Advanced motion control with up to 400 moves per axis and various single- and multi-axis operations including position and speed control, helical interpolation, and ellipse interpolation
FREE IEC programming with structured text, ladder logic, and more
Multiple networking options including support for EtherNet/IP, Modbus TCP, Modbus RTU and ASCII
High-density I/O (32 points embedded on CPU and select I/O expansion modules)
High-speed I/O (integrated 2- or 6-axis pulse/direction motion inputs/outputs (up to 200kHz) on the CPU module, and up to 4 channels of high-speed inputs at up to 500kHz on each high-speed counter module)
FREE award-winning service and technical support
By combining PLC products from a well-established global PLC manufacturer (LS Electric) with a customer-focused value-centric online supplier, you get the best of both worlds, otherwise known as the LS Electric XGB PLC from AutomationDirect. The LS Electric controller has many great features including cutting-edge motion control and powerful software, but add to that the customer satisfaction, the amazing $299.00 starting price, and the FREE tech support provided by AutomationDirect, and you’ll de nitely say “YES!” to LS!
One controller can handle PLC, motion control, secure cloud connectivity and beyond
Don’t bog down your digital transformation with expensive standalone IoT gateway devices that only do one thing – connect. And for that matter, you can skip the standalone controllers for PLC, motion, safety and more. PC-based machine controllers, including the CX52x0 series Embedded PCs from Beckhoff, deliver all the automation and connectivity functions you can throw at them. For complex control, edge computing and IoT applications, they provide an unbeatable price-to-performance ratio with extensive PC and fieldbus interface options. Let’s find a better way to go from sensor to cloud and reach your digital transformation goals – with Beckhoff.
CX5230: Intel Atom® x5-E3930, 1.3 GHz, 2 cores
CX5240: Intel Atom® x5-E3940, 1.6 GHz, 4 cores
INSIGHTS ANSWERS
9 | Career Update: Is your change management up to par?
| International: How to integrate process, digital
| Market Update: Automation M&A, video on motors and mobile robots, robot orders, AI
15 | Pack Expo Las Vegas 2023: Developing automation systems for facilities, Digital twins, new servos, machine performance advantages, Five pillars to improve operational cybersecurity, Robots as a service, learn from more interviews at www.controleng.com, ONLINE: Headlines, conference, shows; Dick Johnson dies
19 | Think Again on Control Engineering 2023 research: SCADA as I say, not as I do
ANSWERS
20 | Three things to consider when deploying edge computing (including AI)
23 | Control Engineering 2023 AI research: Faster acceleration or hesitation?
24 | Data analytics, machine learning on the plant floor
28 | 7 ways SCADA advances IIoT, if you do it right
30 | PLC standards, modern programming tools
32 | Turnkey automation for first-of-a-kind process: Before/after HMI
36 | Improving efficiency through algorithmic production scheduling
Best of Industrial Cybersecurity Pulse
37 | Taking IT/OT convergence from theory into practice
INSIDE MACHINES (after 38)
M1 | How electric linear actuators improve material handling automation
COVER: Companies that invest in cybersecurity and infrastructure at the edge can optimize plant operations with improved data gathering and tools such as artificial intelligence and machine learning. (AI/ ML). Courtesy: Interstates
M4 | Four manufacturing concepts that benefit from under-rider AMRs TM Technology and
INNOVATIONS
45 | New Products for Engineers – See products in this issue.
See more products in the New Products for Engineers Database. www.controleng.com/products
47 | Back to Basics: Securing OT with IT cybersecurity best practices
With digital transformation comes the need for robust cybersecurity specific to the operational technology (OT) domain. The information technology (IT) domain can help.
NEWSLETTERS ONLINE
Machine and Process Safety
• Five steps for driving safety culture; Safety, productivity can be compatible Mechatronics and Motion Control
• How electric linear actuators improve material handling automation; robots as a service CE System Integration
• Unified environment for control system integration benefits; Benefits of legacy equipment upgrades
Watch for the next edition with the November/ December issue; until then, reference the last edition. Have a story to tell about system integration? Integrator Giants. Contact: kparker@cfemedia.com; cvavra@cfemedia.com. www.controleng.com/GSIR
u Control Engineering eBook series, now available: Fall edition
AI & Machine
Learning eBook
Artificial intelligence (AI) and machine learning are becoming crucial to manufacturing’s success. A machine and an industrial network learn and adapt.
Security the IIoT eBook
The industrial Internet of Things (IIoT) offers manufacturers a great deal of potential because it connects many devices to the internet that could not before. That connectivity, however, comes with a potential drawback because it also makes devices more vulnerable to cybersecurity attacks.
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
Online Highlights
Hot Control Engineering digital transformation articles in 2023
u Control Engineering most-viewed articles online about digital transformation published in the last year include stories on new technologies impact on digitalization, digital twin simulations, digital transformation and system integration and more. Also: See additional digital transformation stories.
1. The impact of new technologies on automation and digitalization system architectures
Digital telecommunication evolution has been rapid over the past several years and is providing near real-time communication.
2. How digital twin simulations advance digital transformation in manufacturing
By increasing visibility into a company’s manufacturing operations and testing an unlimited number of what-if possibilities in real-time, a digital twin can provide factories a reliable way to save time and money.
3. Digital transformation at Gibson, control system integration for chemical, food and beverage 2023 System integrator of the Year, Eosys, excelled in digital transformation, batch control, and other control and automation system project integration, with emphasis on mentoring and continuing education.
4. MQTT’s benefits for digital transformation Message queuing telemetry transport (MQTT) addresses many of the challenges involved in today’s increasingly complex industrial networks and can boost digital transformation initiatives.
5. How digital twins can enable optimization
Digital twins are being used to achieve process design and operational performance improvements for manufacturers. ce
– Chris Vavra is web content manager for CFE Media and Technology.
Tiny, shape-shifting robot can squish itself into tight spaces
u CU BOULDER RESEARCHERS have developed the Compliant Legged Articulated Robotic Insect (CLARI), which is designed to passively change its shape to work in tight environments, which could make it useful in emergency situations. CLARI can passively change its shape from square to long and slender or wide like a crab. Courtesy: Casey Cass, CU Boulder https://www.controleng.com/articles/ tiny-shape-shifting-robot-can-squish-itself-into-tight-spaces
VIDEO: AI improves robot picking
u ARTIFICIAL INTELLIGENCE improves robot performance, as explained in a video interview with Richard Ankney, global account manager, robots and discrete automation, Robotics Business Unit, ABB, at Pack Expo Las Vegas 2023.
Courtesy: Mark T. Hoske, Control Engineering
Also online, see Pack Expo Las Vegas interviews with automation experts from Emerson, Mitsubishi, Siemens and Yaskawa. Search Pack Expo Las Vegas at www.controleng.com.
In this issue, see more from Pack Expo, pages 15, 16; and more on AI on pages 20-25.
Control Engineering hot topics, August 2023
u HOT TOPICS in Control Engineering, for July 2023, for stories posted in the last three months included:
1. PLC programming language fundamentals for improved operations, maintenance
2. Is Industry 4.0, smart manufacturing working for you?
3. Automation upgrades reduce sortation system wiring and lower costs
4. Edge controllers save money, lower risk for water pipeline, pumping, storage
5. SCADA’s role in Industry 4.0, manufacturing applications
6. How electrification of linear actuators improve material handling automation
7. Are you making the most of PLC programming standards from PLCopen?
8. Motion control, ease of use, sustainability: Pack Expo Las Vegas 2023
9. Turning smart devices into valuable IIoT devices
10. Are you prepared for the future of manufacturing?
David Miller is a Control Engineering content manager, dmiller@cfemedia.com.
Join us at Automation Fair 2023, the world’s premier manufacturing technology event, and experience the hottest innovations, the smartest experts and the latest strategies for industrial automation and digital transformation.
This year’s event is bigger and better than ever before — more training, more technology, more inspiration, more ways to connect. It’s everything you love about Automation Fair plus the best of ROKLive, PowerPlex, and Process Solutions User Group — all in one extraordinary event. No matter your role or specialty, there’s something for everyone at Automation Fair.
WHAT WILL YOU DISCOVER?
Learn more about the event and how to register: rok.auto/AutomationFair
NOVEMBER 6-9, 2023 | Boston, Massachusetts, USA
Register now!
Is change management working?
How to ensure your change management investments don’t go to waste
Global corporate expenditures on change management programs in 2016 were $10 billion a year. At a 5% per yearly increase, annual change management expenditures exceed $14 billion dollars today. Despite this significant expenditure, 70 percent of these projects fall short of their objectives as they fail to demonstrate any sustainable improvement in performance.
Sometimes slow is needed
The speed at which change programs are implemented often jeopardizes the project's outcome. Many result in a greater chasm between the workforce and management than before the change program was initiated. As workers who are suspicious of management's intentions resist adopting workflow changes, morale, customer service and productivity often decline—sometimes irreversibly.
Employee resistance to change reveals an underlying trust problem between management and employees. It’s exacerbated by a constant flow of change initiatives that create fatigue. If there’s no analysis or learning from the last failed attempt, companies risk launching an endless wave of change initiatives that never deliver on their promises.
Place employees at the center
Management is responsible for applying best work practices, utilizing current technology and implementing efficient workflows. Given the disappointing results of their change efforts to date, it may be time for them to reconsider change strategies and adopt new methods that are inclusive and transparent. This management re-think is critical for companies if they are going to succeed in our hypercompetitive global economy. As a management consultant, I have participated in change projects with public corporations on four continents and 10 countries. What I’ve learned about organizational change is simple, but essential: management must approach change holistically. Successful change programs incorporate both the human and the process sides of change. They elevate the
human contribution to workplace improvement.
This approach does not impose change on employees who are not given a voice. Rather, it empowers them as agents of change. It aligns workforce goals with management objectives. Placing employees at the center of the change strategy can alleviate apprehension, fear of job loss and lack of trust.
Key takeaways for management consideration
Organizations can consider the following before embarking on their next change initiative:
• Think about your senior team's management style. Is it authoritarian? Participative? A hybrid of the two? What type of organizational structure supports your management of the business? Are you organized around revenue streams or silos?
• What would your employees say about your working environment? Do they see it as benevolent, benign or toxic?
• How would your employees define the organization’s culture? We are not referring to whether your culture is viewed as customer centric or a clan culture. These are manifestations of what you do as an organization. We are interested in the inputs that determine your culture. For example, which values guide the organization? Unfortunately, most corporate cultures are by default, not by design. Instead, culture should be shaped and cultivated by leadership.
These human behavioral issues can no longer be ignored by management. They must be addressed as part of the change process. Work has evolved from labor intensive to knowledge intensive, and is now becoming a creativity intensive effort. The management of organizational structures that support work must change significantly to complement this evolution. ce
Peter Harlamon, senior consultant and associate, Daniel Penn Associates. Edited by David Miller, content manager, Control Engineering, CFE Media and Technology, dmiller@cfemedia.com. Daniel Penn Associates is a CFE Media content partner.
controleng.com
KEYWORDS: Change Management, Workforce Development
LEARNING OBJECTIVES
Learn why 70% of change management projects fall short of their objectives.
Explore how giving employees agency in driving change initiatives can improve trust, morale and overall outcomes. Discover other techniques for ensuring the success of change management initiatives.
ONLINE
This article online has twice the information. Click the headline in the digital edition to see. CONSIDER THIS
What strategies can you implement to improve your next change management initiative?
How to integrate process, digital technologies to increase petrochemical factory output
Automation and controls company and Chinese petrochemical firm integrate technologies for smart factory benchmarking. One plant reduced manual operation more than 50% and increased propylene yield by more than 0.1%.
With new technological advancements and rapid changes in new concepts, the construction of intelligent factories in the petrochemical industry has become more complex and diverse. How can petrochemical enterprises realize digital transformation more effectively?
Honeywell and Shenghong Petrochemical jointly released the white paper June 28, “Dual Technology Integration, Operational Excellence: Honeywell-Shenghong Petrochemical Smart Factory Practices” during the 14th Summer Davos Forum. Plant benefits include reduced manual operation of more than 50% and increased propylene yield by more than 0.1%.
The core secret of dual-technology integration
For many years, Honeywell and Shenghong Petrochemical have maintained a close strategic partnership. For two years both discussed how to promote digital and intelligent transformation of Chinese petrochemical enterprises. Starting in 2021, they conducted comprehensive cooperation in intelligent factories and advanced control around the Propane Dehydrogenation (PDH) device of the second phase project in Sierbang. Shenghong is promoting the process of digital transformation through digital operation and intelligent production.
Bai Wei, president of Shenghong Petrochemical Industry Group, said, “Honeywell is not only a supplier of process control systems and a provider of process technology.” Empowered with Honeywell digital intelligence technology, Shenghong connected the process of procurement, production, sales, logistics, human resources and finance, building a strong innovation empowerment platform for the digital transformation of the industrial chain.
The project included Honeywell’s in-depth integration of its UOP refining process technology and expert insights.
