integration provides real-time weather updates for each site.
See more at vertech.com/case-studies/sb-energy
info@vertech.com • 480-756-2300 www.vertech.com
CaSe Study
Semiconductor company needs new systems to meet 2025 water reduction goals at multiple plants
Challenge: A leading semi-conductor company must increase its recycling to meet its 2025 global water goals. Systems need to be designed, installed, and supported at multiple sites with unique application programs for each plant that conform to stringent corporate design standards.
Solution: Wunderlich – Malec used integrated office teams to design and implement the control systems for the unique site applications of the customized water treatment skids.
ReSult: The multi-site systems successfully maximized standard aspects of the water treatment system applications at each installation with unique programs for local plant customer requirements and support achievement of the water recycling
SummaRy: Wunderlich – Malec successfully fulfilled the semiconductor company’s need to implement first-of-its kind, multi-site water treatment skid technology that would assist in achieving its sustainability goals for water usage thru the application of new recycling technology.
Wunderlich – Malec leveraged its subject matter experts and experienced, in-depth talent in control system technology and wastewater recycling applications located in its numerous offices to design, implement and support the systems at multiple local sites. WM engineers maximized all standard skid applications and tailored each control system to integrate seamlessly with each plant’s existing control and MES systems within the customer’s stringent corporate design standards.
The scopes of work at each facility included: GE Cimplicity SCADA development; Rockwell Studio Logix version 30; Rockwell RS Logix version 20; PLC to PLC redundant Ethernet (EnetIP); PLC to SCADA Ethernet (Telecom Network); Simulation testing to ensure programs meet design and Sequence of Operations (SOO) intent; I/O checkout procedures and automated applications for the Commissioning process, and more.
The customer benefited with the application of unique control systems that met their stringent corporate requirements. WM’s collaboration with the customer ensured maximum reuse of control system design and programs to reduce project costs. The customer received commissioning support assurance of long-term service from WM’s local office.
Phone 952-933-3222 or visit us online at www.wmeng.com
CaSe Study
How Yokogawa Migrated Legacy Systems at HDPE Plant with Integrated CENTUM DCS PCS and ProSafe-RS SIS.
Challenge: IRPC’s 152,000 t/y high density polyethylene(HDPE) plant relied principally on legacy pneumatic instruments and a PLC based safety system. Due to high maintenance costs and low efficiency, the plant needed new control systems.
Solution: Yokogawa successfully installed a fully integrated CENTUM DCS production control system (PCS) and ProSafe-RS safety instrumented system (SIS) together with a plant information management system (PIMS) and an asset management system (PRM).
ReSult: Phadet Prarom, the Division Manager, said, “We are now very comfortable operating the HDPE plant and are experiencing no major problems with Yokogawa’s systems. Yokogawa’s systems and products are highly reliable.”
SummaRy: The biggest challenge was applying the latest digital technology. Digital and pneumatic systems are fundamentally different in design and function. It took about five months to do a detailed study of all the control loops and configure the production control system, and another month to do all cabling/wiring and systems installation. In addition to the wiring of about 5,000 I/O points for the new systems, some field equipment was also replaced.
Operators also underwent training in the new PCS. Engineers and maintenance personnel went to Yokogawa’s office for training in system configuration using feedback and sequence control functions.
A fully integrated CENTUM DCS was installed alongside the ProSafe-RS SIS to give the polymerization process an emergency shutdown capability, and the SIS was integrated with the PCS. In addition, all PCS and SIS HART field devices can be monitored from the central control room with the Plant Resource Manager (PRM) package, enabling a more predictive and proactive maintenance approach that reduces total cost of ownership (TCO). Also, all process data can be handled in an integrated manner by the Exaquantum PIMS for improved product quality and system operation.
