Level sensors monitor the level of liquids, pellets, powders, and other similar products in tanks and process systems.
• Ultrasonic level sensors
• Float, capacitance, and vibration level switches
• Rotating paddle level switches
• Guided wave radar level sensors
• Differential pressure level transmitters
NEW! Endress+Hauser Capacitance Level Switches
Starting at $221.00 (FTI26-CA4MWDG)
Endress+Hauser capacitance level switches are contact sensors that provide point-level detection of powders, fine-grained bulk solids, or water-based conductive liquids. Many models have hazardous location ratings or are FDA-compliant for food and beverage industry applications when installed with appropriate hygienic fittings.
• DC PNP switches and IO-Link communication output options
• Select models are marked with the 3-A symbol for food and beverage industry hygienic applications
Endress+Hauser submersible level sensors provide continuous liquid level measurement by sensing the hydrostatic pressure produced by the height of liquid above the sensor, providing a 4-20 mA output signal compatible with PLCs, panel meters, data loggers, and other electronic equipment.
• Up to 2 bar (66.9 ftWC) sensing range
• Rugged 316 stainless steel construction
• NSF Certified models for drinking water applications
• Models with FM hazardous location approvals for intrinsically safe applications
Temperature sensors provide accurate and reliable feedback for temperature control and monitoring applications.
reliable flow or measurement.
• Mechatronic flow switches and transmitters
• Magnetic-inductive flow meters
• Thermal and vortex flow sensors
• Variable area mechanical flow meters
Pressure Sensors
Starting at $87.00 (QPSL-AP-42)
Flow measurement devices monitor liquid media and provide reliable flow indication, detection, or measurement.
• Pressure switches and transmitters
• Digital pressure switches/transmitters
• Differential pressure transmitters
• Winters pressure accessories: siphons, snubbers, and isolation needle valves
• SCU-2501 universal frequency transmitter with analog and relay outputs
• SCU-2502 universal frequency transmitter with (2) relay outputs
• SCU-2503 universal frequency transmitter with analog and frequency outputs
Pressure sensors measure pressure at a specific point in the process and transmit the measured value or trip point to a control device.
ProSense frequency signal conditioners are extremely versatile, affordable, and will convert, transmit, scale, and isolate input signals from a wide variety of process sensors and controller I/O.
Slotted Aluminum Rails
SureFrame T-Slotted Aluminum Rails
SureFrame T-slotted aluminum rails are available in the most popular profiles and dimensions. T-slotted rails are ordered in your custom cut-to-length sections for maximum flexibility and minimum waste.
We also offer a full selection of assembly hardware for T-slotted rail systems, which includes T-nuts, fasteners, connecting components, joining plates and brackets, as well as floor, door and panel elements. SureFrame T-slotted rails, along with the assembly hardware components offered, are compatible with many other brands.
Also Available
• AC variable frequency drives (VFDs)
• Motors
• Wiring and electrical connection solutions
• Just about everything you need to complete your automation projects!
Features
• You specify length and cut angles for each piece
• No cut fees
• Free 2-day delivery on all orders over $49*
• Available in 1 inch, 1.5 inch, 30mm, 40mm and 45mm profiles
• Complete selection of Fath installation hardware available
ease of use, sustainability: Pack Expo Las Vegas 2023; NIST drafts major update to its widely used cybersecurity framework; ONLINE: Headlines, conference
| Six advanced strategies to add
| PID loop control tuning advice; see video.
22 | How 5G will revolutionize manufacturing, benefits 23 | How to keep a factory running beyond using PLC diagnostic tools 24 | How can PID methods protect compressors from surge and choke? 28 | Are you applying a PID control to non-linear processes correctly?
| Industrial cloud, automation 32 | Engineering Leaders Under 40: What makes an engineering trailblazer? 40 | What’s new in wireless, RFID for IoT asset tracking?
MACHINES (after 42)
| Embrace the industrial cloud
From the digital edition, click headlines of each article or search at www.controleng.com
INNOVATIONS
46 | New Products for Engineers – See products in this issue. See more products online on the Control Engineering website. www.controleng.com/products
LTE4 cellular router protects against cyber threats; L-type magnets for the industrial market; Wireless access point, client bridge; Angle seat valves to control liquid and gas flow; Small radiometric thermal camera; Electronic position indicators for rotating shafts; Programmable temperature transmitter.
Search the database here: www.controleng.com/NPE.
47 | Back to Basics: Benefits of upgrading legacy PLCs, HMIs for a water well expansion project System integrator discusses upgrades.
NEWSLETTERS ONLINE
Motors and Drives newsletter
• Slash carbon emissions now: Harness VFDs for efficiency
CE Control Systems
• Cybersecurity, analytics, MES/ERP integration, robotics: The future is here, are you keeping up?
CE Digital Transformation
SEPTEMBER 2023
u Control Engineering eBook series, now available: Fall Edition
IIoT Cloud
Leveraging MQTT, industrial edge devices in automation projects; How the cloud can improve embedded system; Edge computing use cases, success stories; Manufacturing needs to be agile, resilient and sustainable
Learn more at: www.controleng.com/ebooks
u AppliedAutomation
Maintenance and troubleshooting fundamentals for industrial automation; Upgrading ventilation equipment systems in automotive tunnels; How logistics can simplify automation processes and operations management; Create a strategic plan when integrating automation in manufacturing facilities
• Digital transformation: Future-proofing your operations beyond the data
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
Five advances in motion control, communications, design to ease automation use
u DISTRIBUTED input/output (I/O) system for electric and pneumatic motion, multi-protocol servo drives, electric motion sizing online software, a 3D computer-aided design (CAD) and an online handling guide are helping machine builders and other designers of automation systems said Festo’s announcements prior to Pack Expo Las Vegas 2023. Advances include:
• Festo CPX-AP-A distributed I/O for electric and pneumatic motion additions mean that “no other supplier in N.A. compares to the breadth of Festo motion solutions and support.”
• A new Festo family of multi-protocol servo drives adds productivity and cost advantages with less inventory for original equipment manufacturers.
• Festo’s new Electric Motion Sizing Online Tool enables quick servo drive selection: Users receive perfectly dimensioned options for electric and electromechanical drive components in minutes, the company said.
• An online Festo 3D CAD Configurator for Actuators and Accessories helps after the configurator’s streamlined design process.
• The Handling Guide Online helps to eliminate interruptions in the value chain because the new configuration and ordering platform is integrated into the online product catalogue from Festo. ce
Read more, see photos online.
5G’s role in the adoption of enterprise augmented reality
u SINCE THE FIRST DEPLOYMENTS of 5G networks, AR has had, and will continue to be, an important chapter in the book of 5G-enabled applications. Certainly, the common perception has been to associate AR to entertainment and media applications, but beyond that easy hype, AR has always had strong potential enterprises looking to improve their performance and efficiencies. 5G is enhancing that, providing the necessary infrastructure for exploring AR-based enterprise applications not possible before.
This is based on research on the convergence between 5G and AR conducted by the Augmented Reality for Enterprise Alliance (AREA) in 2021. The article examines how the enterprise AR ecosystem perceives the coming of 5G, which enterprise AR solutions can be developed using 5G deployments, what are the difficulties in achieving, and what are the benefits. The analysis is based on a collection of enterprise 5G deployments, covering the period 2017-2021. The overall result shows that the development of 5G-based enterprise AR applications were in an early stage of development in 2021, but there are promising use cases that showed the potential of 5G in driving adoption of enterprise AR applications in various sectors, particularly in manufacturing.
Read more, see graphics online.
Collaborative robots deliver half a million dollars in annual savings for cosmetics company
u A GLOBAL cosmetics company used eight collaborative robots on four mobile carts in one factory to automate the picking and packing of products at the powder presses. For Paul Baublitz, project manager at Coty Cosmetics, the issue was clear: “We currently have twelve presses, and the challenge with automation is always how do you, in a cost-effective manner, automate such a large operation?” Baublitz had multiple reasons for automating, including meeting the company’s drive for increased efficiency as well as addressing the repetitive nature of the task, which was not ergonomically friendly for human operators. This was a task that Coty had previously looked into automating, but found that the technology available at the time wasn’t up to the complexity of the application.
WHILE SOME WORKERS at Coty Cosmetics were initially fearful of robots taking over part of their jobs, they are now very appreciative of their new cobot colleagues as they take over several tedious tasks such as doing the quality inspection of each godet. “Now there’s a computer doing all of that work,” says Paul Baublitz, project manager at Coty Cosmetics. “If you see something that needs to be improved, you can immediately react.” Courtesy: Universal Robots
Flexible collaborative robots were able to step up where traditional robots could not. Recently, Baublitz brought the problem to Chris Sydorko, owner of the integration firm Sydorko Automation, who said, “The challenge for me was to try to determine how I could build a robotic system that was mobile enough to meet their automation needs while still being cost-effective enough to meet their budgetary needs.” Traditional industrial robots are not easily moved due to safety regulations, which meant Coty would need a robot for each of 12 presses. This was not within budget, so Sydorko looked to collaborative automation for the solution.