Talking about project integration, Liu Maoshu, vice president and general manager of Honeywell Performance Materials and Technologies Group in Asia-Pacific, said: “Honeywell can fully and closely integrate UOP’s century-old process technology with mature digital intelligence technology, and provide the process industry with the most effective and efficient way to optimize operations and make decisions by focusing on the safety of the enterprise's production, operation optimization and decision-making, providing innovative ideas for technological change in the process industry and helping to build a new digital ecosystem in China.”
Explore more digital technology application possibilities
As early as 2019 in the refining industry, Honeywell presented a forward-looking “future refinery” concept. To build a smart factory for the process industry, it is necessary to realize the digital construction and transformation of the whole lifecycle from the vertical application layers (including the perception and control layer, the production and operation layer and the enterprise management layer), as well as the horizontal implementation process, such as making full use of the digital delivery results in the design phase.
Stone Shi, Control Engineering China
‘The plant integrated operating windows, advanced control and optimization, intelligent operation management and digital twin and interconnected applications.’
Based on empowerment and focusing on the construction goals of ensuring process safety, optimizing plant efficiency, improving production management, reducing operating costs and creating a benchmark for intelligent plants in the propane dehydrogenation industry, Honeywell implemented seven sub-systems in the Sierpong plant using integrated operating windows, advanced control and optimization, intelligent operation management and digital twin and interconnected applications. Doing so delivered considerable digital benefits. Through the deployment, implementation and efficient operation of seven major subsystems, Honeywell helped Shenghong solidify its device performance, production costs and key carbon emission indicators. The PDH device in Sierbang has become the first production device in China that combines process technology and intelligent technology applications to achieve comprehensive intelligent production and digital operation.
In the modern central control room of the Sierbang factory, operators can use the large screen of the Honeywell Experience PKS Orion Console to clearly view the trend monitoring and real-time key-performance indicators (KPIs) of multiple sets of operating data. Led by the successful practice of this smart factory, Sierbang reconsidered the application of digital intelligence technologies, expects to continue to deepen and promote digital technology in the future and continues to explore and unlock the wider application of new technology in more installations.
Implement dynamic iteration of connected factories
As one of the important pillar industries of the national economy, in recent years, the petrochemical industry has faced the opportunities of the commissioning boom with more severe market uncertainty, operational safety, green dual-carbon, human resources and other challenges.
Bai Wei said: “Petrochemical companies with heavy resource inputs and continuous operations
HONEYWELL and Shenghong Petrochemical Courtesy integrate and optimize digitalization and control optimization throughout plants’ lifecycles. Control Engineering China
will face more difficult challenges in the face of market volatility and uncertainty. But the more difficult the context, the more meaningful the digital and intelligent transformation of the industry.”
Through the digital transformation journey, Shenghong has benefited. Taking the most intuitive level of plant automation for example, Bai Wei said: “the original operator daily flow, temperature, pressure of the operating habits, through the application of Honeywell's automation, intelligent technology, to achieve the manual operation of more than 50% reduction in the frequency and improve the device self-control rate of more than 95%.” In addition, the solution “improves the device self-control rate to more than 95%, increases the propylene yield by more than 0.1%, and successfully creates a model of intelligent plant in the PDH industry.”
Enterprises can start with intelligent pilots of individual devices (such as PDH, etc.), gradually expand to enterprise-level applications and related organizational support and explore the potential of the application of technologies such as artificial intelligence and process digital twins, to increase digital capabilities. Liu Maoshu said that Honeywell has rich experience in digital transformation, one-stop totalization and automation solutions and strong local research and development team. These can tailor the operation system according to the enterprise’s characteristics, help the industry to solve the challenges faced in the process of digital transformation and ensure the smooth project delivery. ce
Stone Shi is executive editor-in-chief, Control Engineering China. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com.
controleng.com
KEYWORDS: Digitalization, process optimization
LEARNING OBJECTIVES
Understand how Shenghong Petrochemical and Honeywell collaborate on integrating digitalization and plant optimization control technologies to decrease manual operation and increase output.
Consider how smart factory optimization includes digital construction and transformation of the plant lifecycle from the vertical application layers and using results in the design phase at other plants, dynamic iteration of connected factories.
CONSIDER THIS Is digitalization helping design, integration and implementation of controls technologies?
ONLINE www.controleng.com/ international
Are you affected by September automation mergers, acquisitions? Check here
uAMONG 17 automation-industry acquisitions reported in September were those involving Ultimation, Matrix, Barcoding, Ametek and United Electronic Industries, according to Bundy Group, an investment bank and advisory firm. The firm provides an update on mergers and acquisitions and capital placement activity for companies that address the manufacturing and plant management fields. While numerous industries are witnessing a lower volume of closed mergers and acquisitions transactions due to higher interest rates and other macroeconomic challenges, the automation M&A market shows no lost momentum. Including a recent-
VIDEO on low-voltage motors, mobile robots reveals how to add flexibility
THE ULTRA-LOW voltage motor market is projected to reach nearly $6.5 billion by 2027, driven by demand from battery-driven applications and increased flexibility in manufacturing and logistics processes.
Strong growth is driven in part from growth in the mobile robotics industry, which is emphasizing greater flexibility. In a video interview, Interact Analysis research manager Blake Griffin and research analyst Brianna Jackson discussed these trends, future outlook and the industries impacted. ce
– Chris Vavra, web content manager, CFE Media and Technology, cvavra@cfemedia.com.
Read more; see video: https://www.controleng.com/articles/ultra-lowvoltage-motor-motor-drive-industry-growth-drivenby-mobile-robotics-increased-flexibility/ Online controleng.com
ly closed transaction (Bundy Group represented Ultimation in a sale to MCE), there continues to be strong interest from strategic buyers and financial sponsors in the automation segment. Business sales include Valstone’s acquisition of Matrix Industrial Control Systems, Graham Partners’ acquisition of Barcoding, and Ametek’s acquisition of United Electronic Industries. This article online has more on the transactions. ce
Clint Bundy is managing director, Bundy Group, a Control Engineering content partner. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com.
u THE BUNDY GROUP reported 17 automation transactions in September; see details online. Courtesy: Bundy Group
Robot orders decline in 23Q2 after record highs in 2022, 2021
THE NORTH AMERICAN robotics market declined for the second consecutive quarter due to a sluggish U.S. economy and high interest rates, resulting in a 37% drop in robot orders and a 20% decrease in value in Q2 2023 compared to the same period in 2022, said the Association for Advancing Automation (A3). Companies ordered 7,697 robots valued at $457 million from April to July 2023, a 37% decline in robot orders and 20% drop in value over the same record-setting period in 2022. Non-automotive customers ordered more robots during that timeframe than automotive customers. See more with this article online. ce
– Association for Advancing Automation (A3) is a CFE Media and Technology content partner. Edited by Chris Vavra, web content manager, CFE Media and Technology.
Edge AI market projecting strong growth; can 5G and IT help?
THE EDGE AI MARKET is expected to grow at a compound annual growth rate (CAGR) of 20.8%, according to a report by Future Market Insights. By 2032, the market is expected to be worth $39.61 billion, up from $5.9 billion in 2022, FMI said. Top organizations use edge AI software to access data and respond in real time, projected to boost edge AI market growth. Real-time data processing, efficiency and accuracy reduces work time. Growing use of IoT, edge AI software devices and 5G will help. See more online.ce
– Edited from a Future Market Insights press release by CFE Media and Technology. Future Market Insights is a CFE Media and Technology content partner.
Accessing Production Data vs Cybersecurity?
Why not both?
An in-depth white paper from Skkynet asks why you should have to compromise between data access and security. Industry 4.0 and IoT are forcing companies to pull data from production and feed it to IT departments or the cloud. The question is, how to do that securely?
Industry experts and governmental agencies agree that the most secure way to connect OT and IT is to segregate networks by using a DMZ (“demilitarized zone”). NIST reference document SP-800- 82 describes zero-trust OT network segmentation like this: “The most secure, manageable, and scalable control network and corporate network segregation architectures are typically based on a system with at least three zones, incorporating one or more DMZs.”
Making connections through a DMZ is not straightforward, however. Neither MQTT nor OPC UA were designed for this. What is needed is the ability to daisy-chain a connection across multiple zones, while keeping all inbound firewall ports closed on both the OT and IT sides. The best way to do this is through secure tunnelling.
The white paper explains how tunnelling works and provides some helpful tips for securing a tunnel connection. It also mentions some potential pitfalls in attempting to use OPC UA or MQTT across a DMZ and explains why a VPN is not a good choice.
More than ever, companies need remote access to their process data. But there’s no need to compromise on cybersecurity. Tunnelling technologies can connect OT and IT systems securely in real time. It is possible to achieve a level of security comparable to an in-plant network, and still access the production data you need.
CLICK to download the white paper.
info@skkynet.com skkynet.com
SCAN QR CODE AT RIGHT FOR SMARTPHONE ACCESS
Pack Expo Recap: Developing automation systems for facilities
uPack Expo returned to Las Vegas and was full of interactive displays and demos highlights many advances in the packaging and logistics industries. Many of the advances displayed highlighted progress with the Internet of Things (IoT), smart manufacturing and artificial intelligence (AI). Manufacturers are trying to deliver products that go beyond their initial offerings because their customers need to resolve many problems at once.
Comprehensive, easy to use
Issues like the skills gap and high customer demand remain constant issues. As a result, many of the manufacturers displaying at Pack Expo reported they were trying to deliver solutions that are comprehensive and easy to use.
Dan Barrera, sales and product management for ctrlx Automation at Bosch Rexroth, described their goal as a “factory automation system.” Their platform is designed to provide a comprehensive IoT connection that provides openness with
Integrated
machine vision
The Beckhoff Vision product family is designed to deliver high scalability and long-term availability in a rugged, sleek – and highly awarded – design.
Courtesy: Chris Vavra, CFE Media and Technology
Open IIoT OS connections
Design of Bosch Rexroth’s ctrlx Automation platform provides a comprehensive IoT connection provides openness with the user’s hardware and software systems. Courtesy: Chris Vavra, CFE Media and Technology
the user’s hardware and software systems.
For Pack Expo, Barrera said, “We’re trying to deliver virtual packaging solutions for factory automation,” to their customers in the packaging and processing industries as well as others.
That’s not an uncommon refrain. Companies are expanding beyond their normal bounds of being a “controls” company or a “motor and drive” company and trying to expand their range across a plant facility.
Matching vision and automation software
With Beckhoff Vision, engineers can see what’s possible when machine vision hardware and automation software are perfectly matched. The line of EtherCAT-enabled industrial cameras, lighting and lensing components are paired with TwinCAT Vision software to round out their product portfolio.
“We can actively control light, position and axes of motion,” said Todd Jarvey, a machine vision and automation specialist at Beckhoff Automation.
Making automation simple, efficient
Nicolas Garcia, vice president and general manager of Rotzinger Group, aims to give consumers in the packaging, food and beverage and other industries an allin-one solution. “We’ve worked to combine everything to turnkey solutions, and we can manage a complete system,” he said, adding they want to supply a full packaging line to customers where there is one point of contact.
Universal Robots’ booth was about emphasizing expertise with collaborative robots, which were picking up differentsized boxes and placing them on pallets.
Michael DeGrace, a UR+ ecosystem manager, said, “We’re all about working with our partners. We know automation and robotics, but they know their industries. We’re here to make things as simple as possible for our partners.”
Kenneth Crawford, director of automation for Weidmueller, agreed. “Simplicity is a key aspect of what we’re doing.” Weidmueller’s emphasis was on transmitting programmable logic controller (PLC) data to an OS and ensuring everything is operating under one piece of software.
Turck’s RFID gate demonstrated in a rather simple way how to track objects using RFID tags and gates that can be positioned throughout a facility. An automated guided vehicle (AGV) carrying a pallet can go through the gate and when the scanner marks the object, a signal is relayed to a tablet or PC or humanmachine interface (HMI) indicating it has gone through. ce
Chris Vavra is web content manager, CFE Media and Technology, cvavra@cfemedia.com.
Digital edition? Click on headlines for more details. See news daily at www.controleng.com
How to benefit from digital twins, new servos, machine performance advantages
uThree major offerings at the Rockwell Automation booth at Pack Expo Las Vegas 2023 were explained by Steve Mulder, North American OEM manager, Rockwell Automation. Emulate3D software, ArmorKinetix Servos and Plex manufacturing execution system (MES) software help packaging machine builders, system integrators and end-users, as well as those in other industries. The video explains some benefits. Emulate3D software by Rockwell Automation is providing value by emulating designs as digital twins before a machine is built. It can take mechanical models, do a digital twin of those and emulate operations, testing how the model operates and interacts with virtual and actual hardware and software. Users can do a full test, debug and performance test before a machine is built. It’s being used for packaging and other original equipment manufacturers to show customers
Emulate a design in software
Emulate3D software by Rockwell Automation is providing value by emulating designs as digital twins before a machine is built, as explained by Steve Mulder, North American OEM manager, Rockwell Automation at Pack Expo Las Vegas 2023. Courtesy: Control Engineering
new machine designs and how new machines integrate with applications, saving time and rework. Part of the Rockwell Automation
Five pillars to improve operational cybersecurity: Do you need essential help?