Innovations
HMI has 5.7-inch high-resolution touch screen, customizable graphical interfaces
The STC6000 series human-machine interface (HMI) from Pro-face has a 5.7-inch display, high-resolution touch screen and customizable graphical interfaces. Connectivity options, such as Ethernet, USB, CANopen, serial, DIO and EXM/TM3 expansion modules, enable integration with other automation systems. STC6000s are easy to setup and user-friendly. The HMIs support various communication protocols and are compatible with a wide range of industrial automation systems. Save cost, time and space in multiple applications such as controlling the speed of the conveyer for an industrial washing machine, motor control and recipe management. Pro-face by Schneider Electric, https://profaceamerica.com/en-US
Capacitive proximity sensors detect up to 30mm
AutomationDirect has added Balluff BCS series capacitive proximity sensors to its robust selection of object detection sensors. The proximity sensors, available in 12 to 30mm tubular, 50mm round and small rectangular body styles, offer sensing distances up to 30mm. These DC-powered sensors feature rugged stainless steel or thermoplastic housings with protection ratings up to IP67 for harsh industrial environments. The BCS series capacitive proximity sensors are UL listed, RoHS compliant and UKCA and CE marked. AutomationDirect, www.automationdirect.com/sensors-capacitive
Entry-level edge AI computing modules add performance, support multiple sensors
Acrosser Technology NVIDIA Jetson Orin NX and Jetson Orin Nano Modules are for edge AI computing applications. NVIDIA Jetson Orin module, AES-ORNXE, can achieve 275 TOPS, its performance is 8 times that of the previous generation, which can provide multiple parallel artificial intelligence inference processes, plus a high-speed interface supporting multi-sensor interface.
Acrosser Technology, www.acrosser.com/en
Electronic flow control for compressed air saves resources
A major benefit to using compressed air is the instantaneous speed at which it can be shut off and re-energized for use. Shutting down supply of compressed air to an application when unneeded can drastically reduce the compressed air consumption of the process over time, producing significant process and facility savings, even with high efficiency pneumatic equipment installed. There are many ways to shut the compressed air off, ranging from a simple ball valve and all the way up to a PLC system using optics to locate parts and turn that air source on and off based on target position. Electronic flow controls applied to compressed air can save resources. Exair, www.exair.com
D-shaped, compact cylindrical reed sensor saves space for proximity, limit sensing
The Littelfuse Inc. 59001 reed sensor is miniature D-shaped and cylindrical, offering a compact size, high performance and customization options, said to be an ideal choice for various industrial, appliances and IoT proximity sensing applications. Its compact size, just 13.5 mm x 5.0 mm x 4.6 mm (0.591 x 0.197 x 0.181-inches) fits in applications where size constraints are a concern. Its D-shape provides a “pokayoke” mechanism that simplifies installation, ensuring proper orientation of the sensor in the assembly. Littelfuse Inc., www.littelfuse.com
Compact magnetic encoder for many brushless DC and stepper motors
The Nanotec compact magnetic encoder NME3 has a modular design and can be combined with a wide range of brushless DC and stepper motors, starting from flange size NEMA 8. With a maximum speed of 30,000 rpm, the NME3 single-turn absolute encoder is an excellent choice for applications that require precise speed control. Even in harsh environmental conditions it provides reliable readings because the magnetic scanning is insensitive to dust, shock, vibration and high temperatures. The encoder has two versions: for incremental signals with a resolution of up to 4,096 CPR and with an SSI interface and 16-bit resolution.
Nanotec Electronic, https://us.nanotec.com
Commercial duty service entrance rated transfer switches
Russelectric, a Siemens Business, announced its new RTSCD-SE commercial duty service entrance transfer switches, a cost-effective option ideal for commercial spaces. Industrial plants and manufacturing facilities can rely on the RTSCD-SE to combine automatic power switching with the necessary disconnecting, grounding and bonding required for use as service entrance equipment. RTSCD-SE transfer switches incorporate a user-friendly operator interface panel that features a keypad with text and icons and comes standard with an historical event log. The product is available in 2, 3 and 4 pole models, with solid or fully rated switched neutral. Featuring rapid and reliable arc quenching, the front connected RTSCD-SE offers manual transfer with rapid arc interruption, as well as a permanently affixed manual handle and mechanically held contactor. Contacts are easily accessible for convenient inspection. The switches meet UL1008 up to 480 (VAC).