Read more, see more photos online. ce
What systems integrators, others should expect in the second half of 2023
An economic and labor update advises shifting performance indicators for the near future.
An “Economic and Labor Update” presented by Alex Chausovsky of Miller Resource Group was one of the highlights at the recent CSIA Executive Conference 2023, held May 15 to 19 in New Orleans.
Chausovsky’s overall message was while the year 2022 brought some bad news, including rising interest and inflation rates, it was no time to panic. Nevertheless, with a mild recession looming, the systems integrators and others in the audience were advised to manage for profitability rather than growth in the immediate future.
ed imports, led to stocking changes, lower inventory goals and slowed growth, while remaining positive overall.”
Industrial investment
Nearly 18% of GDP comes from gross private domestic investment as opposed to personal consumption or government spending. The last several years have seen unprecedented growth in retail sales, which isn’t proving sustainable.
AN UPDATE on current market and labor conditions, specific to the concerns of systems integrators was one of the highlights of the recent CSIA Leadership Conference. Courtesy: Miller Resource Group at 2023 CSIA Executive Conference
Amid a global economy estimated by the Visual Capitalists website at $104 trillion, the total U.S. economy was estimated at $35.7 trillion and that of China at $19.9 trillion, Chausovsky said.
Current-dollar U.S. gross domestic product (GDP) increased 9.2%, or $2.15 trillion, in 2022 to a level of $25.46 trillion, compared with an increase of 10.7 percent, or $2.25 trillion, in 2021, according to the U.S. Bureau of Economic Analysis.
Chausovsky noted, however, the rate of GDP increase has slowed. “The last six quarters have been close to recession,” he said. “This has impact-
Industrial production remains at its highest rate since 2019, and despite a slowdown in new orders, remains 2.5% over last year. “The propensity is for recession in early 2024. It will be mild and last about six months. It’s challenging to focus on profitability when so much growth has taken place. Others say they still need to raise prices,” Chausovsky said. (See sidebar 1)
In prognosticating on the business cycle, economists make use of leading indicators that presage larger changes. Chausovsky cited 1) total industry capacity utilization rate, 2) copper prices, and 3) the ISM Purchasing Managers Index as relevant leading indicators for the industrial sector.
With inflation slowing, including for energy, other sectors remaining flat and prices for core services starting to fall, Chausovsky predicted an inflation rate of 3.5 to 4%. He believes Federal Reserve-mandated interest rate hikes are over for the present.
Labor profiles
Many of the discussions at the CSIA Leadership Conference event concerned skilled labor shortages and recruitment of young engineers, and most especially the phenomena of having to offer higher salaries to new employees while veteran employees are paid at a lower rate.
Chausovsky said a unique feature of the
Induction motors market will reach $40.5 billion by 2032
The induction motor global market sales are anticipated to reach $40.5 billion in 2032. Between 2022 and 2032, a strong CAGR of 7.4% is expected. It was worth around $19.9 billion in 2022. Induction motors require little to no maintenance if any at all. The lack of sliding rings, commuters, or brushes is one of the primary factors driving the growing demand for these motors.
In an induction motor, a fluctuating magnetic field created in the stator interacts with the current generated in the rotor coils to produce torque. This type of motor is stronger and more ecologically friendly than traditional motors. It is an excellent choice for durability and low maintenance needs. A major aspect influencing its growing popularity is its capacity to operate in a range of weather conditions. The increased emphasis on reducing greenhouse gas emissions, and the need for energy-efficient products, are two factors driving popularity of electric vehicles. The International Energy Agency (IEA) estimates that 2 million electric car units were sold in first-quarter 2022, a significant increase over the prior year.
It was a 75% increase over the same period
impending recession is the U.S. economy will experience at the same time full employment, i.e., an unemployment rate of less than 4%. Now, there are 1.7 million open professional and business services jobs unfilled and 9.6 million openings total.
While large tech companies are shedding jobs the manufacturing sector is looking to add workers. (See sidebar 2 for talent strategy tips.)
The first thing to consider for a systems integrator, said Chausovsky, is whether its employment offers are competitive compared to those of others. Moreover, are those offers fair in light of what established employees are paid?
Manage so as to make money
Things to consider when managing a business for profitability as opposed to growth:
• Optimize cash flow
• Narrow your focus
in 2021. The need for induction motors is expected to rise as the EV sector grows. Electric vehicle (EV) manufacturers like these motors because of longevity, dependability, and low maintenance. To supply the growing demand for electricity and sustain global growth, consistent and considerable investments in power generation are necessary. Usage of induction motors in the electrical industry has expanded. Optimized electric motor systems can deliver energy savings and reduced operating costs in industrial facilities and buildings. U.S. Department of Energy said motors consume around 50% of the nation’s power, with AC induction motors accounting for 90% of that figure. ce
Induction motor market trends, 2022-2032, are noted by Future Market Insights. Courtesy: Control Engineering with information from Future Market Insights
– Future Market Insights is a CFE Media and Technology content partner.
• Look for smaller projects
• Emphasize maintenance best practices
• Build your channel and system of partners
• Discount prices for longer-term contracts.
Finding talent a challenge?
Some tips on how best to pursue a talent strategy in a time of labor shortages:
• Allocate resources needed for a comprehensive approach
• Be data-driven
• Find partners and allies
• Communicate and strive for efficiency
• Ask for input and respond to that input
• Two interviews per candidate should be sufficient. ce
Kevin Parker is senior contributing editor, CFE Media and Technology, kparker@cfemedia.com.
Read more: The Bundy Group reported 10 automation company M&A transactions in August. Online controleng.com u
KEYWORDS: Control system integrators, automation outlook
LEARNING OBJECTIVES
Systems integrators and others were advised to manage for profitability rather than growth in the immediate future by Alex Chausovsky of Miller Resource Group.
While a recession is projected to happen in 2024, it will be different than others because it will still have full employment and will be overall mild.
Are you applying these seven SCADA innovations?
Courtesy: Avanceon
SEE THE WEBCAST https://www.controleng. com/webcasts/scadaseries-new-scada-featuresand-functions/ Online controleng.com
From its inception, Industry 4.0 has emphasized the pursuit of system-wide efficiencies and data- based decision making. Interest and investment in supervisory control and data acquisition (SCADA) systems has grown in recent years as companies seek to adapt. SCADA systems can provide end-users with a variety of benefits, including:
• Holistic visibility.
• Data integration and analysis.
• Adaptive and predictive control and maintenance.
In an Aug. 15 Control Engineering webcast, “SCADA series: New SCADA features and functions,”
Know What Happened...
Matt Ruth, president at Avanceon, and Nicholas Imfeld, operations manager at Avanceon, discussed SCADA trends and innovations. Ruth said: “It’s not just about the technology. Today, many manufacturing leaders are really frustrated that they can’t see what’s going on with their systems,” Ruth said. “They also have the issue that even while they have very many people in their organization, they overrely on ‘that one guy’ who has been with the company a long time and knows the secret sauce to troubleshooting the existing system.”
Imfeld detailed seven innovative SCADA features and explained how end-users can benefit from each. The features discussed include 1) Situational awareness, 2) Windows hierarchy and tiered navigation, 3) Enhanced alarms, 4) Historical data and trending. 5) Standards and conventions, 6) Distributed architecture and virtualization, 7) Variety of access. ce
David Miller is content manager and webcast moderator, Control Engineering, CFE Media and Technology, dmiller@cfemedia.com.
With the Next Generation Sequence of Events Recorder!
In Critical Power Facilities, all data recorded during a power outage is vital! Sequence of Event Recorders collect precision data to quickly identify the root cause, providing a clear picture of what happened, and what is needed to restore power quickly!
How flexible I/O helps process industries, cuts downtime, improves ROI
Webcast on flexible input/output (I/O) platforms explains how to increase flexibility while lowering costs and improving reliability.
Challenges of process control systems include system flexibility, tight project schedules and reductions in maintenance budgets, said Armand Prezioso, senior global product manager, and Chris Stearns, product manager PlantPAx DCS, from Rockwell Automation. New generation high availability input/output (I/O) platforms can help to reduce downtime and meet the demand for flexibility in project schedules and delivery complexities. By coupling a modern distributed control system (DCS) with flexible and configurable I/O platforms, it’s possible to cut downtime, increase flexibility, simplify maintenance and optimize lifecycle costs, said Prezioso and Stearns in an Aug. 31 Control Engineering webcast, “Augmenting DCS Capabilities with Universal I/O.”
Prezioso and Stearns explained how a universal I/O platform can be effectively implemented in distributed field enclosures, resulting in minimized lifecycle costs, optimized footprints and maximized return on process assets. The webcast discusses differences between traditional I/O platforms and a universal I/O platform along with how new generation high availability I/O platforms reduce downtime and bring flexibility to project schedules and ease delivery complexities. Also covered are ways to minimize lifecycle costs, optimize footprints and maximize return on investments. ce
Edited by Mark T. Hoske, content manager and webcast moderator, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com.