HAVE YOU DONE ENOUGH to thwart avoid a cybersecurity breach? Constantine Antoniou, cybersecurity business consultant, Schneider Electric, spoke at Pack Expo Las Vegas 2023 in a presentation called: “Cybersecurity essentials too many CPG firms overlook.” He also talked to Control Engineering about how greater cooperation between information technology and operational technology experts can lead to greater success when applying five pillars to improve operational cybersecurity. Antoniou discussed how the cybersecurity threat landscape is becoming more sophisticated. Worst cases have to deal with injuries, death, damage, property loss and long downtimes. Average downtime is 21 days, average fee for ransom in 2021 was $200,000, with the largest payout at $40 million. With this article online, see more details and a video.
Mark T. Hoske is content manager, Control Engineering www.controleng.com/system-integration/cybersecurity
Greater cooperation between information technology and operational technology experts can lead to improved cybersecurity says Constantine Antoniou, cybersecurity business consultant, Schneider Electric. Courtesy: Control Engineering
on-machine portfolio, ArmorKinetix Distributed Servo Drives are available as standalone drives and as integrated motor and drives. Plex MES software from Rockwell Automation offers a data-ready package to help OEMs visualize plant-floor data from around the plant or around the world. A display showed performance data from four machines at other locations. ce
Mark T. Hoske is content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com.
Click headlines in digital edition to see more online, including those below.
Dick Johnson, long-time Control Engineering, Plant Engineering senior editor, dies
Top 5 Control Engineering content: August 7-13, 2023
How robotics-as-a-service can help manufacturers with operations challenges
SHOWS, CONFERENCES, EVENTS
Sept. 26-28, Ignition Community Conference, Oct. 17-19, The Industrial Transformation Event, LNS Research, https://www.theixevent.com/s/ The-IX-Event-2023/home
Oct. 23-25, Process Expo, Messe Frankfurt, Chicago, https://process-expo.us.messefrankfurt.com/ us/en.html
Oct. 23-26, Aveva World, San Franciso https://events.aveva.com/aw-st-2023
Nov. 6-9: Rockwell Automation’s all-new Automation Fair - Rockwell Automation Inc. opened registration for Automation Fair 2023. The annual event, hosted by Rockwell and members of its global PartnerNetwork program, is at the Boston Convention and Exhibition Center this year. Organizers expect to attract more than 10,000 participants globally to “Discover What's Possible” (the theme), with innovations, experts and strategies. It has more than 325 sessions in multiple tracks, 26 off-site tours, audience summits, and 20 hours of advanced training with opportunity to earn more than 20 professional development credits. https://www.rockwellautomation.com/en-us/company/events/ in-person-events/automation-fair.html
IMPROVE BUSINESS OUTCOMES WITH END-TO-END ASSET RELIABILITY
In capital-intensive industries, proper management of machinery and equipment is crucial to ensure sites operate efficiently, reliably, and safely. Operators are paying even more attention to asset performance management (APM) as they are realizing its role in improving profitability and as a means of achieving business goals.
Companies can experience end-to-end asset reliability through a valuebased programmatic approach, using predictive analytics covering critical assets of all types and a unified asset management platform including adaptable digital work processes.
Honeywell’s unified asset management platform provides outcome-based asset management leveraging end-to-end solutions that include maturity assessment, a value-based roadmap, program delivery, and benefits realization services.
DRIVE ENTERPRISE-LEVEL ASSET MANAGEMENT WITH NATIVE CLOUD SOLUTIONS
Honeywell Forge Performance+ for Industrials | Asset Performance is SaaSbased APM leveraging predictive analytics and faster, scalable enterprise deployment to address asset health, integrity, cybersecurity, efficiency and energy performance in one solution. Outcome-based SaaS software and services leverage predictive analytics for standardized, faster, scalable deployment. View the Honeywell/Microsoft webinar.
Reduce Unplanned Downtime: Hybrid AI/ML models help recover processes autonomously.
End-to-End Solutions: Include maturity assessment, a value-based roadmap, program delivery, and benefits realization services.
Realize Value Faster: Automatic updates and continuous functionality upgrades provide standardized, faster, and scalable enterprise-wide deployment.
Prevent Failures: Addresses asset health, integrity, cybersecurity, efficiency and energy performance in a single solution.
Proactively Recover Processes Earlier: Close the loop between process and maintenance strategies with integrated workflows.
HONEYWELL FORGE PERFORMANCE+ FOR INDUSTRIALS |ASSET PERFORMANCE
Predictive Analytics: Hybrid models leverage more realistic simulation for earlier risk detection.
Standard Model Library: No expert experience is required, allowing personnel to focus on optimizing operations.
Guided Root Cause Analysis: Helps you to proactively identify and analyze issues before they escalate.
Cross-functional Collaboration: Includes closed-loop workorder integration, persona-based displays, and enterprise-level KPIs.
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Aileen Jin, Control Engineering China aileenjin@cechina.cn
David Bishop, chairman and a founder Matrix Technologies, www.matrixti.com
Daniel E. Capano, senior project manager, Gannett Fleming Engineers and Architects, www.gannettfleming.com
Frank Lamb, founder and owner Automation Consulting LLC, www.automationllc.com
Joe Martin, president and founder Martin Control Systems, www.martincsi.com
Rick Pierro, president and co-founder Superior Controls, www.superiorcontrols.com
Mark Voigtmann, partner, automation practice lead Faegre Baker Daniels, www.FaegreBD.com
CFE Media and Technology Contributor Guidelines Overview
Content For Engineers. That’s what CFE Media stands for, and what CFE Media is all about – engineers sharing with their peers. We welcome content submissions for all interested parties in engineering. We will use those materials online, on our website, in print and in newsletters to keep engineers informed about the products, solutions and industry trends. www.controleng.com/contribute explains how to submit press releases, products, images, feature articles, case studies, white papers, and other media.
* Content should focus on helping engineers solve problems. Articles that are commercial or are critical of other products or organizations will be rejected. (Technology discussions and comparative tables may be accepted if non-promotional and if contributor corroborates information with sources cited.)
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Learn more at: www.controleng.com/contribute
Mark T. Hoske, Control Engineering
Many wait too long to upgrade software
Upgrades for SCADA software should be implemented sooner for better results, says SCADA software buyers, specifiers and integrators.
When upgrading supervisory control and data acquisition software, it’s “SCADA as I say and not as I do,” said Control Engineering subscribers who buy, specify or integrate SCADA software in an August survey. Among respondents, 79% said SCADA upgrade should happen before the software is not supported, though only half said they actually upgrade before then. Similarly, only 13% said SCADA software should be upgraded after the software is not supported, though, remarkably, 39% said that’s when they upgrade.
More concerning, 64% said SCADA software should be updated before unexpected downtime that could have been prevented by advanced software, though only 35% actually upgrade SCADA software by then. About half said SCADA should be upgraded before talent leaves, and only 27% do so. A later question noted that an updated SCADA platform has considerable value or is very valuable in upskilling and in efforts to attract new talent, according to 64% of respondents.
Given these results, think again about when your organization upgrades SCADA software.
How do you use SCADA?
Respondents explained how they use SCADA software and were allowed to select more than one reply: SCADA software enables automation and control applications 71%; SCADA is another word for human-machine interface (HMI) software 47%; SCADA operates mostly process-related applications 45% ; 45% SCADA operates in hybrid applications; SCADA operates mostly discrete-related applications 21%; Other 10%.
Another question asked: What features do you want in your next SCADA software that you don't have (or are inadequate) in current SCADA software? Leading responses (multi-
ple allowed), in a statistical tie for first, were: Easier data sharing 53%; Universal connectivity (for I/O readiness, Industry 4.0, smart manufacturing) 52%; Easy conversion from prior software 50%; Analytics 50%; Easier programming 49% and Automated transfer of screen design to other devices, such as tablets, smartphones 49%.
Tied for second place at 37% and 36% were automated tag updates and programming object libraries. Integration of AI/ML capabilities was farther down the list at 27%.
A related question put ranked traits or features to value of an upgrade, “What are key traits, features or justifications of SCADA software packages (some may be considered platforms) that make an upgrade worth the investment?” Leading replies were consistent: Built-in communications and easier connections to other devices, software and systems 67%; Better integration with distributed control system (DCS), process control software or other systems 59% and Analytics 53%.
Benefits suggest earlier upgrades
Given usefulness assigned to SCADA software, it is surprising that many respondents were not upgrading as soon as they should. Respondents were asked to finish this sentence (with the following supplied answers and several others): “SCADA is helping my organization with....” Leading replies were: Preventive/predictive maintenance 64%; Avoiding downtime 60%; Greater return on investment (ROI) 39%; Sustainability 38%.
See more survey results online. See more on SCADA on pages 26 and 28. ce
Mark T. Hoske is content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com. Amanda McLeman is the research director and project manager of awards programs for CFE Media.
ANSWERS
Jackson Cates, Nick Malott and Tiati Thelan, Interstates
Three things to consider when deploying edge computing
Edge computing is changing manufacturing in many ways and companies can take advantage of the benefits it involves. See three aspects of edge computing to consider, including AI.
Edge computing is changing analytics, artificial intelligence (AI) and machine learning (ML) applications. Substantial investments in libraries and frameworks have provided a new frontier for engineers and operations specialists to integrate these capabilities alongside process control. While the possibilities for valued applications are endless, security, management and scalability must be carefully considered during design.
However, it adds a layer of abstraction impacting processing efficiency and introducing latency. Physical devices allow low latency and substantial process power, but they lose flexibility in resource allocation and are often procured for a single application.
controleng.com
KEYWORDS: edge computing, virtual machines
LEARNING OBJECTIVES
Learn how edge computing is changing manufacturing applications and making artificial intelligence, machine learning (AI/ML) and analytics better.
Learn about the three aspects manufacturers need to know when deploying edge computing in their facility.
ONLINE
See additional edge computing stories at https:// www.controleng.com/ edge-cloud-computing/
CONSIDER THIS
How can edge computing improve your facility?
Companies looking to deploy edge solutions need to consider three primary pieces: the applications running at the edge, the infrastructure supporting the edge and the security and orchestration of edge appliances.
Edge computing refers to the execution of applications near controls processes or machinery. An edge device generally lives on the same network as operational technology (OT) devices and exhibits low-latency communication in data collection and response. An edge device may be a physical appliance; however, a virtual machine (VM) with low network latency to process equipment also can be considered at the edge.
One trade-off between physical devices and VMs is the preference for processing power or flexibility. The decision simplifies down to having edge virtual machines or edge physical devices. Virtual machines can be spun up or down as needed providing flexibility in resource allocation.
The utilization of edge computing provides a spectrum of advantages, such as quick response times (low latency), efficient use of internet resources (bandwidth efficiency), the ability to handle data in real-time (real-time analytics scalability) and efficient application scalability. Localizing applications removes the need to send data to a central server, reducing the logical distance from data generation and data processing. When properly applied, this approach can result in near realtime solutions; applications gain the capability to make quick decisions and deliver rapid responses. Scaling edge infrastructure is crucial for increasing demands and maintaining performance and responsiveness. Scaling is done by adding an edge device to the infrastructure. The distributed workload limits bottlenecks, increases node management and improves load balancing.
Applications running at the edge are use-case specific and often purpose-built. Some examples include analytics or models to optimize process control such as reducing scrap, improving yield, reducing utility consumption, predictive maintenance and more. Data is brought locally to the edge device to be processed. Raw or aggregate data may be pushed up to enterprise servers or the cloud for further analysis; aggregating the data reduces data transfer and storage costs in the cloud.
Edge computing infrastructure
The supporting infrastructure for edge applications is often one of the most unknown aspects when integrating edge applications. Detailed scope of the edge application is required to understand
‘ Functional requirements of an edge application are used to specify the security requirements for processing data. ’
what process parameters need to be collected, what the application's output is, and what defines success in the process.
Additional considerations, such as readiness of the process for data collection and advanced analytics, can be derived from an analytics maturity model. Advanced process analytics require investment in data collection, cleansing, contextualization and storage are supported through complementary infrastructure. Not all organizations are ready for advanced process analytics. Work with analytics experts to ensure these solutions can be supported. As devices are deployed and applications begin to scale, the network load also increases. Understanding where data is being transferred over the network is crucial to minimizing load issues with the current infrastructure; upgrades of network switches to support larger data sizes may be required to minimize network interruptions from bandwidth contention. Consultation with plant floor network integrators during the planning phases can identify and provide solutions to mitigate network contention.
Edge computing security and orchestration
The security of edge devices should be considered first in the design process. Functional requirements of an edge application are used to specify the security requirements for processing data. Common examples of these security requirements may include data encryption in transit and/or rest, transport level security (TLS) communications and system patching. Orchestration platforms also can secure edge devices and manage their lifecycle as well as update devices and their respective applications. An orchestration platform also can operate at scale, providing these services to a large fleet of deployed edge devices. Management actions can be performed across the fleet of devices, such as
COVER: Companies that invest in security, orchestration and infrastructure at the edge can optimize plant operations and improve their ability to gather data.