Russelectric, A Siemens Business www.siemens.com/us/en/products/energy/russelectric.html
See more New Products for Engineers www.controleng.com/NPE
24-V power supply has space-saving design, smart diagnostics
The Trio Power 24 V power supply from Phoenix Contact features a space-saving design, easy handling and smart diagnostic functions. Output currents range from 5 to 40 A. The line includes options with an integrated multichannel circuit breaker. The power supplies’ narrow overall width saves space, making it possible to mount them directly, side by side. The low overall depth enables installation in 210 mm small housings. Push-in connection technology, marking fields, stripping identification and tamper-proof setting make it easy to install and handle. The devices have an intuitive commissioning concept and diagnostic options.
Phoenix Contact, www.phoenixcontact.com/en-us
VOC gas detectors
GasDog VOC gas detectors provide a range of fixed sensors and portable gas monitors for the detection of volatile organic compounds (VOCs). It is important for many industries to have accurate and fast detection of harmful VOC gases to avoid the gas reaching dangerous toxic levels. Products include GasDog handheld methane gas detector, industrial fixed methane (CH4) gas detector, fixed ethylene (C2H4) gas detector and others. The detectors can help with risk assessments and for design of effective gas detectors and detection systems.
GasDog, https://gasdog.com
Ultra-compact Industrial PC adds power, interface options
With the new C6040 ultra-compact industrial PC (IPC), Beckhoff is adding more scalability in power and interface options to its C60xx series. Leveraging 12th Gen Intel Core processors with up to 16 cores, the controller is ideal for handling extremely complex automation projects in one ruggedized controller measuring just 132 x 202 x 76 mm. New applications include greater capabilities for sophisticated multi-axis motion, complex HMI applications and systems with extremely short cycle times, including onboard machine learning or machine vision integrated into the standard automation software and hardware from Beckhoff. Beckhoff Automation, www.beckhoff.com/en-us
Two-in-one analyzer for petrochemical, gas processing, biogas and gas pipeline industries
Keco offers the CS Hound Two-in-One Analyzer for measuring hydrogen sulfide (H2S) and carbon dioxide (CO2) as part of quality and process control in chemical plants, gas processing facilities and landfill/waste treatment operations. The analyzers offer a fast and cost-effective method for measuring H2S and CO2 in natural gas, biogas and air. Employing microprocessor-based technology, the CS Hound provides continuous online analysis based on NDIR sensor for and electrochemical cell technologies. In operation, the gas is introduced to an electrochemical detection element and NDIR sensor that provides an output proportional to gas concertation. Analytical Systems Keco, https://liquidgasanalyzers.com
Cased pumps for biotechnology applications, fluid handling
Developed for biotechnology applications, WMFTS’ range of peristaltic pumps resolve fluid handling challenges. Applications include processing for a wide variety of biopharmaceutical applications that demand sterility, repeatability, flexibility and precision. The 500, 600 and 700 series Watson-Marlow cased pumps are EtherNet/IP and Profinet-enabled for digital network control to reduce operating costs and minimize downtime. With network dispensing functions, operators can create dispensing and dosing recipes which can be remotely adjusted and controlled to ensure accurate and repeatable filling. The direct interface provides an extended, smart communication capability that enables seamless integration with pressure and flow sensors to safeguard process integrity. Watson-Marlow, www.wmfts.com/en-us
MEDIA SHOWCASE FOR ENGINEERS
Back to Basics
How digitalization, digital transformation strategies are evolving
The goals of industrial digitalization have changed; there are many potential disruptions in the digitalization journey for manufacturers.