DISCOVER how to deliver projects faster and reap lifecycle benefits with a Rockwell Automation PlantPAx system with the FlexHA 5000 I/O platform from Rockwell Automation. Courtesy: Rockwell Automation
controleng.com
SEE THE WEBCAST www.controleng.com/ webcasts/augmenting-dcscapabilities-with-universal-i-o/
Complete with dashboard for instant visualization of network health and topology maps for quick troubleshooting. These switches offer the tools of industrial networking such as firewalls & ring redundancy without all the office IT application overhead.
www.wago.com
/us/lean-managed -switches
Motion control, ease of use, sustainability
uOrganizers, calling Pack Expo Las Vegas 2023 the “most comprehensive packaging and processing event in North America this year,” highlighted sustainability, noting the Sept. 11-13 event includes “partners, vendors, and exhibitors are working together to create actionable sustainable solutions in manufacturing, materials, and design as well as through improved processes on the show floor.”
PMMI, the Association for Packaging and Processing Technologies, said increased sustainability emphasis includes expert speakers, actionable sustainable solutions in manufacturing, materials, recovery, logistics, analytics and design. Pack Expo Las Vegas, as of mid-July, expected more than 2,000 suppliers in more than 40 vertical markets. Dow is the show's official Sustainability Partner. Victor Zapata, commercial vice president, packaging and specialty plastics North America, Dow, said, “Sustainability is no longer a ‘nice-to-have,’ but a necessary part of any company’s business strategy and growth. Yet, no one company can do it
Beckhoff Automation
Beckhoff Automation MX-System is a pluggable platform for cabinet-free packaging machines. The modular system has pluggable IPCs, I/Os, couplers, motion, relays, and more on scalable baseplates for direct installation on the machine. It is IP67-rated with robust metal housing for control cabinet-free machine and system concepts. Courtesy: Beckhoff Automation
alone. Enabling a circular economy requires all of us working together to advance collective solutions.”
Among show-related efforts, exhibitors can participate in a post-show donation program, benefiting area organizations by donating unwanted food, electronics or booth materials. After the show, PMMI will donate or recycle remaining carpet.
Automation at Pack Expo
Automation, an integral part of packaging and production-line machine technologies, remains a significant part of Pack Expo Las Vegas, and Control Engineering plans coverage at the show. (See also p. 7.)
Releases and developments related to automation and controls for packaging, motion control and machine design, as of mid-August, include the following.
PC-based controls, robotics
Beckhoff Automation emphasized PC-based controls and EtherCAT communications for high-speed and precision-focused packaging-related automation. Product-transport motion-control systems integrate with a wide portfolio of computers, human-machine interfaces (HMIs), motors, drive, input-output devices, networking and TwinCAT software platform for engineering and runtime. Other specific products include the MX-System for control cabinet-free packaging application (photo), XPlanar for floating product transport, XTS for flexible machine motion control concepts, XTS with NCT for mobile product processing and Atro, a modular industrial robot system.
Kuka Robotics KR 3 Delta HM Hygienic robot (photo: ceiling-mounted robot with reach of 1,200mm, a maximum payload capacity of 3 kg and cycle times as low as 0.5 seconds) and KR IonTec robot can help for food processing. In a pick-and-place/ bin-picking application, Kuka will simu-
Kuka Robotics
Kuka Robotics KR 3 Delta HM Hygienic robot is a ceiling-mounted robot with reach of 1,200mm, a maximum payload capacity of 3 kg and cycle times as low as 0.5 seconds. Courtesy: Kuka Robotics
late a fast-moving consumer goods (FMCG) production environment in a cell with KR 3 Delta Hygienic robot along with KR 6 SCARA (6-kg payload positions at a repeatability of +/- 0.02 mm) and KR 6 Agilus robots (10-kg payload and comes in a wide range of variants for challenging applications such as clean rooms and potentially explosive environments).
Motion control standards
Lenze Americas touts 75 years of packaging industry experience, offering motion-related products and services for machine retrofits or new designs. Benefits include experts, a comprehensive automation platform with modular software and scalable hardware, reliable drive systems, use of open standards, global services and training.
PLCOpen said its combined technologies and standards with OMAC and the OPC Foundation, provide more than individually. They each focus on a different section of the production flow and combine well with their vision, standards, and activities, PLCOpen said. PLCopen Motion Control efforts include mapping of OMAC PackML State Diagram to IEC 611313. Application examples with PLCopen Motion Control will be discussed.
Rockwell Automation plans to bring smart manufacturing life by simplifying data access and contextualization from
machine design through impactful enterprise use cases. Demonstrations include virtual reality and emulation demonstrations of advanced technologies. Discussions will cover workforce, production optimization and data solutions. Packaging automation innovators can help with the latest advanced technologies for a more flexible, scalable and data-driven future. The Rockwell Automation ArmorKinetix Distributed Servo Drives (photo) provides customers with a scalable drive solution that helps deliver leaner, greener and more powerful machine designs. The new distributed servo drive is said to lower total system costs, improves productivity and increases uptime for manufacturers, making it a desirable option to enabling the next generation of production machines with power output up to 5.5kW in distributed or integrated designs.
Motors, motion, robotics
Siemens Digital Industries provides an array of design, automation, connectivity and lifecycle solutions. Among many Siemens products appropriate for packaging applications is the Sinamics S200 servo, which contains a Sinamics S200 drive and Simotics S-1FL2 motor with standard or flexible cable options. It’s designed for easy
Rockwell Automation
The Rockwell Automation ArmorKinetix Distributed Servo Drives is available as a distributed servo drive or as an integrated servo drive and motor, has power output up to 5.5kW, advanced analytics using integrated vibration and thermal sensors, integrated safety technology capable of achieving SIL 3, CIP Security capability and IP66 certification. Courtesy: Rockwell Automation
setup with the electronic type plate on the 1FL2 motor and one-button tunning in the S200 drive. The motion-control combination serves stand-alone and networked machine market applications.
Profinet and Pulse Train versions of single-axis ac/ac drive are available. It has a security chip and UMAC protection. Related machine simulation is fit for digitalization. Global standards for worldwide use including UL, CE and SEMI 47. It has a built-in web server and one-button tuning and can be used for positioning, conveyorized moving and processing, whether standalone or operated by a motion controller.
Yaskawa Motoman said customer demands and market pressures continue to prompt company leaders to find innovative ways to effectively manage processing and packaging operations, including flexible and capable robotic technologies. From saving energy and reducing waste to optimizing current workflow and creating a more resilient workforce, a growing number of economical and intelligent technologies are helping. Chris Caldwell, Yaskawa product manager said, “At the show, Yaskawa will feature multiple robot demonstrations showcasing extremely fast, flexible and easy-to-program robots” along with “versa-
Siemens
The new Siemens Sinamics S200 servo-drive system, comprising the S200 drive and Simotics S-1FL2 servo motor with Motion Connect cabling, bring an enhanced level of performance to a stand-alone or networked machine for various market uses. Courtesy: Siemens
Click headlines in digital edition to see more online, including those below.
Sensing, controlling microscopic spin density in quantum materials
Laser-array processor can help improve AI computing efficiency
Top 5 Control Engineering content: August 7-13, 2023
SHOWS, CONFERENCES, EVENTS
Sept. 26-28, Ignition Community Conference, Inductive Automation, https://inductiveautomation.com/resources/icc#
Oct. 1-4, MHI Annual Conference, Fort Lauderdale, Fla.
https://www.mhi.org/conference/
Oct. 3, 4, Manusec (Cybersecurity for Critical Manufacturing), Chicago https://usa.manusecevent.com
Oct. 17-19, LNS Research: The Industrial Transformation Event https://www.theixevent.com/s/ The-IX-Event-2023/home
Oct. 23-26, Aveva World, San Francisco https:// events.aveva.com/aw-sf-2023
Nov. 6-9, Automation Fair 2023, Boston https://www.rockwellautomation.com/en-us/ company/events/in-person-events/automation-fair.html
tile suite of proven products and peripherals can help boost production stability.” Technologies planned include robotic induction, collaborative palletizing, interactive mixedprocessing, industrial pallet pattern generation and hands-on robotic programming opportunities. ce
Edited by Mark T. Hoske, content manager, Control Engineering, mhoske@cfemedia.com.
controleng.com
uSearch Pack Expo at www.controleng.com for more from the show.
How to automate in 2024: Your top advice from Control Engineering research
Control Engineering research shows the importance of control systems, motors and drives, process instrumentation and sensors, system integration and industrial networking.
By now many are well into planning 2024 automation and controls optimization projects, and Control Engineering research results and advice can help. Each year Control Engineering asks subscribers what topics to cover and for advice on how to automate more effectively.