Courtesy: Interstates
updating application versions, pushing new analytic models or security patching.
Building solutions on an orchestration platform accelerates the development and scalability of an application. A small proof of concept or pilot solutions can be evaluated and deployed to the fleet of edge devices working alongside the process. The speed of innovation on an orchestration platform, alongside the built-in security, affords developers a powerful tool to focus on delivering solutions over managing deployments and architectures.
Edge computing, embedded with AI/ML, opens doors for new possibilities and challenges in controls engineering. Applications at the edge allow for low-latency communications and can be tailored to target various business goals. Understanding and investing in the supporting infrastructure is necessary for analytic and network readiness at scale. Security and orchestration, with a security-first mindset and robust orchestration platform, ensure edge devices are managed and protected endpoints.
Investing in security, orchestration and infrastructure can pave the way for AI/ML solutions at the edge to optimize plant operations. ce
Jackson Cates, business analyst; Nick Malott, technology analyst; Tiati Thelen, business analyst II; all with Interstates, a CFE Media and Technology content partner. Edited by Chris Vavra, web content manager, CFE Media and Technology, cvavra@cfemedia.com.
Insightsu
Edge computing insights
uEdge computing, integrated with AI/ ML, offers low-latency communication and tailored applications, revolutionizing controls engineering. Proper infrastructure investment ensures analytic readiness and network scalability.
uPrioritizing security, utilizing orchestration platforms,and investing in infrastructure are vital for successful AI/ML implementation at the edge, optimizing plant operations and ensuring managed and protected endpoints.
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As an increasing number of industries embrace hydrogen, understanding the inherent hazards is paramount. While hydrogen possesses some advantages over conventional fuels—it disperses rapidly in the air and is non-toxic— it remains highly combustible and can act as an asphyxiant gas. These unique properties necessitate specialized safety measures and systems. Beyond standard fuel safety regulations, there are specific requirements tailored to hydrogen handlers.
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Mark T. Hoske and Amanda McCleman, CFE Media and Technology
Research: Integrating AI, industrial automation
More than half of survey respondents were challenged when trying to integrate artificial intelligence (AI) and industrial automation. See advice.
More than half of respondents (57%) to a Control Engineering and Plant Engineering survey of use of artificial intelligence (AI) for industrial automation have had a challenge or obstacle when integrating AI technologies into existing industrial automation systems; 14% have not, and 29% have yet to implement AI. Internal champions for increasing use of artificial intelligence (AI) in respondents’ facilities are found in various departments and titles. Among leading titles are end-user engineer, director and project manager, according to the September research, “Artificial Intelligence in Industrial Automation.” Results showed a three-way tie when deciding about AI use, considering margin of error for the research.
• Same level of scrutiny as they would any other new technology.
• Take a closer look due to lack of AI experience.
• Great deal of scrutiny given AI’s potential issues.
Why use AI for operations?
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.
Some survey respondents explained how to overcome those AI integration challenges in a write-in question, lightly edited below.
Acceptance by management without technical skills.
Lack of client knowledge regarding AI. It takes a lot of training and educating clients before deployment, even before owner engagement.
RESEARCH respondents to a Control Engineering and Plant Engineering AI for industrial automation survey were equally divided (withing margin of error) in saying they were somewhat confident, very confident and too early to tell. About 1 in 10 expressed no confidence. Courtesy: “Artificial Intelligence in Industrial Automation” research from Control Engineering, Plant Engineering
Operational technology system integrators have no knowledge in machine learning (ML) and AI to understand how it works as the following: 1) What is an ML model? 2) What is an ML algorithm? 3) What is ML training and inference? 4) What are the critical data, information and outcomes for selected topics? 5) How to define the valuable topic and return on investment (ROI)? 6) What are labels and features? 7) How to store time series data of data sources from industrial field to information technology (IT) systems, database (DB) or data lake.
IT workers have no knowledge in physical world and industrial automation. Be the consultant to interview the C-level and plant manager for valuable topics from managing matrix then collect the field data from PLC tags to OPC [Unified Architecture] server to DB then import as data source for ML utility training. ce
Mark T. Hoske is content manager, Control Engineering, CFE Media and Technology, mhoske@ cfemedia.com. Amanda McLeman is the research director and project manager of awards programs for CFE Media and Technology.
controleng.com
KEYWORDS: Artificial intelligence for industrial automation
LEARNING OBJECTIVES
Implementing AI in industrial automation has challenges, according to respondents who also provide advice in a Control Engineering and Plant Engineering survey.
CONSIDER THIS
Have you integrated AI and automation, yet? Or maybe you have, and it’s so embedded, you didn’t know. ONLINE
With this article online, see more about feature selection, methodology and review other findings by downloading the full report. www.controleng.com/ research
David Miller, Control Engineering
Video interview: Data analytics, ML
Matt Ruth, president and CEO at Avanceon, discusses benefits of data analytics and machine learning on the plant floor.
Data analytics is the process of gathering information pertaining to a particular problem, and using it to explore and model the potential outcomes of various approaches to solving that problem. In an exclusive interview with Control Engineering Matt Ruth, president and CEO at Avanceon, discussed the application of data analytics to the OT space and gave examples of specific applications, including control loop analytics, alarm rationalization and management, process sequence and flow analytics, scheduling optimization and product cost management. Ruth walked viewers through the dif-
ference between descriptive, diagnostic, predictive and prescriptive analytics. “Most people have some form of descriptive analytics, some of it is gathered by hand and written on the wall and some of it is on KPI boards being displayed in the break room or a supervisor’s office. As you go up the food chain, it gets more and more rare,” he says. According to Ruth, while over 90% of plants have some form of descriptive analytics, less than 10% are deploying prescriptive analytics. As such, there is significant room for most manufacturers to better leverage their data.
IN AN INTERVIEW with Control Engineering, Matt Ruth, president and CEO at Avanceon, discussed plant floor application of data analytics and machine learning. Courtesy: Control Engineering
View the video interview online. ce
David Miller, content manager, CFE Media and Technology, dmiller@cfemedia. com. Avanceon is a Control Engineering content partner.
Complete with dashboard for instant visualization of network health and topology maps for quick troubleshooting. These
Chris Vavra, Control Engineering
How AI/ML are changing process manufacturing
Manas Dutta of Honeywell discusses the process industry changes future impact of AI/ML.
Manufacturing has gone through many changes in the last several years and artificial intelligence/machine learning (AI/ML) has the potential to change it more. Manas Dutta, a general manager for Honeywell’s Workforce Excellence Growth Initiative, discussed changes happening and what he thinks the future of AI/ML is in process manufacturing. Dutta did a recent interview in May and a webinar in February with CFE Media and Technology on the connected worker and digital transformation.
Dutta said process manufacturers are looking to overcome several challenges. "The utmost challenge is process optimization. The production, cost optimization and increasing the efficiency of the production," he said. He listed several other challenges:
• Energy management. Dutta said costs are rising in the industry and it is impacting production
costs. They're looking for solutions to reduce greenhouse gas emissions and optimize costs and AI/ML use cases are helping companies explore potential solutions.
• Asset management. Dutta said companies are looking to extend the lifespan of products and equipment. Predictive maintenance can help reduce maintenance and repair costs.
• Human reliability improvement. The collaboration between people and the machines they work with is critical, Dutta said, because workers, with the right tools, can make better decisions daily.
• Sustainability. "Every process industry is looking for sustainability, and they all have their own sustainability goals," he said. ce
Chris Vavra, web content manager, CFE Media and Technology, cvavra@cfemedia.com.
MEDIA SHOWCASE FOR ENGINEERS
PROCESS manufacturing is changing and AI/ML will impact the industry in many ways. Courtesy: CFE Media and Technology
3 ways visualization software can align operations across enterprise layers
Obtaining a clear high-level perspective of operations throughout an organization calls for a consolidated software environment able to unify OT, IT and ET, providing corporate users with one-pane-of-glass visibility.
Obtain a 360-degree overview for manufacturing, processing companies
1. 360 views: Relevant data takes many forms and originates from an exceptionally wide range of sources and systems across all levels of a business, sometimes even external to the business. Three examples spanning various organizational areas include:
• OT sources: process data, quality data, alerts/ events, key performance indicators (KPIs) and energy consumption
Online controleng.com
KEYWORDS: SCADA, HMI, digital transformation, manufacturing visibility
LEARNING OBJECTIVES
Understand how a 360-degree visualization overview is possible for manufacturing and processing companies to derive intelligence from software integrating multiple enterprise levels.
Consider how visualization software can improve consistent information across applications.
CONSIDER THIS
Are people across your organization seeing what they need to see to make best decisions when they should?
It is common sense for any manufacturing or processing company to strive for maximizing efficiency on the production floor, including the operation of all field equipment. There also are gains to be made at the site-wide operational and at the enterprise-wide corporate tier. But what is the best approach for coordinating and optimizing gains from all functional areas?
Implementing digital technologies is a key element for helping companies maximize operator effectiveness and operational efficiency. Human machine interfaces (HMIs), supervisory control and data acquisition (SCADA) and other manufacturing and enterprise software can help. But addressing company needs across the entire enterprise requires more than common HMI/SCADA visualization and analytics or business intelligence tools.
To obtain complete enterprise operations performance visibility in real time, companies need software enabling them to fully unify operations. Enterprise visualization converges field operations technology (OT) and corporate information technology (IT), supporting analysts and other users over the engineering technology (ET) life span of the systems in their realm of responsibility.
• IT sources: Enterprise resource planning (ERP), including financials, orders, shipments, suppliers, bills of material and others; analytics; weather and environmental data; market and commodity information and video surveillance
• ET sources: 3D modeling, map and GIS integration, engineering schematics and maintenance documentation
Process data is needed to inform analytics efforts. Alerts and events are associated with imminent maintenance work. Energy and commodity pricing can prompt decisions about how much and when to run. Yet it is all too easy to see how such varied data can remain siloed, trapped in specialized and sometimes proprietary systems. Relating numerous disparate data with proper context is a challenge of its own. But reducing the effort for users to deploy such software, while delivering valuable understanding when and where it is needed to support effective action, demands capabilities spanning all layers. Effective convergence is the key to delivering a full 360° view of the com-
plete enterprise and requires a solution that can be deployed flexibly for diverse consumers of organizational data.
Visualize operations with software at multiple levels
Personnel working at the operational edge rely on panel-based visibility, and increasingly on handheld devices for mobile and off-site viewing. At the supervisory level, workstation and process control room (PCR) visibility become more relevant to support control and execution efforts. The enterprise may have several categories of users, each with unique visualization needs.
Command center integrates disparate IT/OT/ET systems
Many large companies use a centralized approach to view the supply chain end-to-end so they can optimize activities on a macro-level regionally or globally. An integrated operations center (IOC) can integrate disparate systems to underpin controlling and sustaining activities, or a centralized operations center (COC) may be more focused on converging IT/OT/ET data across the business value chain for command and dispatch decisions.
Remote operations center for distributed organization
Distributed organizations often find it difficult to staff subject matter experts (SMEs) at all sites. In these cases, a center of excellence (CoE) is typically the best way for SMEs and other experienced groups to handle performance and other issues spanning many sites. Local site-based personnel can engage the CoE team as needed, and the team can work to solve complex problems across the business and fleets of assets.
ONE PANE OF GLASS: The Aveva Unified Operations Center is an enterprise solution for enabling intelligent operations spanning OT, IT and ET, delivering single-pane-of-glass visibility and contextualized information to all user levels. Courtesy of Aveva
Occasional users, web-based interface views
Even the largest organizations will have executive and strategic analysts, ranging from just a few to perhaps hundreds, pursuing independent projects. These projects often require investigation of operations activities, key performance indicators (KPIs) and other topics in the pursuit of optimization and reporting. Users in these areas require access to the information, preferably though a webbased experience.
‘ Connect with assets, processes and operations to effectively produce information for the right people. ’
Connecting with assets, processes and operations to effectively gather data and produce information, and then get it to the right personnel, requires an integrated and layered software approach (Figure).
Delivering data-derived intelligence
Digital transformation technologies have revolutionized all levels of enterprise operations, supervision and management. While addressing each of these areas individually is good, complete visibility is better, but only possible if all operational levels are fully unified. Organizations should look for a consolidated software environment that goes beyond traditional HMI/SCADA by incorporating analytics, advanced visualization, and multiple deployment models to support users in all roles. ce
Doug Warren is the Aveva monitoring and control business lead; Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com.
Insightsu
SCADA for IIoT insights
u A 360-degree visualization overview is possible for manufacturing and processing companies to derive intelligence from software integrating multiple enterprise levels.
uVisualization software can improve consistent information for a command center and disparate IT/OT/ ET systems, remote operations center and occasional users providing web-based interface views.
ANSWERS
Tom Burke, Iconics
7 ways SCADA can advance IIoT
Latest trends in supervisory control and data acquisition (SCADA) software are helping industrial internet of things (IIoT) implementation, including with more integration, infrastructure monitoring and three other areas.