While the initial wave of industrial digitalization was primarily driven by the need for efficiency, productivity and cost reduction – with a focus on integrating systems, automating processes and optimizing operations – as sustainability and environmental responsibility have become more urgent, the drivers for digitalization are evolving in tandem.
This is confirmed by Stefanie Frank, head of strategy at Siemens Digital Industries. “Today, organizations are leveraging digital tools not just for operational excellence but also to achieve their environmental impact and carbon emission reduction targets. Advanced analytics, industrial Internet of Things (IIoT) sensors and AI-driven insights are being used to monitor and reduce energy consumption, optimize resource usage and minimize waste. Digital twin technology, for example, allows companies to simulate, test and optimize new products and more eco-friendly production methods in a virtual environment before implementing them in the real world.”
tions more efficient and effective. This is why collaborating with companies that specialize in managing industrial data is crucial, as they can significantly augment the chances of a successful digitalization initiative.”
Interconnections, communications
Read more of this article: www.controleng.com/articles/ how-digitalization-digitaltransformation-strategies-areevolving
Even as the objectives of improving efficiency and productivity remain relevant, there is definitely a new focus – employing digital tools directly for sustainability goals. With increasing regulations and consumer preferences for more sustainable products and supply chains, companies that integrate sustainability into digitalization strategies will have an advantage.
Sustainable manufacturing initiatives
Barry Turner, technical business development manager at Red Lion, said: “Initially, the digitalization movement was aimed primarily at unlocking valuable data buried within industrial applications. As organizations ventured deeper, they discovered that this data could not only drive business successes but also foster sustainability initiatives. They found that the field data could be utilized to craft strategies that enhance business sustainability.” Now digitalization offers value by facilitating access, connection and visualization of data. “This process, intrinsically, is fostering more sustainable organizations, as they are able to develop initiatives based on concrete data, making their opera-
Eric Halvorson, partnership marketing manager II – strategic programs, automation and control at Digi-Key, pointed out that industrial digitalization has been more of an evolution than a revolution. “When we look at industrial digitalization” used to mean “interconnecting motors and equipment through a network of industrial sensors as a means to actively monitor assets throughout their life span on the floor. This enabled operators to see where equipment and assets were operating within specified tolerances and where they may not be. Operators could create maintenance plans that would reduce down time, increase productivity and efficiency all while reducing waste and environmental impact.” Now, he said, digital twins enable operators to add machine learning into the equation.
Cutting, reducing energy consumption
Chris Smith, director of projects and engineering at Wago, highlighted the role that industrial digitalization has to play in helping companies cut down on their energy consumption by integrating renewable energy into their operations. “Various technological solutions – such as energy storage systems and smart grids – can help companies manage their energy usage. Industrial digitalization enables organizations to adopt sustainable methods by enhancing the traceability and monitoring of their materials. This enables them to reuse or recycle products more effectively by ensuring that their conditions are documented throughout their life span.” ce
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No coating. Brilliant for the environment.
Coating-free aluminum gearmotors – the ECO2 design ECOlogical, ECOnomical, and uncompromisingly sustainable.
Drives in the ECO2 design: Efficient and reliable
Aluminum reacts with oxygen to form a thin protective layer
– In indoor spaces with a maximum humidity of 60%
– At temperatures of -20 °C up to a maximum of +60 °C
– The ECO2 design meets the requirements of ISO 12944 corrosivity category C1.
In a dry, neutral environment, aluminum and plastic are well protected from corrosion
ECO2: economical and ecological
The demand for eco-friendly products is growing. We have responded to this with our sustainable, coating-free drives and our responsible use of raw materials. ECO2 describes our high performance gearmotors made from uncoated aluminum. They’re both ecological − thanks to their environmentally friendly coating-free design − and economical, as a result of their cost-efficient manufacturing and assembly process. What’s more, components can be recycled more efficiently and sustainably at the end of their life cycle. All this is good for the environment and for your wallet.