We’re also on a path of continuous improvement and chose to think again about how we categorize input, based on the how-to-automate topic pages on the Control Engineering website, www.controleng.com. With this article online, see more details and live links.
2024 preferences by topic
Among the “how to automate” topics at www.controleng.com, ranked in the following order of importance, according to subscribers. In the July 2022 survey to make the 2023 editorial calendar, the two leading categories also included control systems and motors and drives. Leading topic categories for 2024 are:
• Control systems
• Motors and drives
• Process instrumentation and sensors
• System integration
• Industrial networking
• New products
• Artificial intelligence and machine learning (AI/ML)
• Mechatronics and motion control
• Digital transformation
• Edge and cloud computing.
Advice from subscribers
Aside from praise, thank you, other key bits of advice focused on how to automate: Training and developing new staff have to be a highest priority with current high turnover.
Wireless communications: We were having issues using to many wireless devices and they were interfering with each other. We had to isolate use test chambers.
Motion control: A conveyor control system design used IEC motor control; the customer would not use NEMA-style motor controls.
Cybersecurity: In a recent project developing a distributed control system for an industrial process, we learned the value of applying security by design from the start. Rather than just bolting on cybersecurity late in the development cycle, we made it a priority from initial architecture through system deployment.
Favorite articles
A survey question asked subscribers to list up to five favorite articles at www.controleng. com. By topic, favorite articles listed included:
12 controllers and programming articles
10 robotics, motors, drives, motion control
9 artificial intelligence and machine learning
5 hot-topic analyses of most-read articles 3 articles related to cybersecurity. ce
Mark T. Hoske is content manager of Control Engineering, mhoske@cfemedia.com. Amanda McLeman is CFE Media and Technology research director and project manager for awards programs.
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Contributing Content Specialists
Suzanne Gill, Control Engineering Europe suzanne.gill@imlgroup.co.uk
Agata Abramczyk, Control Engineering Poland agata.abramczyk@trademedia.pl
Lukáš Smelík, Control Engineering Czech Republic lukas.smelik@trademedia.cz
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
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Learn more at: www.controleng.com/contribute
Dan Riley, Interstates
7 model predictive control benefits
Model predictive control offers food and beverage operations a variety of gains in efficiency, safety and waste reduction.
The Food and Beverage (F&B) industry is characterized by a highly competitive landscape, ever-changing consumer demands and stringent regulations, and attention to advanced process controls can help. Plant engineering and operations managers face the challenge of optimizing production processes to minimize waste, reduce energy consumption and ensure product quality. One innovative solution is model predictive control (MPC), a control strategy that can help achieve operational excellence.
Operators can expand understanding of advanced process control by looking at the essential steps required to evaluate and execute a successful MPC project in the F&B industry from the perspective of a control system integrator.
STEP 1: Define MPC objectives, scope
Before diving into the technicalities, defining the project's objectives and scope is crucial. Some common goals for implementing MPC in the F&B industry include:
• Maximizing throughput
• Minimizing energy consumption
• Reducing waste and product variability
• Ensuring product quality and safety
Once the objectives are clear, identify the specific processes and equipment to be included in the project scope. This step helps establish a solid foundation for the project and facilitate alignment with stakeholders.
Step 2: Assess the control system
Perform a thorough evaluation of the existing control system to identify gaps, limitations and potential areas for improvement. This assessment aids in gauging the feasibility and potential benefits of integrating MPC into the plant. Some essential aspects to consider include the following:
• Control system architecture: Determine if the current architecture can support adding an MPC layer. If not, upgrading the control system to a more advanced platform may be necessary.
• Control system performance: Analyze historical data and benchmark the current control system's performance to identify areas where MPC could provide significant benefits.
• Integration compatibility: Assess the compatibility of the existing control system with MPC software to ensure seamless integration.
STEP 3: Select the right MPC technology and vendor
Choosing the appropriate MPC technology and vendor is crucial to the success of a project. An MPC project can be complicated and costly if your partner doesn’t have the right knowledge or capabilities. Consider the following factors when making a decision:
• Technical capabilities: Evaluate the vendor's ability to deliver a customized MPC solution that meets specific requirements.
• Industry expertise: Select a vendor with a proven track record in the F&B industry, demonstrating a deep understanding of unique challenges and needs.
• Scalability: Ensure the chosen MPC technology can be scaled up or down to accommodate future changes in the plant’s operational needs.
• Support and training: Opt for a vendor that offers comprehensive support and training to ensure a smooth transition and long-term success.
STEP 4: Develop a detailed project plan
After selecting the right MPC technology and vendor, develop a detailed project plan that includes:
• A timeline with milestones for all project stages, from system design and implementation to testing, commissioning and post-project support
• A risk management plan that identifies potential
‘Analyze historical
data and benchmark the current control system's performance to identify areas where MPC could provide significant benefits.
’
ANSWERS
CONSIDER THE 7 STEPS to MPC implementation in your food and beverage application. Courtesy: Control Engineering with Interstates information
obstacles and mitigation strategies
• A resource allocation plan that outlines the personnel, equipment and financial resources required for each stage of the project
STEP 5: Implement the MPC
u
Online
controleng.com
KEYWORDS: Model predictive control, food and beverage
LEARNING OBJECTIVES
Explore how MPC can improve outcomes in the F&B industry.
Understand seven steps to effectively implement MPC into a plant or other facility.
Work closely with the selected vendor during the implementation phase to ensure that the MPC solution meets the project objectives and integrates seamlessly with existing control systems. Key activities during this phase include:
• System design: Collaborate with the vendor to design a customized MPC solution that addresses the plant’s needs and challenges.
• Data collection and modeling: Gather historical process data to develop an accurate mathematical model of the plant’s dynamics, which is essential for MPC’s predictive capabilities.
• Control strategy development: Design a suitable control strategy based on the developed model that optimizes the plant’s performance according to the defined objectives.
• Software integration: Integrate MPC software with existing control system, ensuring necessary interfaces and communication protocols are in place.
STEP 6: Testing, commissioning
Before deploying the MPC solution in a production environment, it’s vital to conduct rigorous testing and commissioning to ensure its effectiveness and reliability. This phase includes:
• Simulation testing: Validate the performance of the MPC solution in a simulated environment to
identify potential issues and fine-tune the control strategy.
• Closed-loop testing: Run the MPC solution in a closed-loop setting within the plant to assess its real-world performance and make any necessary adjustments.
• Operator training: Train plant personnel to use the MPC solution effectively, ensuring a smooth transition and long-term success.
STEP 7: Monitor, optimize performance
Monitor the MPC solution’s performance to ensure it meets the defined objectives and delivers the desired results. Key activities during this phase include:
• Performance benchmarking: Compare the MPC solution’s performance against predefined benchmarks and the previous control system to assess improvements.
• Data analysis: Analyze process data to identify trends, potential issues and areas for more optimization.
• Optimization: Fine-tune the MPC solution based on the collected data and insights to maximize effectiveness and achieve optimal plant performance.
• Periodic reviews: Conduct regular reviews with the vendor and plant personnel to discuss MPC performance and address concerns or challenges.
Systematic approach for MPC project includes assessment
Implementing a successful MPC project in the F&B industry requires a systematic approach encompassing clear objectives, thorough assessment, vendor selection, implementation, testing and continuous monitoring.
By following these steps, plant engineering and operations managers can unlock the full potential of MPC technology to enhance operational efficiency, reduce waste and ensure product quality in their facilities. With the right planning, execution and partnership with a reliable control system integrator, you can harness the power of MPC to drive your plant’s success in today’s competitive landscape. ce
Dan Riley is analytics manager, Interstates, a Control Engineering content partner. Edited by David Miller, content manager, Control Engineering, CFE Media and Technology, dmiller@cfemedia.com
NIST drafts major update to its widely used cybersecurity framework
The world’s leading cybersecurity guidance is getting its first complete makeover since its release nearly a decade ago.
After considering more than a year’s worth of community feedback, the National Institute of Standards and Technology (NIST) has released a draft version of the Cybersecurity Framework (CSF) 2.0, a new version of a tool it first released in 2014 to help organizations understand, reduce and communicate about cybersecurity risk. The draft update, which NIST has released for public comment, reflects changes in the cybersecurity landscape and makes it easier to put the CSF into practice — for all organizations.
“With this update, we are trying to reflect current usage of the Cybersecurity Framework, and to anticipate future usage, as well,” said NIST’s Cherilyn Pascoe, the framework’s lead developer. “The CSF was developed for critical infrastructure like the banking and energy industries, but it has proved useful everywhere from schools and small businesses to local and foreign governments. We want to make sure that it is a tool that’s useful to all sectors, not just those designated as critical.”
NIST is accepting public comment on the draft framework until Nov. 4, 2023. NIST does not plan to release another draft. A workshop planned for the fall will be announced shortly and will serve as another opportunity for the public to provide feedback and comments on the draft. The developers plan to publish the final version of CSF 2.0 in early 2024.
Why the update?