Supervisory control and data acquisition (SCADA) software was initially designed to aggregate information from distributed sources and provide operators with the information needed to best control processes. Today, with SCADA being so easy to implement and taking on more analytic functions, it has become the staple for every serious manufacturer. Although the market is mature, SCADA technology is evolving and improving. Below find 7 key SCADA developments critical for manufacturers to know today.
bility usually means the inclusion of BACnet, SNMP or operating system services connectors to collect and monitor data from those sources.
KEYWORDS: Modern SCADA benefits, SCADA upgrades
LEARNING OBJECTIVES
Understand how modern SCADA software upgrades bring advantages.
Learn how SCADA integration and applications have improved with tighter and faster configuration and connections.
See how software has improved using available and emerging standards for better design and implementation, including with 3D representations where appropriate.
CONSIDER THIS
Are you using modern SCADA software to your best advantage?
ONLINE
In this issue on p. 19 and online, see Control Engineering SCADA research. Online controleng.com
1. Southbound integration: SCADA applications continuously grow and tend to integrate with more industrial data, thereby enabling owners to build additional value into their existing SCADA systems. Where in the past, the SCADA was installed to improve the performance of primary processes, today, these systems are collecting far more data, especially distributed and previously difficult to access data which is now available through internet and cellular connections.
The biggest change in connectivity below the SCADA is the introduction of IoT protocols, the three most common being a Web Services client, an message queuing telemetry transport (MQTT) broker and client, and an OPC Unified Architecture (UA) client. These Internet-ready protocols offer high performance and security and are ideal for use in collecting data from remote sensors.
2. Infrastructure monitoring is another key area of development, tying SCADA to building infrastructures and network infrastructures and other areas for the benefit of improving system reliability. This capa-
3. Northbound integration: Modern SCADA systems are vast repositories of data and layered analytics. This information is integrated into other systems, specifically manufacturing execution system (MES) solutions that are either local or remote as well as cloud analytics and dashboards to involve a wider audience in performance tracking and improvement. SCADA solutions are now equipped with modules that can package data into contextualized transactions, as appropriate for the information systems these are feeding. SCADA solutions are often called workflow or bridge modules that not only create aggregations of data, but transact the datasets with other systems for genealogy tracking, order processing, work in progress tracking, scheduling and dispatching, maintenance management and other functions. SCADA software have become enhanced with web services, MQTT publishing, OPC UA server, and purpose-built interfaces for key industry needs.
4. Database integration: Modern SCADA software platforms are more than industrial solutions, with ability to integrate with all other plant systems, feeding and extracting data for display and analytics. This means SCADA graphics are enhanced for more database- and forms-oriented applications, in addition to the capability to deliver objects for traditional operator interfaces. When thinking about SCADA displays, users should consider the data in inventory systems, asset management systems, and even customer relation management (CRM) systems as potential sources of valuable information to be integrated with SCADA dashboards.
5. Rapid development: Time is money, and the path to a more cost-effective SCADA implementation is a simpler and more intuitive configuration. While developers are always getting smarter with the use of software development tools and technology, in the end, the SCADA is the property of the end customers,
and it is important to have some autonomy in supporting how SCADA is applied. SCADA systems are trending to more canned solutions with configurable functionality over the need for custom development and scripting. SCADA is being delivered with rapid development tools to enable high degrees of scalability through importing, exporting, and automated replication functions for cloning and multiplying configurations.
6. Information models: One of the biggest industrial changes in progress is the drive toward Industry 4.0, smart manufacturing and digital transformation. The idea is to make optimal use of all data to improve performance and quality and reduce costs. Optimizing data use is a lofty goal that may seem out of reach for most, outside the best and the brightest or the largest corporations. To improve data use, the industry will be relying on and integrating future standards. That includes not just data transfer standards, such as MQTT or those from OPC, but data structure standards for equipment and processes (information models). If data exists in standard forms, then applications can be developed to consume these models, configuring automatically benefitting users. Users can create data models to deliver incremental improvements within an organization (a unified namespace) or users can leverage industry standard data models (a relatively new development).
The future where value-added applications will be
able to communicate with information sources (such as SCADA), will automatically discover information models of machines and processes, and will be configured at the press of a button. SCADA software should support information models (asset definitions) and follow standards like ISA-95 for enterprise to control system integration.
7. 3D graphics: Process graphics that are 2D in design are common. The focus is on the simplification of operator screens to deliver progressive disclosure when more information is needed and to leverage muted colors to remove eye fatigue, with graphics becoming bolder when conditions require it. This trend is called high performance graphics and is embodied in a standard called ISA-101.
But technology is delivering the capabilities for 3D animations, based on real-time process data. Depictions of robot positions can match real world conditions. 3D is especially valuable in depicting information in building information/management/ automation systems (BIM - BMS – BAS). SCADA systems also are improving to leverage 3D models from computer-aided design (CAD) software offerings to animate these with real-world information. ce
Tom Burke is director of strategic marketing, Iconics; edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com.
SUPERVISORY control and data acquisition software platforms of today offer many more capabilities and advantages compared to platforms of 20 years ago. Shown is an Iconics Genesis64 High Performance SCADA view of a chilled water cooling system. Courtesy: Iconics
ANSWERS
Jackson Cates, Nick Malott and Tiati Thelan, Interstates
Three things to consider when deploying edge computing
Edge computing is changing manufacturing in many ways and companies can take advantage of the benefits it involves. See three aspects of edge computing to consider, including AI.
Edge computing is changing analytics, artificial intelligence (AI) and machine learning (ML) applications. Substantial investments in libraries and frameworks have provided a new frontier for engineers and operations specialists to integrate these capabilities alongside process control. While the possibilities for valued applications are endless, security, management and scalability must be carefully considered during design.
However, it adds a layer of abstraction impacting processing efficiency and introducing latency. Physical devices allow low latency and substantial process power, but they lose flexibility in resource allocation and are often procured for a single application.
controleng.com
KEYWORDS: edge computing, virtual machines
LEARNING OBJECTIVES
Learn how edge computing is changing manufacturing applications and making artificial intelligence, machine learning (AI/ML) and analytics better.
Learn about the three aspects manufacturers need to know when deploying edge computing in their facility.
ONLINE
See additional edge computing stories at https:// www.controleng.com/ edge-cloud-computing/
CONSIDER THIS
How can edge computing improve your facility?
Companies looking to deploy edge solutions need to consider three primary pieces: the applications running at the edge, the infrastructure supporting the edge and the security and orchestration of edge appliances.
Edge computing refers to the execution of applications near controls processes or machinery. An edge device generally lives on the same network as operational technology (OT) devices and exhibits low-latency communication in data collection and response. An edge device may be a physical appliance; however, a virtual machine (VM) with low network latency to process equipment also can be considered at the edge.
One trade-off between physical devices and VMs is the preference for processing power or flexibility. The decision simplifies down to having edge virtual machines or edge physical devices. Virtual machines can be spun up or down as needed providing flexibility in resource allocation.
The utilization of edge computing provides a spectrum of advantages, such as quick response times (low latency), efficient use of internet resources (bandwidth efficiency), the ability to handle data in real-time (real-time analytics scalability) and efficient application scalability. Localizing applications removes the need to send data to a central server, reducing the logical distance from data generation and data processing. When properly applied, this approach can result in near realtime solutions; applications gain the capability to make quick decisions and deliver rapid responses. Scaling edge infrastructure is crucial for increasing demands and maintaining performance and responsiveness. Scaling is done by adding an edge device to the infrastructure. The distributed workload limits bottlenecks, increases node management and improves load balancing.
Applications running at the edge are use-case specific and often purpose-built. Some examples include analytics or models to optimize process control such as reducing scrap, improving yield, reducing utility consumption, predictive maintenance and more. Data is brought locally to the edge device to be processed. Raw or aggregate data may be pushed up to enterprise servers or the cloud for further analysis; aggregating the data reduces data transfer and storage costs in the cloud.
Edge computing infrastructure
The supporting infrastructure for edge applications is often one of the most unknown aspects when integrating edge applications. Detailed scope of the edge application is required to understand
‘ Functional requirements of an edge application are used to specify the security requirements for processing data. ’
what process parameters need to be collected, what the application's output is, and what defines success in the process.
Additional considerations, such as readiness of the process for data collection and advanced analytics, can be derived from an analytics maturity model. Advanced process analytics require investment in data collection, cleansing, contextualization and storage are supported through complementary infrastructure. Not all organizations are ready for advanced process analytics. Work with analytics experts to ensure these solutions can be supported. As devices are deployed and applications begin to scale, the network load also increases. Understanding where data is being transferred over the network is crucial to minimizing load issues with the current infrastructure; upgrades of network switches to support larger data sizes may be required to minimize network interruptions from bandwidth contention. Consultation with plant floor network integrators during the planning phases can identify and provide solutions to mitigate network contention.
Edge computing security and orchestration
The security of edge devices should be considered first in the design process. Functional requirements of an edge application are used to specify the security requirements for processing data. Common examples of these security requirements may include data encryption in transit and/or rest, transport level security (TLS) communications and system patching. Orchestration platforms also can secure edge devices and manage their lifecycle as well as update devices and their respective applications. An orchestration platform also can operate at scale, providing these services to a large fleet of deployed edge devices. Management actions can be performed across the fleet of devices, such as
COVER: Companies that invest in security, orchestration and infrastructure at the edge can optimize plant operations and improve their ability to gather data.
Courtesy: Interstates
updating application versions, pushing new analytic models or security patching.
Building solutions on an orchestration platform accelerates the development and scalability of an application. A small proof of concept or pilot solutions can be evaluated and deployed to the fleet of edge devices working alongside the process. The speed of innovation on an orchestration platform, alongside the built-in security, affords developers a powerful tool to focus on delivering solutions over managing deployments and architectures.
Edge computing, embedded with AI/ML, opens doors for new possibilities and challenges in controls engineering. Applications at the edge allow for low-latency communications and can be tailored to target various business goals. Understanding and investing in the supporting infrastructure is necessary for analytic and network readiness at scale. Security and orchestration, with a security-first mindset and robust orchestration platform, ensure edge devices are managed and protected endpoints.
Investing in security, orchestration and infrastructure can pave the way for AI/ML solutions at the edge to optimize plant operations. ce
Jackson Cates, business analyst; Nick Malott, technology analyst; Tiati Thelen, business analyst II; all with Interstates, a CFE Media and Technology content partner. Edited by Chris Vavra, web content manager, CFE Media and Technology, cvavra@cfemedia.com.
Insightsu
Edge computing insights
uEdge computing, integrated with AI/ ML, offers low-latency communication and tailored applications, revolutionizing controls engineering. Proper infrastructure investment ensures analytic readiness and network scalability.
uPrioritizing security, utilizing orchestration platforms,and investing in infrastructure are vital for successful AI/ML implementation at the edge, optimizing plant operations and ensuring managed and protected endpoints.
Kendon Jacobson and Wayne Noblin, Gray Solutions
Turnkey approach for automating first-of-a-kind red sorghum extract process
Redleaf Biologics is a manufacturer producing botanical extracts from the red sorghum plant. The company worked with system integrator Gray Solutions to move its operation from the pilot and laboratory scale to full-scale industrial production. Read the case study below.
After several years of product development, the RedLeaf Biologics team had reached a point where extract from its unique red sorghum plant was commercially and economically viable for various markets, including food, beverage and cosmetics. Until then, the process had only been validated on a pilot or laboratory scale. Not only was the product first of a kind, but the dried sorghum required custom designed extraction equipment. As a result, space for primary extraction and subsequent downstream processing required fitting out an existing industrial facility. A system integrator was solicited for process and automation integration services to support the effort. Initially, the RedLeaf team relied on internal resources to begin the build-out. The system inte-
FIGURE 1: Traditional HMI animation example is shown. See a high-performance HMI in Figure 2. Courtesy: Inductive Automation.
gator was able to provide gap assistance in other key areas including contract documentation, power distribution, compressed air systems and process design. Ultimately, however, the project consisted of automation design, programmable logic controller (PLC) and human machine interface (HMI) development, process integration, installation and commissioning for the new production process. It provided the customer a solution to move from the R&D environment to an automated food grade production facility. The process included receiving of raw material, material handling, process, packaging, CIP, data collection, quality, traceability and interfacing with other OEM control systems.
Formalizing knowledge transfer for automation functional design
When kicking off a project with a key process control scope, the state of the art of the process technology should be as well known by the team as possible. Prior knowledge from the system integrator of plant-based extraction and drying technologies were used to facilitate knowledge transfer workshops with the customer. The RedLeaf team had spent years correctly identifying and specifying parameters that were unique to its operation including special solvents or co-solvents, plant rheological behavior, desired and undesired reaction data, preferred dewatering technologies and issues pertaining to safety and quality.