The CSF provides high-level guidance, including a common language and a systematic methodology for managing cybersecurity risk across sectors and aiding communication between technical and nontechnical staff. It includes activities that can be incorporated into cybersecurity programs and tailored to meet an organiza-
tion’s particular needs. In the decade since it was first published, the CSF has been downloaded more than 2 million times by users across more than 185 countries and has been translated into at least nine languages. While responses to NIST’s February 2022 request for information about the CSF indicated that the framework remains an effective tool for reducing cybersecurity risk, many respondents also suggested that an update could help users adjust to technological innovation as well as a rapidly evolving threat landscape.
Changes to the NIST framework
The CSF 2.0 draft reflects a number of major changes, including: The framework’s scope has expanded — explicitly — from protecting critical infrastructure, such as hospitals and power plants, to providing cybersecurity for all organizations regardless of type or size. This difference is reflected in the CSF’s official title, which has changed to “The Cybersecurity Framework,” its colloquial name, from the more limiting “Framework for Improving Critical Infrastructure Cybersecurity.”
The CSF has described the main pillars of a successful and holistic cybersecurity program using five main functions: identify, protect, detect, respond and recover. To these, NIST added a sixth, the govern function, which covers how an organization can make and execute its own internal decisions to support its cybersecurity strategy. It emphasizes that cybersecurity is a major source of enterprise risk, ranking alongside legal, financial and other risks as considerations for senior leadership.
The draft provides improved and expanded guidance on implementing the CSF, especially for creating profiles, which tailor the CSF for particular situations. The cybersecurity community requested assistance in using it for specific economic sectors and use cases, where profiles can help. The
National Institute of Standards and Technology (NIST) released a draft version of the Cybersecurity Framework (CSF) 2.0, a new version of a tool it first released in 2014 to help organizations understand, reduce and communicate about cybersecurity risk. Courtesy: NIST
draft added implementation examples for each function’s subcategories to help organizations, especially smaller firms, to use the framework effectively.
A major goal of CSF 2.0 is to explain how organizations can leverage other technology frameworks, standards and guidelines to implement the CSF. The CSF 2.0 reference tool (planned NIST release before fall.) will help. A future version will provide “Informative References” showing relationships between the CSF and other resources. Pascoe said the development team is encouraging anyone with recommendations about the updated CSF to respond with comments by the Nov. 4 deadline.
“This is an opportunity for users to weigh in on the draft of CSF 2.0,” she said. “Now is the time to get involved if you’re not already.”
–Edited by Gary Cohen, gcohen@cfemedia.com, content manager, Industrial Cybersecurity Pulse, from CFE Media and Technology. A longer version of this appears online. https://www.industrialcybersecuritypulse. com/regulations/nist-drafts-major-update-to-its-widely-used-cybersecurity-framework
ANSWERS
William Hughes, PE, Maverick Technologies
Beyond PID: 6 advanced strategies to add value to modern process control
While
PID control is a good choice for
most process control applications, six
strategies
can simplify the process.
The proportional-integral-derivative (PID) control scheme is a popular approach used in programmable logic controllers (PLCs) and distributed control systems (DCSs) to control complex processes and manage dynamic industrial systems. Many available online resources center around the fundamentals of setup and control loop tuning methods used to control errors and minimize process fluctuations – including how to pick the initial gains, when to use derivative control, how to adjust a PID for response time, how to reduce overshoot and more.
and the CV will be slammed to a minimum or maximum value immediately. Adjusting or replacing the instrument producing a noisy PV can turn an erratic control loop into a well-behaved system.
2. Signal filtering cleans PID information
Ensure PID uses clean data: Some process properties are noisy, and the instrumentation accurately records this noise. One way to deal with this noise is signal filtering. This approach involves applying a time-based filter to the PV and replacing the signal’s instantaneous value with a value averaged over a certain time window.
Online controleng.com
KEYWORDS: PID, proportional-integralderivative, process control
LEARNING OBJECTIVES
Understand proportionalintegral-derivative’s (PID’s) role in process control applications.
Learn about six strategies that can help complement PID in challenging situations.
See additional PID stories at www.controleng.com/ control-systems/pid-apc/ CONSIDER THIS
Which of these PIDsupplemental strategies do you use?
While PID control is a good choice for most industrial control applications, it’s sometimes not enough to handle a system that is challenging or can’t be boiled down to a simple setpoint (SP), process variable (PV) and control variable (CV). Some systems have large deadtimes, which means the time it takes for a change in the CV to make a noticeable change in the PV. PID is most effective on processes that are linear in their control range, so processes with non-linear responses, such as pH, can be difficult to control with a PID loop.
1. Tune the instruments
Well-tuned instruments improve PID: The PV input to the PID drives everything that happens in the rest of the control loop. A noisy measurement will make the error calculation (the difference between the SP and PV) erratic. If derivative control is presented with a significant change or fluctuation in the error within a single cycle of input and output (I/O) scans, then the derivative is gigantic,
When choosing a filtering scheme, the goal should be to preserve as much meaningful signal as possible while eliminating noise. It’s important to recall that the integral term of the PID is a time-filtered evaluation of the error, so the filtering is essentially applied twice. Some control loops are tuned too aggressively for the noisy PV they’re trying to control. In this instance, reducing the gains to de-tune the PID would work better than signal filtering.
Signal filtering can hide important process information from operators and control loops, so use it sparingly and intentionally.
3. Cascade control
Controlling a challenging PV: Another way to control a challenging PV is to use one PID to control another PID, which is known as cascaded PID control. The high priority PV is fed to a slow-moving primary PID, which sends a dynamic SP to a fast-moving secondary PID that controls a different, secondary PV, which then influences the primary PV via process interactions. For example, a steam heat exchanger’s pressure is a fast-moving property that can be adjusted to control the slow-moving temperature of the fluid exiting the exchanger. Controlling the secondary PV, pressure, gets the primary PV, temperature,
BASIC proportional-integral-derivative (PID) control is often sufficient for process control applications; other tools can help. Courtesy: Maverick Technologies
to its SP faster and keeps it there with little or no oscillation that would be present using one PID to control temperature directly.
4. Feedforward control
Change the future: Control system designers sometimes know precisely how a PV will react to a change in CV, and they can encode that knowledge in the control strategy. This is broadly known as feedforward. A PID system is fundamentally a feedback scheme, in which the CV is changed, and the resulting PV change is measured to calculate a new error term. In feedforward, the CV change is used in the control logic to calculate an expected change in the error term, and this is used in the PID logic. Many modern PID control logic objects include an input for this feedforward term, which often has its own gain tuning constant. Often if a proportional-integral (PI) controller is struggling, the best way to improve it is to add some feedforward instead of adding derivative control, if a suitable leading feedforward variable can be identified.
5. Gain scheduling
‘ When a process requires constant, active |supervision by operations personnel, consider the advanced control strategies.’
How gain scheduling can help PID: For processes that are nonlinear over the intended operating range, PID control can still be an option if each segment of the operating range has an essentially linear response. The proportional, integral, and derivative gains can be determined for each segment and then programmed to be changed in the PID object as the process moves along different linear domains. This is often known as gain scheduling. Exercise caution with gain scheduling and pay special attention to the boundaries between gain regimes. If the process is often operated close to a boundary, consider changing the gain schedule to avoid constant switching between gains.
6. Model-predictive control
Model-predictive control uses modern controllers to help processes: Faster central processing units (CPUs) are included in modern PLCs and DCSs. Some may recall those long-gone days of assiduously managing controller memory usage and clock cycles to avoid controller faults or skipped routines. Today’s controllers feature CPUs with amazing calculation
capability, which has unlocked the control-scheme innovation called model-predictive control (MPC). In MPC, control system engineers collaborate with experts on the physical process to design a mathematical model of it that resides in the controller. This real-time process model enables the control logic to predict all relevant PV changes for different CV settings throughout the whole process. These predictions are used to identify the best CV changes required to achieve the desired overall process state.
Don’t abandon hope
For controlling a complex process or dynamic industrial system, basic PID control is often sufficient, but it is by no means the only tool available. There are many different options available to control these processes and systems. Combine these options in various ways to achieve the outcomes that operations personnel and production demands require. When a process seems doomed to oscillation and requires constant, active supervision by operations personnel, consider the advanced control strategies reviewed here. They can turn the most challenging process into a reliable, high-uptime, almost invisible part of a smooth-running facility. ce
William Hughes, PE, is a senior engineer at Maverick Technologies, a CFE Media and Technology content partner. Edited by Chris Vavra, web content manager, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.
Insightsu
PID insights
uProportional-integralderivative (PID) is a valuable tool for process control applications, but sometimes the application is too complex for basic PID.
uStrategies such as PID tuning, signal filtering, cascade control, feedforward control and gain scheduling can help solve some of these challenges.
uModel predictive control (MPC) helps design a mathematical model that resides in the controller.
Moving forward towards more autonomous operations
More and more companies aim to increase the autonomy of their mill or plant operations. In an autonomous mill or plant, an autonomous system can monitor its own performance, which brings several benefits, like improved safety and efficiency, lower costs and reduced environmental impact. Digitalization and more autonomous operations also mean that there is less need for human intervention. The role of people will continue to be important, evolving towards supervising and ensuring that different process areas perform well together, and towards managing exceptions. Operations and maintenance work will become more collaborative in the future as well.
Whether you are just beginning your digital transformation journey or you’re further along in the process, Valmet’s framework helps you recognize the necessary steps and building blocks. Our experts are there to support you as you move towards more autonomous and optimized operations.
More on valmet.com/autonomousoperations
PID loop control tuning advice
Brian Fenn from Avanceon offers advice on proportional-integral-derivative (PID) control loop tuning using examples from a recent project.
Proportional-integral-derivative (PID) control loop tuning is a major component of process manufacturing operations. Successful loop tuning is as much an art as a science and the goal is to adjust the output (OP) to move the process variable (PV) as quickly as possible to the set point without excessive changes.
Recent developments in machine learning (ML), artificial intelligence (AI) and Big Data make it possible for process manufacturers to make smarter and better-informed decisions. Brian Fenn, COO for Avanceon, a CFE Media and Technology content partner, discussed in a video interview how the company analyzed PID control loops to find inefficiencies and production losses at a food and beverage plant.
“The project provided a data analysis on the largest process efficiency offenders and captured the recommendations for how to eliminate those problems,” Fenn said. Advanced analytics play a key role in making better decisions, Fenn said, and there are four types that can help: Descriptive, diagnostic, predictive and prescriptive. They have similar traits, but they are defined by complexity and potential user value. While descriptive analytics may provide general answers, predictive and prescriptive can look at future possible trends. This is especially valuable when trying to improve process manufacturing operations.
Fenn said they wanted to conduct advanced diagnostic analysis on 20 key PID loops focused on cleanin-place (CIP) against 2+ years of data to identify patterns and trends and to develop insight into the reasons for losses along with potential resolutions to address them. They leveraged piping and instrumentation diagrams (P&IDs) and supervisory control and data acquisition (SCADA) screens to better understand operations and determine the correlation of the issues found in the data analysis. They used a report card to show the data to the customer, which gave an overview of the performance and
degradation and the performance variability for a comprehensive picture. Advanced analytics and machine learning allowed them to get a better handle and understanding on what was being done, the improvements for the facility and other areas.
“At the end of the day, not only did this give them specific quantifiable detail to that general feeling of poor performance, but we were able to discover significant savings in energy and runtime due to a number of issues,” Fenn said. “We saw issues with the PID implementation, with general and multimodal tuning parameter changes that needed to be made as well as taking a look at the auto to manual transfer. We’ve been remediating those loops to realize the benefits.”
Fenn said the biggest lesson he took from the project “Was not just accepting ‘it is what it is’ and how things are. It’s really about looking for innovation from the new tool sets that are available through Industry 4.0 as a realistic path to shed light on those prior unaddressable plant performance issues.” ce
Brian Fenn is COO for Avanceon, a CFE Media and Technology content partner. Edited by Chris Vavra, web content manager, Control Engineering, CFE Media and Technology, cvavra@cfemedia.com.
Proportional-integral-derivative (PID) control loop tuning is a major component of process manufacturing operations, and advanced analytics can help. See related video. Courtesy: Avanceon, CFE Media and Technology
controleng.com
KEYWORDS: analytics, PID LEARNING OBJECTIVES
Learn how artificial intelligence (AI), machine learning (ML) and data analytics can improve PID tuning practices.
ONLINE
See video interview on the ControlEngTV YouTube channel. Direct link follows. https://youtu.be/ BQMsqOeERF0
CONSIDER THIS
How can PID control loop tuning help your facility?
Brian Fenn, Avanceon
ANSWERS
Raza Khan, Semtech
How 5G will revolutionize manufacturing, benefits
5G has potential to enable new high-value use-cases and will require large bandwidth, ultra-low latency and lower power.
RAZA KHAN is director of marketing - wireless, Semtech. Courtesy: Semtech
How will increased AI use lead to a significant increase in data traffic as 5G transitions from talk to reality?
connectivity so that anyone can have access, anywhere. By increasing bandwidth while decreasing power consumption and latency, we can equip fiber already in the ground to better handle current and future use cases, even in remote settings.
What technologies support 5G applications like virtual reality, autonomous vehicles and machine learning?
KEYWORDS: 5G, AI
LEARNING OBJECTIVES
Learn about the infrastructure requirements of large-scale 5G.
Understand breadth of new use-cases and applications 5G can enable.
ONLINE
See more answers with this article online, such as how smart cities are helping industrial applications.
CONSIDER THIS
What new applications could you deploy if 5G was available in your facility? Online controleng.com
Precedence Research, in a GlobalNewsire release, forecast the AI market to surpass $1,597.1 billion by 2030, with a compound annual growth rate of 38.1% from 2022, with demand coming from a variety of industries including retail, healthcare, food and beverage, automotive and logistics. AI applications, and the 5G technology that helps power them, require higher bandwidth transmission capacity at extremely low latency and power without sacrificing performance. These applications put an immense amount of pressure on the data center. This demand requires even more interconnects within one data center due to the parallel compute algorithms used and reduced latency, or time delay requirements, of a data center’s interconnects, which can affect the overall performance.
How are 5G technologies helping augmented reality (AR) and virtual reality (VR) for industrial and operationsrelated education?
5G is helping to transform the way we interact with virtual worlds. The implementation of 5G increases the availability of both AR and VR by providing reliable connectivity, improving data streaming and reducing latency, and eliminating some of the hurdles preventing companies from embracing new technologies for learning. Optical technology plays a vital role in overcoming the challenges of adapting AR and VR, by maximizing current deployments and further improving
5G use is growing exponentially. By 2025 5G connections in North America are expected to grow to 410 million, said Statista [with about 200 million in 2023, according to multiple sources]. To address growth, 5G deployments need to increase capacity and decreasing power consumption and latency to move data. Optical technology will play a key role, as it helps current fiber deployments transfer data efficiently and sustainably.
How is 5G-enhanced AR and VR helping demographic transitions?
5G-enhanced is a step toward 6G by enabling higher bandwidths, lower latency applications. The ability to evolve connectivity toward 6G opens an array of new use cases.
5G-enhanced AR and VR use cases have new demographic and regional possibilities. Some examples include virtual teaching, learning, which can overcome distances to assemble diverse people and talents. In other instances, AR and VR can connect medical professionals and patients in remote locations with telemedicine. The impact of these practical, yet historically challenging use cases is unmatched. 5G-enhanced AR and VR has the power to help solve some of the world’s biggest challenges and make this planet smarter. ce
Raza Khan is director of marketing - wireless, Semtech. Edited by David Miller, content manager, Control Engineering, CFE Media and Technology, dmiller@cfemedia.com.
How to keep a factory running
Understand options for industrial network fault monitoring and detection.
Programmable logic controllers (PLCs) run millions of processes and machines inside factories. PLCs have a lot of processing power and handle a variety of inputs or outputs. They typically run protocols like Profinet, Profibus and, to a lesser extent, CANbus.
Depending on the factory, plant personnel have created tactics over time to get production lines up and running as fast as they can when there’s an unexpected interruption. But these tactics typically struggle to pinpoint problems, precisely analyze issues and reduce downtime.
When it comes to automation protocols, most have built-in diagnostics. So, if something goes wrong with a machine, the PLC gets a message. That’s fine if the problem is at the level of a component. But, in general, downtime in manufacturing means a whole process (such as sorting packages) grinds to a halt. In those cases, either a protocol’s built-in diagnostics don’t adequately convey the problem, or the diagnosis is just a symptom of another problem.
A go-to diagnostic solution for many Ethernet-based protocols would be running Wireshark, an open-source network protocol analyzer, that grabs and shows data traveling back and forth on a network. With the Wireshark trace, a plant technician would tap into the plant’s protocol via a switch to catch all the message traffic, while mirroring it on, say, his laptop to see what might be wrong on the network. But Wireshark is catching SNMP traffic and all kinds of other packets.
Quickly pinpoint what’s wrong
If a technician isn’t well schooled with the use of Wireshark, there are other diagnostic and monitoring technologies. These technologies sit permanently on an industrial Ethernet factory network to record the traffic around a particular event and download the data to a web browser. From there, a technician can use Wireshark to run a trace. Diagnostic and monitoring technologies like this allow network administrators, engineers and operators to
ADVANCED MONITORING KIT for industrial networks: ComBricks is from gridconnect. Images courtesy: gridconnect
monitor complex systems and quickly see from a remote location when trouble is brewing to prevent unexpected, expensive downtime.