The RedLeaf team provided a vision regarding the future of the plant size and broke it down into three phases. The first phase was a low capacity, initial launch followed by proof of concept of the process. The two remaining phases were tied to plant capacity benchmarks. As part of this, both teams worked on scope development early to identify key customer requirements for the automation systems, both from scale and functionality perspectives. One of the challenges faced by the integration team was implementation of pre-existing hardware, field devices, switch gear and equipment skids with the new systems. Part of the scope would therefore include evaluation of needs for such devices. New process valves and instruments were selected to support potential developments in process control and monitoring. Considerations were made for preferred automated sequencing of liquid extract transfers between each of the processing steps. Digital communication buses were considered, but ultimately not required to support future phases. Devices were discrete or analog, excluding drives. The selected drives were installed with EtherNet/IP ODVA protocol for all three-phase equipment.
The functionality of running each extraction was essential to the process. The batch is time and pH sensitive, and both parameters require control and timing. The addition of water was necessary through two piping inlet locations, which the operators would be given the option of quantities to add
KEYWORDS: Scalability, Case Study
LEARNING OBJECTIVES
Explore the process of scaling up from an R&D environment to an automated food-grade production facility.
Learn how pre-existing hardware, field devices and other equipment can be integrated into a new plant or facility.
Discover how open architecture can be used to ease future scaling efforts. ONLINE
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FIGURE 2: High-performance HMI animation example. See traditional HMI in Figure 1.
Courtesy: Inductive Automation.
ANSWERS
per location. There was further discussion
‘ Prior to specification of hardware, a series of workshops included identifying field devices. ’
per location. There was further discussion regarding batch sequencing, and it was also acknowledged that a hybrid automatic-manual approach to step progression would be needed. Operators would be required to issue commands back to an automation system to acknowledge the change in batch state. There were handshakes to be made between unit operations that operated in batch mode (e.g., pH adjustment steps) and continuous modes (e.g., dewatering). Again, following the hybrid approach to batch progression, hold time prior to dewatering is a key parameter. Hold time was counted down automatically and alerted operators that dewatering may commence. However, operator intervention would be required for eventual change in state from holding to transferring.
Product dewatering equipment had been previously selected prior to project commencement. The system integrator evaluated the third-party technology for integrability, as well as other OEM features. It was then determined that the core operation would remain with the existing equipment, especially as it included custom ramping programs to drives. Discrete status signals from the equipment skid were available to provide potential operability handshakes. For example, if the signal indicated a “running” state, raw product could be transferred accordingly.
After the series of workshops that included identifying field devices, final hardware selection proceeded. This did require swift attention and decision turnaround times. Supply chain disrup-
tions were still and the team did evalu-
tions were still prevalent, and the team did evaluate components to prioritize when putting out an order schedule. the system integrator specified a CompactLogix 5069-L320ER PLC with 440CCR30 Safety Relay from Rockwell Automation. The CR30 allowed the safety zones to be divided as needed throughout the process. Then, if it were to be decided to change the zoning, only minor programming changes would be needed. Some of the features of the PowerFlex 525 from Rockwell Automation used on this project were the safe torque off (STO) and auto device configuration (ADC). The STO feature reduced the time of design and programming of the safety system, while allowing the VFD to remain powered during a controlled safety stop. It was designed such that there would be no need to disconnect the line power. The ADC allows the parameters of the drive to be stored in the PLC, providing a major time savings if the VFD ever needs to be changed out. It helps prevent accidental misconfiguration of the parameters and restricts access. Therefore, drive replacement could be simplified with little to no configuration required depending on the type of switch being used. The PLC would automatically download the parameters to the drive.
Leveraging an open architecture framework for product and process commercialization
Beginning with an ISA 95 model for defining the plant system, each layer required a degree of flexibility and agility to support the project. During the scoping phase, it was understood the quality systems would still need further definition in the
FIGURE 3: Raw and dried red sorghum extracts. Courtesy: RedLeaf Biologics.
future, as it pertained to record-keeping and data security. It was generally preferred to utilize the same system for plant level control as accessibility to historians. Although no manufacturing execution system (MES) was selected as of this writing, there was consideration for a platform to support a potential seamless integration.
The system integrator ultimately chose to use Ignition for HMI and supervisory control and data acquisition (SCADA) services from Inductive Automation. The SCADA decision was primarily based on future considerations. The scalability, unlimited licensing model, cross-platform compatibility, web-based deployment, open-source technology and development efficiencies were major advantages that overcame the alternatives in this particular application. The SCADA open-source platform allowed ease of data collection from other controllers, systems and field devices to store the data in a SQL database for historizing, trending, reporting, alarming and traceability. For purposes of verification, the customer wanted the ability to see who made changes and modifications or started a process. The SCADA includes a built-in auditing system to support this feature, where it records actions such as user login/logout, tag writes, database writes, query and script execution, alarm notifications, report execution and so on. This was displayed on a power table that could be filtered to quickly find a tag or action. Ignition simplifies database programming with its named queries, transaction groups and query builder. Specialized database programming training was not necessary to build tables, modify columns, or to read/ write, create or modify. The SCADA has access to an extensive library of training videos and user manuals, which were used during the development phase. Another beneficial SCADA feature was brought forth when performing the factory acceptance test (FAT). The team completed this virtually with the use of the SCADA’s Web-based platform. On this project, the system integrator worked with the customer to develop a high-performance HMI by adopting ISA 101 concepts. Some benefits to the ISA 101 approach include consistency, navigation efficiency, reduced distractions, minimal glare and, most importantly, the ability to highlight abnormal situations. As with many HMI development projects, there are varying levels of visual-
ization, but the intent was to allow the operator to see any alarms or abnormalities at a glance. Examples compare traditional HMIs versus high-performance HMIs.
To provide a more efficient navigation method, the SCADA’s multi-tier tab strip fit was used. The customer asked if quality data could be included, and the SCADA made the addition seamless. We were able to quickly add batch IDs, product IDs, chemical IDs, bale IDs, pH levels, leaf weights, water weights and other product weights throughout the system. This data was stored in the SQL database and displayed for the customer to meet its traceability and mass-balance needs.
Launching future potential
After physical and digital architectures were put in place to satisfy the immediate project needs, considerations were made for scalability. Although specific production targets were part of the discussion, the hope was for continued growth and innovation beyond. While the emphasis was placed on leaf processing and extract recovery, the RedLeaf team has established a vertically integrated production model. This included an on-farm presence with associated sorghum selection and development program. Such improvements add a layer of complexity to traceability and integration.
While manufacturing execution systems (MES) were not included in the project, the SCADA offers a platform for either creating or integrating potential systems for RedLeaf. There are modules such as overall equipment effectiveness (OEE), track and trace, statistical process control (SPC), batch procedure, and MES enterprise. As RedLeaf integrates the operations from multiple locations, industrial Internet of Things (IIoT) integration will become key as well. ce
Kendon Jacobson is senior process engineer, Gray Solutions. Wayne Noblin is manager, automation, Gray Solutions. Edited by David Miller, content manager, Control Engineering, CFE Media and Technology, dmiller@cfemedia.com.
uWhen kicking off a project with a key process control scope, the state of the art of the process technology should be as well known by the team as possible.
uBeginning with an ISA 95 model for defining the plant system, each layer required a degree of flexibility and agility to support the project.
uAfter both physical and digital architectures were put in place to satisfy the immediate project needs, considerations were also made for scalability.
ANSWERS
Joshua Montoya and Brandon Brock, Polytron
Improving efficiency through algorithmic production scheduling
Beginning in 2017, food and beverage manufacturer Farmer Brothers began its shift to Industry 4.0 by integrating a manufacturing execution system (MES) platform.
Farmer Brothers embarked on their Industry 4.0 journey in 2017 after selecting as their manufacturing execution system (MES) platform to provide actionable insights into asset performance and optimization. Upon successful completion of these initial phases, Farmer Brothers turned to production schedule optimization as its next phase to optimize their complex scheduling process, further improve production throughput and meet client commitments.
Q: What was the project scope?
The scope of the project was to configure the algorithmic production scheduling (APS) component of MES software to optimize scheduling of all manufacturing assets at Farmer Brothers new Northlake, Texas, facility. Production schedule optimization was deployed in two phases. The initial phase included dump station, roasters and packaging lines. The second phase included incorporating additional assets such as packaging lines, flavor line, grinders, dump stations and sack line.
Q: What automation was used?
The software downloads the production orders, routing options and product attributes from the existing enterprise resource planning (ERP) and supervisory control and data acquisition (SCADA) systems then runs these through an algorithm in order to develop an optimal production schedule sequence. The algorithm takes into account multiple factors, such as floor constraints
(routing options, staged materials, equipment status, etc.), weighted priorities (due date, longer running jobs, how to minimize number of changeovers, etc.), changeover times between SKUs, planned line throughput and more to create an optimally sequenced schedule that will maximize efficiency. The newly created/adjusted optimal schedule is then pushed back to the ERP/ SCADA system for execution.
Q: What were project challenges?
Most schedulers leverage experience and tribal knowledge in creating their production schedules, often having to do this multiple times a day as conditions and priorities change. This becomes more of an art than a science. Due to lack of clarity with what is considered a best practice process, getting stakeholder buy-in becomes more of a challenge. This makes it difficult to define the appropriate rules and criteria, required to codify the appropriate algorithm.
Q: How were those issues resolved and what were positive metrics?
Creating early stakeholder alignment with the scheduling team was critical to obtaining their input into best practices and help ensure buy-in. A side-by-side comparison was developed so that the schedulers can compare the old way and new way to build confidence with the results from the new system. Once confidence was established, the duplicate system was no longer used, and the focus turned to further fine tuning of the algorithm in the new system.
Resolving issues migrating to software
STAKEHOLDER buy-in and alignment was achieved by a comparison of the old scheduling methodology and the new scheduling methodology to bolster new-system confidence. TrakSYS manufacturing execution system (MES) platform was used.
The project helped define criteria to create an optimal schedule and create alignment among stakeholders. Schedulers can work as a collective team to continuously refine the scheduling approach and develop best practices across shifts instead of each scheduler operating independently. The schedule can be generated multiple times daily as needed for changing conditions and priorities (previously too time consuming). The schedulers need to be consulted often to identify known scheduling components and create stakeholder alignment early. This helps ensure the schedule produced via APS is optimally sequenced and realistic and the team is engaged. ce
Joshua Montoya, MES and supply chain IT manager, Farmer Brothers. Brandon Brock, senior system architect, Polytron. Edited by David Miller, content manager, Control Engineering, CFE Media and Technology, dmiller@cfemedia.com. Polytron is a CFE Media content partner.
Dino Busalachi, Velta Technology
Taking IT/OT convergence from theory into practice
Building a strong relationship between information technology and operational technology teams can help improve efficiency, enhance operations and harden your organization’s security posture.
Information technology (IT) and operational technology (OT) convergence continues to be a topic of conversation among industry experts.
Theoretically, it’s a good idea [for reasons including cybersecurity], however, IT/OT convergence isn’t as simple as one may be led to believe. Fundamental organizational challenges need to be addressed to achieve convergence, from political and cultural barriers to technical complexities.
IT/OT convergence is about building the relationship between information technology and operational technology to gain clear insights to improve efficiency, enhance operations and metrics, and harden a business’ security posture. In reality, one of the groups is overhead and administrative and relies on operational expenditures (OPEX), and the other defines why the business exists, is revenue generating and relies heavily on capital expenditures (CAPEX).
These groups are siloed, working with minimal communication, creating a political and cultural indifference toward each other. The key is defining and aligning the needs of OT, the revenuegenerating side of the business, by collaborating and creating seamless communication and transparency. OT, with the assistance of IT, will need to lead the party out of the OT cybersecurity wilderness to create a more seamless and secure plant floor.
Being proactive with IT/OT convergence
Every business and plant is unique, with its own set of challenges, priorities, equipment and technology. In most instances, each manufacturing site
is its own kingdom and operates independently of corporate governance groups, such as IT. This means there’s no standard approach to IT/OT convergence, and therefore a one-size-fits-all solution doesn’t exist. IT and OT departments don’t operate the same, and they shouldn’t. However, to improve functionality between IT and OT departments within organizations, it’s essential to encourage deeper conversations and collaborations between the disciplines to help bridge the gap.
Instead of pointing fingers or continuing to foster a culture of indifference, there should be a shared commitment to determine where they are and how they can come together to secure the overall business. One way to foster this newfound culture is through educating each other regarding process, people and technology. They should work together on joint technology decision-making and determine which group has ownership as well as responsibility and governance of people, process and technology. Whether it’s purchasing maintenance support or planning for digital security, a combined perspective with well-rounded expertise will benefit the business and begin to move the needle toward convergence. Being proactive with convergence offers significant security benefits. In an increasingly digital manufacturing world, businesses can’t afford to keep a line drawn in the sand between the two departments. It also needs to be understood that IT cannot own the plant floor industrial control systems (ICS), for obvious reasons including safety, operation and production. When it comes to risks and threats, cyber crime now has an $8 trillion price tag, according to a recent Security Intelligence report. That’s another
controleng.com
KEYWORDS: IT/OT convergence, digital safety, manufacturing, critical infrastructure, OT cybersecurity
LEARNING OBJECTIVES
Understand the cultural reasons IT and OT teams remain separate
Build strategies to foster collaboration and enhance cybersecurity
Learn how tabletop exercises can help identify vulnerabilities and bring teams together.