Fault monitoring, detection
With a diagnostic technology permanently installed to monitor industrial networks, or an advanced monitoring kit, factory managers can detect faults and diagnose problems. A process often shuts down because a worker inadvertently jars loose a cable or disturbs a shield during routine maintenance. Advanced monitoring tools can spot an issue with firmware, cabling or a misconfiguration in seconds.
Using an advanced monitoring kit, which sits atop a plant’s network, maintenance managers can identify issues with, say, the Profibus stack or elsewhere. Several monitoring kits on the market have a built-in oscilloscope, so technicians can determine if voltages are at the proper level. Some industrial diagnostic technologies to analyze fieldbus networks work with specific protocols, such as Profibus.
Network analyzers, graphing capabilities
A monitoring kit permanently linked to a factory’s network means a technician can open a web browser and troubleshoot an outage.
Often, the outages that drive control engineers and maintenance managers to the brink are interrupted processes that occur intermittently. These faults are hard to catch if a manager isn’t on guard with a tool; otherwise, the odds are slim of catching what’s causing intermittent faults. ce
Rick Rockershousen is vice president of Grid Connect, a provider of embedded and networking technologies. Edited by Mark T. Hoske, content manager, Control Engineering , CFE Media and Technology, mhoske@cfemedia.com.
ANALYZER for fieldbus networks: Profitrace 2 is from gridconnect.
INDUSTRIAL NETWORK
DIAGNOSTIC: capabilities: Atlas2 is from gridconnect
Understand options for industrial network fault monitoring and fault detection.
CONSIDER THIS
Does your industrial network let you know what the problem is, or do you have to go looking?
ONLINE
With this article online, learn more about network analyzers and alwayson industrial network monitoring tools www.controleng.com/ industrial-networking
Roman Bershader, consultant, retired engineer
How can PID methods protect compressors from surge and choke?
Application: Advanced controls avoid hazardous surges to centrifugal and axial compressors. Processes described make it easier to find optimal PID settings using standard tuning routines that can be the basis for autotuning and makes it easier to implement adaptive control.
FIGURE 1: NASA research on jet engine compressors included extensive field and wind tunnels testing followed by data analysis in coordinates typical of aerodynamic experiments, presenting compressor maps of total pressures ratio versus corrected mass flow. All images courtesy: Roman Bershader
The rapid development of aviation, which began in the last century, required even more powerful and economical engines, in which compressors play an important role. Since compressor surge has potentially catastrophic consequences, great attention always has been paid to the prevention of this phenomenon. Proportional-integral-derivative (PID) feedback controllers can help.
NASA research on jet engine compressors included extensive field and wind tunnels testing followed by data analysis in coordinates typical of aerodynamic experiments, presenting compressor maps of total pressures ratio versus corrected mass flow, as shown in Figure 1.
The total pressure is the sum of the static and dynamic pressures. Figure 1 shows a hypothetical compressor map that includes constant speed performance curves that can vary greatly in shape and slope; surge and choke limit lines. The ratio of total pressures on the vertical scale and the corrected mass flow on the horizontal scale form a reference rectangular coordinate system for comparing compressor prototypes.
Maintain a compressor surge margin, the space between operation and surge
To assess the risk of operation of compressors behind the surge line, a parameter called surge margin was introduced, which is a quantitative characteristic of the space between the operating point and the surge point located on the same performance curve. Given that jet engine compressors run on air, hence a constant molecular weight substance, the corrected mass flow rate is proportional to the input Mach number, which is a dimensionless quantity defined as the local velocity divided by the speed of sound in that medium. This parameter, which is one of the similar criteria used in gas mechanics, turned out to be critical for study-
ing how stall flow patterns behave in the same way under the influence of the compression ratio at certain Mach numbers, regardless of other variables.
Compressors in jet engines, industrial compressors
For compressors operating at sea level, such as industrial compressors, the static pressure can exceed the dynamic pressure by two orders of magnitude. For such compressors, the ratio of static pressures (Rc) is more suitable as a vertical scale. Industrial compressors also often use differential pressure sensors to measure flow.
Dimensionless non-measurable (but calculated) value (∆P/P), which is defined as the pressure drop ∆P across a given type of flowmeter divided by the static pressure at the location of the flowmeter, which is proportional to the square of the Mach number. The dimensionless value (∆P/P) can be used as a horizontal scale for compressor maps. Then, in the coordinate system of the ratio of static pressures and the dimensionless calculated value (∆P/P) and the boundary of the unstable gas flow, the surge line turns out to be independent of the molecular weight of the substance. This operates under the assumption the specific heats ratio does not change much.
PID feedback controllers adjust an antisurge valve, discharge throttle valve
The rectangular coordinate system, by definition, positions the operating point relative to the surge and choke lines using projections onto the axis. This can be used to convert the two-dimensional representation of compressor operation into a one-dimensional process variable PV that can be used for control. PID feedback controllers are the most practical and are commonly used to protect compressors by adjusting the anti-surge valve to prevent surge line crossing or by adjusting the discharge throttle valve to prevent choke line crossing.
The surge protection and choke protection PID controllers continuously calculate the error value (ER) as the difference between the desired setpoint (SP%) and the input process variable (PV%) to update the controller output. For this reason, the surge and choke lines must be stored in the compressor control system as table functions. The operating point (OP) position must then be calculated from the input signals from the flow and pressure sensors, after which the PV can be determined.
For nearly vertical performance curves, as shown in Figure 1, the concept of “surge margin” in a rectangular coordinate system is defined as the distance between the projections of two points on the vertical axis: the surge point (SLV) (the point of intersection of the vertical line drawn from the operating point to the surge line) and the OP.
For flatter performance curves, as shown in Figure 1, which is the most common characteristic of industrial compressors, the concept of “surge margin” is defined as the distance between the projections of two points on the horizontal axis: One is the OP and the second is the surge point (SLH) (the intersection point of the horizontal 1 line drawn from the operating point to the surge line). The rectangular coordinate system sets limits for determining the actual distance between an operating point and a surge point located on the same performance curve.
Safety threshold corresponds to the safety margin
As shown in Figure 2, the actual surge margin cannot be equal to the distance to the surge line. However, the compressors are protected by calculating the PVs, according to formula (1) or similar:
‘ The most recommended safety threshold for compressors is about 10%, measured from the surge line to the operating point at a given pressure ratio.’
Formula (1) calculates a process variable comparable to the safety threshold that must be set for rectangular coordinates when the actual distance, surge margin, is measured along the performance curve. Therefore, to achieve maximum efficiency, the safety threshold must be chosen in such a way so it corresponds to the actual safety margin. Thus, the rectangular coordinate method does not provide an explicit setpoint selection, and the selected fixed setpoint may not be suitable for different performance curves.
The most recommended safety threshold for industrial compressors is about 10%, measured from the surge line to the operating point at a given pressure ratio. As can be seen from Figure 2, the desired safety threshold, SP, should be set above 10% to correspond to a safety level of 10% of the actual surge margin. How much higher than 10% depends largely on the shape and slope of the performance curves and the slope of the surge line.
Insightsu
PID application tuning insights
uFind out how to optimize proportional-integralderivative (PID) settings using standard tuning routines that can be the basis for autotuning, which makes it easier to implement adaptive control.
uThe role PID plays in compressors, aviation and aerospace engine design might not be widely known, but it is crucial for efficiency, precision and safety.
ANSWERS
FIGURE 2: The actual surge margin cannot be equal to the distance to the surge line.
PID drawbacks in formula 1
Despite the success of protecting compressors with the methods described by formula (1) or similar ones, they have some drawbacks.
The first of these is the distance between the operating point and the surge line stored in the compressor control system cannot be equal to the actual distance between the operating point and the surge point on the performance curve to which both points refer.
mula (2), the parameter related to increase in flow is squared and put in the denominator).
This creates a non-linear relationship between the PV and the flow rate, making it difficult to tune a PID controller that should, under all circumstances, prevent surge line crossing and be less dependent on additional open-loop response.
Plant automation personnel often set assigned SPs for PID controllers that receive input, calculate PVs, and send output to drives according to plant operation. Visualization of the position of the operating point on the compressor map, as shown in Figure 1, does not quantify compressor performance, which is limited by proximity to surge and throttle choke. This makes it difficult for operators to assess the risk of manual intervention if necessary.
Learn how to optimize proportional-integralderivative (PID) settings using standard tuning routines that can be the basis for autotuning, to make it easier to use adaptive control.
Safety requires a compressor surge margin — the space between operation and surge — without choking the compressor.
CONSIDER THIS
How does this PID application’s operating margin help your advanced process control applications?
ONLINE
www.controleng.com/ control-systems/pid-apc
Since the projection of flatter performance curves onto the vertical axis, or the projection of nearly vertical performance curves onto the horizontal axis (as shown in Figure 1) can have a very narrow range of change, where a small change in the vertical coordinate causes a large change in the horizontal coordinate and vice versa. Sensitivity to the slightest changes can lead to instability in the control system. Stabilizing the system in such a case can only be achieved by slowing down the PID controller, which leads to an expansion of the safety threshold, followed by unwanted recirculation or blow-off.