How will greater collaboration lower cybersecurity risk in your organization?
ANSWERS
FIGURE: Shared experiences can help break down barriers between the departments and nurture an environment where information technology (IT) and operational technology (OT) are aligned with priorities, goals and ways to accomplish them, lowering cybersecurity risk, suggested Dino Busalachi of Velta Technology. Image courtesy Brett Syles
reason why IT/OT convergence is imperative.
When IT and OT work together, businesses can gain a comprehensive view of their operations that can help identify security risks and vulnerabilities. This visibility is crucial, as key manufacturing industries continue to be a target for cyberattacks and ransomware due to a variety of issues from software misconfigurations to unknown assets on the plant floor. Being proactive with collaboration across disciplines creates an opportunity to get safer sooner rather than waiting until it’s too late, which can result in lost data, costly downtime and physical safety hazards.
How can tabletop cybersecurity exercises help IT, OT
A tabletop exercise can improve collaboration and identify vulnerabilities in an organization’s ICS environments. The tabletop exercise includes step-bystep methodology that displays how vulnerable an organization is to an adverse cyber event. This exercise typically involves the C-Suite, risk management and employees from the IT and OT disciplines.
A tabletop exercise is vital and beneficial in establishing ownership of ICS security. A defined plan and ownership over digital safety and security can offer much-needed clarity. By facilitating this comprehensive conversation and bridging the gaps between the two groups, improvements can be made to internal communications and ownership of security across the organization. This ultimately can help with convergence by breaking down the silos that have historically kept the departments separate.
Additionally, a tabletop exercise can help eliminate the “not invented here” syndrome often found in business. It’s common when a preference exists for an established approach or way of doing things, even when it may not be the best approach across every department within the business.
Businesses may see the need to standardize their practices, but if a company has a large number of plants, it can be a challenging task to create a plan that will work for everyone. Often, each individual plant may have different equipment and separate management teams. A standard approach may not be practical or work for all of them. By having an open dialogue about unique solutions, this problem can be resolved.
Working together for IT/OT convergence
Another way to foster collaboration between IT and OT departments is through hands-on experience. By working together on the manufacturing side or spending a little time on the plant floor, IT can gain a deeper understanding of the challenges of physical equipment directly from engineers. This shared experience can help break down barriers between the departments and nurture an environment where IT and OT are aligned with priorities, goals and ways to accomplish them.
IT/OT convergence better prepares businesses for the continuously evolving manufacturing landscape. By prioritizing convergence and a strong digital safety and security posture, businesses can get ahead of the curve and be ready to take advantage of new developments in manufacturing as they emerge.
As Industry 5.0 and the Internet of Things (IoT) continues to evolve and shape the manufacturing space, IT and OT must prioritize working together. By working as equal partners and leveling the playing field, they can improve processes, increase operational efficiency and achieve well-defined metrics that are in alignment. They may also uncover security issues that previously have gone undetected. By having an open mind with IT/OT convergence and making it a priority within their business, businesses can effectively position themselves for greater digital and cyber safety and security. ce
Dino Busalachi, Velta Technology. Edited by Gary Cohen, senior editor, Industrial Cybersecurity Pulse, CFE Media and Technology, gcohen@cfemedia.com.
Travis Gilmer, Thomson Industries
How electrification of linear actuators improve automation
Electric actuators help connect digital and physical worlds. See three factors impacting industrial motion and seven linear actuator advances.
Electric linear actuators are helping raise material handling application to new heights. As digital transformation extends the scope of automation to more axes and electric linear actuators handle increasingly heavier loads, more material handling system designers are converting hydraulic and pneumatic motion control to electric, especially in new projects. Linear actuator suppliers are developing innovations that extend the scope of material handling automation in load management, sizing, intelligence, durability, energy efficiency, safety and ergonomics.
Material handling automation
Electric linear actuators now offer sophisticated, advanced capabilities for material handling automation. Whether it be the peripheral intralogistics of conveying and transporting or support for production processes such as feeding and filling, material handling is increasingly vital to industrial operations. (Figure 1) In an assembly operation, for example, linear actuators might feed materials, manipulating them to optimize access to work surfaces or diverting objects from one conveyor to another. In another example, setting up can consume up to half the work cycle in food packaging operations. Linear actuators might reduce the time by automating the unfolding of cardboard or cutting film.
Electric actuators also can expand the controllable working radius, carrying materials toward or away from processing. They might support motion on forklifts, automated guided vehicles (AGVs), telescopic lifting units or overhead conveyors.
Industrial motion: 3 factors
Automating material handling motion sequences requires close consideration of the following:
1. Physical properties. Material handling automation developers must consider the shape, weight, size, position and direction stability of packages moving along a plant or conveyor system. They also must consider how the package materials affect their rollability, slide-ability, stack-ability, surface sensitivity and stiffness.
2. Environmental parameters. Material handling equipment designers must consider parameters such as room layout, machine size limitations and available degrees of freedom.
FIGURE 1. Forward-thinking factories incorporate multiple of interconnected machines and devices that take advantage of advanced actuator features to enable a fluid, synchronized and safe manufacturing process. These uses can include forklifts, assembly/control stations and fixtures, AGVs, and components that can be easily and quickly adjusted on the fly. All images courtesy: Thomson Industries Inc.
ANSWERS
had previously dominated. Electric linear actuators had previously been limited to 300 or 400 mm per stroke; they now can span up to 1.2 m.
FIGURE 2. The integration of onboard electronics into electric actuators enables enhanced control functions that were previously external, such as switching, position feedback and system diagnostics, directly into the actuator. Thomson smart actuators incorporate microprocessor-based printed circuit boards with complementary software that allows communication between remote networks.
3. Motion parameters. Like most motion control applications, material handling applications consider weight and inertia of the payload as determined by speed and acceleration within cycle times and the required accuracy.
Material handling applications may require special attention to kinematic factors such as drift, overshoot, stabilization time and interchangeability, with particular attention to the drive, power transmission system, position measuring system and bearings. Friction can lead to play in the bearings, poor resolution of the position measuring systems and structural static deformation. Dynamic flexibility can contribute to neural weaknesses, which can lead to errors and failures. Equipment designers must address all these factors within the context of maintenance, safety and durability.
Electric linear actuators: 7 advances
Electric linear actuators have been used in material handling operations for years. During that time, there have been many advances, optimizing them for supporting new industrial operations. These include:
1. Heavy load handling. Electric actuators can now handle heavy duty loads up to 25 kN, which had been relegated to hydraulic or pneumatic cylinders. These improvements are due in large part to component material improvements and advancements in ball screw technology, such as implementation with ball bearings.
2. Extended stroke lengths. Electric linear actuators are now also capable of longer strokes, tackling applications that hydraulics and pneumatics
3. Compact design for confined spaces. Actuators are often designed into confined spaces. On a packaging line, for example, feeding and cutting systems may compete with other units for space. On an AGV or forklift, space is always at a premium, and actuator size can also impact energy usage. Actuators with housing the size of a passport can now handle loads up to 2000 N (450 lbs.) They fit into small spaces that previous-generation actuators would be either too large or too weak.
This compactness and simplicity are a major difference from hydraulics and pneumatics, which require an imposing infrastructure of equipment such as pumps, hoses, valves, reservoirs and compressors. Electric actuators simply plug into a power supply and connect to a network. Integrating a programmable logic controller (PLC) with an electric actuator allows for more efficient and seamless control, resulting in reduced downtime, increased productivity and cost savings.
4. Improved intelligence and network integration. Electric linear actuators are now available with modular onboard controls that enable simple on/ off switches, low-level switching, position feedback and CAN bus network integration. They can monitor and control, diagnose, read position and operating statistics in real time, and be fine-tuned on the fly. (Figure 2) As factories become more digitally advanced, designers will integrate material handling capabilities into more sophisticated operations. Loads will move more intelligently, enabling programmed motion sequences, remote system operation and synchronization across multiple actuators.
5. Longer operating life. Material handling applications often run 24/7 in set-and-forget applications. Production line applications, such as an arm that diverts items from one conveyor belt to another, have high-duty cycles and are subject to wear and tear. AGVs, forklifts and other mobile equipment may be deployed in those applications and usually run on batteries. (Figure 3) Equipment used outdoors or in hazardous environments, and subject to ingress from moisture and dust can require long life.
Linear actuators using brushless motors can have duty cycles of 100% and up to 600 km of maintenance-free life. This is a major advantage over hydrau-
FIGURE 3. For AGVs without human involvement, remote control over radio, WiFi, satellite and other communications is vital. In addition to their remote benefits, electric actuators reduce maintenance and environmental concerns thanks to sturdy designs. This all-in-one actuator package makes it possible for AGVs to move goods over larger areas no matter how demanding the conditions.
lic and pneumatic technologies, which require almost constant maintenance. Lubrication technology has advanced to the point where some actuators are factory lubricated for life. Adherence to IP standards of IP65, IP66 and IP69K prevent particulate, moisture and other ingress that can shorten an actuator’s life.
6. Safety and ergonomics. Material handling equipment constantly puts humans at risk. For example, a machine that loses power may drop its load faster than a human can get out of the way. There might be ergonomic challenges resulting from repeated movements or awkward workpiece positioning. Electric linear actuators aid in these situations with electromechanical and static holding brakes, which hold the load in place in case an application loses power. They also can make work safer by raising, lowering, or tilting worktables to comfortable, more ergonomic angles.
Automated picking helps avoid long feeder routes and relieves the operating personnel from the work cycle of the machine as much as possible, keeping ergonomics and safety a priority. (Figure 4) Replacing hydraulic cylinders also removes the risk of slipping and falling on leaked fluid as well as product contamination from solid fluid leaks.
7. Customizing linear actuators for competitive advantage. While the range of available technologies is growing, application diversity is driving the need for custom solutions. Designers are increasingly requiring components and systems to fit unique needs.
FIGURE 4. Assembly/control stations and holding devices are experiencing an increase in automation. The individual adaptation of workstations facilitates work, increases operator comfort and reduces the risk of injury, while securing material and other equipment during the assembly process.
Manufacturers often can meet these needs with minor modifications to standard offerings, but on occasion they may have to design something from the ground up. Actuator suppliers with the broadest offerings are most likely to adapt standard lines or have the expertise to design something from scratch. Their flexibility and willingness to augment their standard offering is a factor. Customization capability is a significant advantage of most new designs for electrified equipment. This equipment is often more modular than earlier generations, and changes can be made by modifying, adding or removing axes. Electric designs reduce the need to redesign to larger components of a system. ce
Travis Gilmer, product line manager – linear actuators, Thomson Industries. Edited by David Miller, content manager, Control Engineering, CFE Media and Technology, dmiller@cfemedia.com.
controleng.com
KEYWORDS: Linear actuators, motion control
LEARNING OBJECTIVES
Learn the advantages of electric linear actuators over their hydraulic and pneumatic alternatives.
Learn about the most important factors to consider when automation material handling motion sequences.
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With this article online, read more about ROI details.
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How can automation optimize motion applications?
Chris Mercurio, Bosch Rexroth
Four manufacturing applications that benefit from under-rider AMRs
Autonomous mobile robots (AMRs) and the software that makes the machines operate can help them thrive in many manufacturing applications. Four applications for underrider AMRs are highlighted.
TOnline controleng.com
KEYWORDS: autonomous mobile robot, AMR, robotics
LEARNING OBJECTIVES
Understand how autonomous mobile robots (AMRs) can help manufacturers.
Learn what an under-rider AMR does and the tasks it can perform.
Learn about the four applications where underrider AMRs can be especially beneficial.
ONLINE
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CONSIDER THIS
What role do AMRs play at your facility, and how are they evolving?
he autonomous mobile robot (AMR) is becoming a critical part of modern facilities, offering its users greater productivity, safety and efficiency with its ability to automate routine tasks. AMRs also offer facilities consistent labor since they show up and do their task daily without process interruptions. While many AMRs can fit any given application, an under-rider AMR can be valuable. They are designed to seamlessly maneuver underneath the payload to pick it up and transfer from point A to B.
Localization software guides AMRs
Before diving into where an under-rider AMR can be used, take a step back and look at how they work. Unlike alternatives like automated guided vehicles (AGVs), which require predefined routes, markers or guides, an AMR can navigate through an environment without human intervention. Since it is critical for an AMR to understand its own location within this environment, we consider the localization software to be the “heart” of an AMR solution and one of the most important considerations when evaluating an AMR. Among multiple types available on AMRs to consider – the most common being simultaneous localization and mapping (SLAM), using lasers or vision.
FIGURE 1: Under-rider AMR in a factory, which can maneuver seamlessly underneath the payload to pick it up and transfer it from point A to point B. Images courtesy: Bosch Rexroth
While localization types have their strengths and weaknesses, laser-based, SLAM-based technology is more flexible because it uses algorithms that allow the AMRs to localize in a variety of changing environments without external infrastructure. However, all laser-based SLAM technology isn’t made equal, so research is critical. Some key features of a reliable software that determines the position and orientation of a wide range of vehicle types in a fast-paced environment include:
• Automatic map updates as the environment changes
• Ability for fast and easy map extension
• Dual laser and wheel odometry fusion capabilities
• Reference alignment, reflector and QR code support for challenging environments
• Easy to use graphical user interface with guided live mapping.
The localization software is a key technology component of an AMR that plays a vital role and resolves the challenge of localizing AMRs with maximum flexibility and usability.
Four key applications for under-rider AMRs
Under-rider AMRs are not an uncommon sight in facilities and can help companies in many ways. In particular, companies should consider these four applications where this style of AMR makes the most sense in many industries.
1. Palletizing
Autonomous mobile robots can help consumer packaged goods (CPG) operations improve their palletizing systems by moving finished pallets to shrink-wrapping stations or storage areas, which has often required an operator with forklift.
One consideration is looking for an AMR that features sophisticated software that lets the robot independently determine its position and the best path to move the pallet to the next station. No tracks need to be laid, and no expert robotics programmers need to be engaged, simplifying a critical intralogistics function and freeing personnel to handle more demanding tasks.
2. Intralogistics within manufacturing
AMRs are a valuable tool to improve critical intralogistics functions — moving raw materials, finished goods, and work in process between warehouses/storage areas, production lines and shipping/receiving. These AMRs feature simplified programming, compact designs for tight turning spaces and versatile load capacities.
They provide an efficient and safe option for moving material from plant storage racks to the production line; this can be helpful in areas with labor shortages and can help reduce maintenance costs associated with fork trucks and pallet jacks.
3.
Packaging line
Robotics play an increasingly important role in packaging environments. As systems become sophisticated enough to handle a wider range of tasks, they can provide the flexibility operations need to address labor force shortages. Technologies like AMRs have a big role to play in improving efficiency and safety in warehouse automation. They can improve flexibility in systemwide processes
FIGURE 2: Example of an under-rider AMR moving a pallet, which can help consumer packaged goods (CPG) operations improve their palletizing systems.
when they’re all connected to one control system that can use data from the production floor to respond to disruptions or optimize flows.
Robots differ in functionality. Packaging lines that require maximum flexibility need AMRs that can handle a variety of payloads and can operate in a variety of spaces and changing production floors. Some AMRs can that meet these requirements, with capacity to handle payloads up to 1,000 kg and 360-deg obstacle detection. Some AMRs can interface with other equipment like conveyor systems or collaborative robots (cobots).
‘ Software can help the robot independently determine its position and the best path to move the pallet to the next station. ’
4. Assembly line
Using new intralogistics technology, mobile robots can help save time in delivering parts to manual workstations and production cells. AMRs are faster and easier to implement than more static delivery systems and don’t require delivery personnel with powered industrial trucks to move material to production lines.
AMRs can be used to move pallets or shelves so fully filled flow racks can be delivered to manual workstations. Tasks can be manually triggered via a wireless button, tablet or automatically through a programmable logic controller (PLC) or a connection to an upstream enterprise resource planning (ERP) system, manufacturing execution system (MES) or warehouse management system (WMS) via an applied program interface (API).
Insightsu
AMR insights
uAutonomous mobile robots (AMRs) can play a key role in manufacturing because of their name: They’re autonomous and do not require constant human intervention the way an automated guided vehicle (AGV) would.
u An under-rider AMR, which is designed to pick payl oads from the bottom, can be valuable in palletizing, intralogistics, packaging and assembly lines, which often have a lot of moving parts and cannot afford downtime.
ANSWERS
Automatic map updates and lidar-based navigation technology enables mobile robots to be more adaptable in rapidly changing environments without the need for special tracks or other fixed navigation aids. Finding the right application for an AMR isn’t as simple as pulling a task out of a hat. Numerous environmental, cultural and technical factors go
‘ Automated map updates and lidar-based navigation technology enables mobile robots to be more adaptable in rapidly changing environments. ’
into setting up a fleet that yields a strong returnon-investment and fits a company’s application. Don’t move into the next phase of factory automation with AMRs alone. Partner with a vendor who will provide support, technical expertise and industry knowledge to help ensure a successful AMR implementation. ce
Chris Mercurio is product manager, AMR/Robotics, Bosch Rexroth. Edited by Chris Vavra, web content manager, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.
Innovations
Open operating system for automation, IIoT
See more New Products for Engineers www.controleng.com/NPE
Weidmuller USA introduced a new open operating system, u-OS, engineered for Industrial IoT and automation applications. The new OS is said to be made for maintenance with easy cloud-based diagnostics and fleet management for remotely deployed devices. It has seamless integration with ability to easily merge proprietary and third-party applications using containerization. It is built on open standards like Linux, OPC-UA (Unified Architecture) and Docker. It integrates the CodeSys APP, an IEC 61131-3 programming tool. Weidmuller USA, www.weidmuller.com/en
Thermal cameras
The focus-free Flir E5 Pro and Flir E6 Pro cameras provide a larger 3.5-inch touch-screen display along with access to Flir Ignite Cloud connectivity within the same point-and-shoot, pistol-grip form factor as legacy Ex-Series thermal cameras. The versatile cameras are designed primarily for close-up, professional-grade mechanical, building and electrical thermal inspection scenarios. Flir, www.flir.com
Gage head sensors
NewTek GAR Series Spring-loaded Gage Heads are used in automated dimensional gaging applica-tions as part of the inline inspection processes, when it is ideal for the sensor probe to move out of the way between readings. The probes of these linear variable differential transformers (LVDTs) ex-tend when taking dimensional measurements, and then retract to the original position to avoid damage to the sensor or next conveyed product. In manufacturing conveyor lines, these air extend/spring retract gage heads conduct tolerance checks as part of quality assurance measures.
Newtek Sensor Solutions, www.newteksensors.com
Next-generation gearmotor has IP69 rating, keeps same dimensions
The Bison new Gen 2 SaniMotor maximizes throughput and reduces lead times while maintaining the robust features. It maintains original exterior dimensions, performance specifications, certifica-tions, mounting holes and power cable connections. It has IP69K rating, and exterior components are manufactured from 304 stainless steel. The output shaft also is 304 stainless steel and support-ed by sealed ball bearings. The gearmotor’s laser-marked permanent nameplate meets extreme washdown rating.
Bison Gear & Engineering Corp., www.bisongear.com
Easy-to-clean bench scales
Hardy Process Solutions announced a new 24 x 24-inch addition to its line of HIBSX Series bench scales, which are easy to clean, low-profile and feature a stainless-steel construction, adding to the 12 x 12-inch size. These scales offer simplicity and robust performance for food processing, chemical, consumer packaged goods and other industrial manufacturing weighing applications. With an internal “X” design, the scales reduce cleaning time and offer a low profile at 2.02 to 2.95 in.
Hardy Process Solutions, www.hardysolutions.com/hibsx
Tool simplifies, speeds hardware development with high-level synthesis
Bluespec Inc.’s new Accelerate-HLS tool simplifies and speeds the development of hardware using high-level synthesis (HLS) by offloading complex functionality that RISC-V processors can more effec-tively implement. Memory management, including address translation, coherence and protection, is a complex, performance-critical requirement that is outside the expertise of the average design-er and problematic for HLS designs. Bluespec Inc., https://bluespec.com
With Beckhoff Vision from Beckhoff Automation, engineers can see what’s possible when machine vision hardware and automation software are perfectly matched. This comprehensive line of EtherCAT-enabled industrial cameras, lighting and lensing components are paired with proven TwinCAT Vision software to round out a complete product portfolio. The new Beckhoff Vision hardware in-cludes area scan cameras, C-mount lenses, multicolor LED illumination and complete vision units. Beckhoff Automation, www.beckhoff.com/en-us/products/vision
Seventh axis for collaborative robots
The rack-and-pinion module is a linear motion device composed of linear guide rails, racks and aluminum extruded profiles connected to the motor, reducer and gears. The HNT series rack and pinion driven linear axis from TPA Robot are made of hard extruded aluminum profiles and equipped with multiple sliders. Even under high load conditions, it can still maintain high drive stiffness and motion speed. To cope with a variety of use environments, it is available with a dust-proof cover to block dust from entering or escaping the module. It can withstand higher loads and has unrestricted stroke while having high accuracy of ±0.04mm and is very suitable for use in automated work-
shops as the seventh axis. TPA Robot, www.tparobot.com
Leviton recently announced the expansion of the VerifEye Series 7000 family line with advanced 3-phase submeters and 24-circuit advanced branch circuit monitors to meet additional applications. The 3-phase submeters provide a versatile power metering solution for commercial and industrial applications, suitable for high density and branch circuit monitoring applications in new construc-tion and retrofit applications for real-time power monitoring, energy allocation, energy manage-ment, load monitoring and other applications. They can monitor current, voltage, instantaneous power, demand and energy consumption of each monitored circuit. Leviton, www.leviton.com/verifeye
Radar level meter concentrates energy for greater reliability, 70 m range
SUP-RD909 Radar level meter from Supmea Automation adopts a recommended industry emission frequency of 26 GHz, so it has beam angle is small, with concentrated energy for stronger anti-interference ability and better precision and reliability of measurement. Measurement range of up to 70 meters, covers a large reservoir water level measurement.
Stahlin Enclosures PolySlim low-profile polycarbonate enclosures are designed for original equip-ment manufacturers (OEMs) and installers to solve application challenges. The enclosures accom-modate existing panel designs, eliminate unneeded depth and material, optimize installations and save space and cost. The low-profile designs work well in tight spaces.
AutomationDirect has added a wide assortment of quality WEG electric contactors and motor con-trol devices to an offering of motor controls and safety equipment. The CWBS series IEC safety con-tactors provide a safe and reliable way to control electrical power in industrial and commercial ap-plications. Available in ratings up to 80A, the contactors comply with IEC and UL standards, providing mechanically-linked and mirror contacts. AutomationDirect, www.automationdirect.com/safety-contactor
Back to Basics
CYBERSECURITY HELP
Securing OT with IT cybersecurity best practices
With digital transformation comes the need for robust cybersecurity specific to the operational technology (OT) domain. The information technology (IT) domain can help.
Alongside plant digitalization comes a need to consider cybersecurity at every step. Information technology (IT) staff have traditionally been responsible for the cyber protection of a business but as operational technology (OT) systems begin communicating with enterprise-wide software, that responsibility is now placed on every member of the team, if not more directly on OT. Studies show manufacturing is being targeted at a higher rate than any other sectors because of the new vulnerabilities that are presenting themselves in OT technology.
Traditionally, the OT environment was "air-gapped" to wider enterprise systems. While outdated, this approach did help protect systems as OT technology was harder for hackers to reach. Fast forward through Industry 4.0 and the digital transformation of the sector, much of that OT technology remains in operation. The issue is that many OT systems were never designed with enterprise-wide communications in mind and today’s open communication between OT and IT highlights the differences in the two environments, but also why a shared approach to cybersecurity is needed. OT environments traditionally focus on safety.
plugging external devices into enterprise systems or having dedicated scanning environments for removable media are often not understood to be critical to OT professionals.
Achieving secure impossible without expert
’
Cybersecurity for OT is a complex and never-ending journey, encompassing a growing list of solutions, products and approaches. OT professionals are often over-stretched, and their workload is expanding as digital transformation advances. Adding the same strain IT feels to the full OT plate may seem like overkill, especially when considering IT has specific training and has been in this space for all their working lives. Finding a viable approach to cybersecurity for OT is a lot like digital transformation; it requires buy in from all levels of a business, input from multiple sources and a collaborative approach that stays up to date with the latest products and services.
Physical systems that can put workers in harms way require complete control and availability, removing that with a ransomware attack, for example, puts a company at risk. Not only will downtime be costly for everyday the company isn’t in control, but in some extreme cases, OT professionals and the general public may be put at risk. While IT cyber incidents may be more frequent and quicker to solve, OT incidents can cause serious damage.
Ensuring OT is cybersecure
The starting point for a secure OT setting is to align approaches in standards, practices and tools. One example of this is how quickly IT systems are updated to ensure ongoing cybersecurity. The same cannot always be said for OT systems. This sees many OT systems remaining vulnerable for longer than they have to be. Even simple best practices such as never
Achieving a secure OT is an almost impossible task without expert help. To alleviate the strain for the already busy OT professional often requires a partner organization. OT professionals need to address their cybersecurity concerns and having a partner to remove the complexity can be helpful. The chosen partner needs to have a deep understanding of digital transformation and must work closely with the organization to navigate the products in the crowded market, and create a cybersecurity approach to align OT schedules.
There is no one-size-fits all approach to cybersecurity for OT, it’s about working closely with partners to meet industrial regulatory and compliance requirements and to achieve peace of mind. ce
Lee Carter is cybersecurity product manager at SolutionsPT. This originally appeared on Control Engineering Europe. Edited by Chris Vavra, web content manager, CFE Media and Technology, cvavra@cfemedia.com.
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WHAT IF?...
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