Another disadvantage is if an increase in flow is required to protect the compressor from a surge, then the increase in the flow parameter in equation (1) is squared (in other similar algorithms, for example, in the Compressor Controls Co. algorithm – for-
These shortcomings can be significantly corrected in a different coordinate system by using angles are used instead of projections when the rectangular coordinate system is replaced by a polar coordinate system. In a two-dimensional polar coordinate system, each point on the plane is defined by a distance from the origin and an angle from a reference direction. To obtain a reference point – the origin of coordinates, it is necessary in Figure 2 change the vertical coordinate from Rc to (Rc-1) and change the horizontal coordinate from ∆P/P to the square root of ∆P/P, which is proportional to the similarity criterion in gas mechanics, the Mach number Ma.
The new polar coordinate algorithms described in U.S. Patent No. 11,434,917 offer more effective surge and choke protection than any other known method.
The first approach to using polar coordinates is reminiscent of the assumption in equation (2) where the surge line has a constant value of one, but in polar coordinates the surge line is assumed to have a constant angle. To do this, the vertical coordinate (Rc-1) should be replaced by a function of f (Rc-1), as shown in Figure 3. The PV can then be calculated as a percentage:
FIGURES 3 AND 4: At left, the first approach to using polar coordinates is reminiscent of the assumption in equation (2) where the surge line has a constant value of one, but in polar coordinates the surge line is assumed to have a constant angle. To do this, the vertical coordinate (Rc-1) should be replaced by a function of f (Rc-1). Then, in Figure 4, compressor operation can be described by moving the operating point in the direction of minimum or maximum flow along the performance curve, or by moving from one curve to another along a variable radius measured from some imaginary origin.
A commonality of formulas (1), (2) and (3) is that the process variable is calculated and then the selected setpoint is measured against the surge line by the “minimum flow” rule regardless of the compressor operating range. The available compressor capacity is determined by a set of constant-speed performance curves with minimum flow points on the left (surge points) and maximum flow points (ideally choke points) on the right.
Optimizing the performance curve, safety margins
Operation of the compressor can then be described by moving the operating point in the direction of minimum or maximum flow along the performance curve, or by moving from one curve to another along a variable radius measured from some imaginary origin, as shown in Figure 4.
The method shown in Figure 4 was obtained by converting rectangular coordinates (Rc-1) versus Mach number to polar coordinates, provided the radii from the center point to the minimum flow point and to the maximum flow point of each performance curve are equal. Thus, the PV can be calculated for each radius in the range of movement of the operating point from minimum to maximum flow:
The process variable PV obtained from formula (4) converts the compressor map into a onedimensional operating point offset scale from 0 to 100% shown in Figure 5, where the movement of the mark simultaneously determines the position of the operating point relative to surge and choke. Only this method of protecting the compressor allows scaling the entire range of compressor operation and can select the exact margins of safety in accordance with compressor capabilities.
Visualization and simultaneous quantification of operating point movement toward surge limit or choke limit based on full operating range scale enhances situational awareness, makes it easier for operators to understand potential risks, and increases productivity and efficiency.
The “high efficiency zone,” depicted in the diagram of the movement of the operating point, is the compressor's maximum efficiency zone, the position of which is important when optimizing the performance of an individual compressor. The proximity to the “high efficiency zone” can be used as a universal process variable for serial and parallel compressors to share the load between them, optimizing the efficiency of a group of compressors.
(Continued on page 30)
‘
This method of protecting the compressor allows scaling the entire range of compressor operation and can select the exact margins of safety in accordance with compressor capabilities.
’
Matt Petras, Alireza Haji-Valizadeh Ph.D., ControlSoft
Are you applying a PID control to non-linear processes correctly?
How to automate: Using a valve characterizer
example, learn how proportional-integralderivative (PID) control can reach outside of usual linear processes to effectively handle real-world, non-linear applications.
One of the most common difficulties when working with proportional-integral-derivative (PID) control is PID control (CO) is designed to work with a linear process. However, in real world applications, many process variable (PV) responses show non-linear behavior. The more non-linear the system response is, the more difficulty a PID algorithm will have in controlling the system. For help applying PID control to a non-linear process, follow these suggestions for processes that are non-integrating and are inherently stable when their controller is put into manual mode.
Resolve process non-linearity
One of the most common ways to try to resolve this process non-linearity is to build a valve characterizer to adjust for the process non-linearities. This method linearizes the process to the PID controller so the PID sees a linear process response to the PV even though the actual process is non-linear. The figure shows a valve characterizer flowchart.
Build a valve characterizer
To build a valve characterizer correctly, look at the percent PV to the percent CO
FIGURE: Flowchart shows a valve characterizer example for handling non-linear PID applications. All graphics, tables courtesy: ControlSoft
and think of the PV in percent instead of engineering units. That way, when doing the reverse conversion, the calculated valve demand will be in percent.
Initial
full-range response
As an example, begin with a process that has been trended with CO val-
TABLE/GRAPH 2: An example converts the process variable (PV) in engineering units to PV in percent and graphs the result.
ues mapped for every 10% change in CO and shows the corresponding PV in engineering units (EU in table). Since there is no characterizer configured yet, the CO is equal to the valve demand. The profile developed for this loop is as follows in Table/Graph 1.
Convert to PV in percent
Next, convert the PV in engineering units to PV in percent. In this example, the PV maximum value is 300 and the PV
TABLE/GRAPH 3: Set the CO = PV to linearize PID controller response.
minimum value is 0, so the scale to convert from engineering units (EU) to percent (%) is (100-0) / (300-0) = 1/3. So, 100 EU = 100/3 = 33.3%, 150 EU = 150/3 = 50%, etc.
Now convert this simple table of valve demand to PV in percent that looks something like Table/Graph 2.
Linearize the PID response by creating a valve characterizer curve
Next, set the CO = PV to linearize PID controller response. Doing so provides a graph of valve demand percent to PID CO percent. Then, create a reverse or inverse profile linearization of Graph 2 by flipping the X and Y axis, as shown in Table/ Graph 3.
When comparing Graph 2 and Graph 3, note they are the inverse of each other. Graph 4 combines them to see the inverse trends more clearly.
In graph 4, the gray line is linear. By using the orange profile for the CO% to Valve Demand %, it will create a PV response that linearizes the PV signal to the CO, so for every desired CO out, the PV shows the same percentage out.
Consider the curve that maps CO% to valve demand %. There’s a lot of data in the range of 20 to 50% of the valve demand, but the linearization is sparser when outside of this range.
Now add new points to the curve using the method of linear interpolation. For example, at 10% CO, the linearly interpolated valve demand is 5%. Insert a new point to the curve that 10% CO renders 5% valve demand. The Table before Graph 5 has more defining points at CO equal to 10, 60, 70 and 80%.
It is important to note the original set of points defining the valve characterizer curve are obtained by testing the process, whereas newly inserted points are obtained by method of linear interpolation and play the role of placeholder points for fine-tuning the curve after its implementation.
The valve characterizer generated from Table 4 can be implemented with a linearization block where PID CO% is the X value, and valve demand percentage is the Y value.
Update the valve characterizer curve
Once in operation, it’s possible the curve does not linearize PID response as accurately as needed due to process shifts in time or due to operating at regions where the curve is defined by means of linear interpolation instead of
TABLE/GRAPH 5: Table before Graph 5 has more defining points at CO equal to 10%, 60%, 70%, and 80%. The valve characterizer generated from Table 4 is implemented in Graph 5 with a linearization block, where PID CO% is the X value, and valve demand percentage is the Y value.
process testing. Next, see a method to update the in-place valve characterizer curve to improve linearization of the PID response.
Consider the valve characterizer of Graph 5 where for 10% PID CO, the valve demand is 5%. A PID CO of 10% would be expected to produce a PV response of 10%. However, this point in the curve was not based on process testing, so the actual measured PV could differ from 10%. To test this, put the CO demand at 10% and assume the actual PV value at 5% and valve demand is 17%. Update the table to include this latest information.
GRAPH 4: Graphs 2 and 3 are inverse of each other, as shown here.
ANSWERS
The top of the linearization curve has the same issue. When the PID CO goes above 70%, the response of the curve is not as good as expected. Setting the PID CO to 80% generates a valve demand of 97.5%, which would be expected to result in a PV of 80%, however, the actual PV
Continued from page 27:
How can PID methods protect compressors from surge and choke?
High accuracy, autotuning, adaptive control
The methods presented in polar coordinates have the highest accuracy in determining the margin of safety compared to all known methods, since the margin does not depend on the slope of the compressor performance curves and is the same over the entire range of process conditions.
Polar coordinate methods provide faster PID control, allowing the compressor to be used over a wider range, which increases efficiency by minimizing recirculation or blow-off.
The process variable in these methods is nearly linear, making it easier to find the optimal surge and choke PID settings using standard tuning routines that can
TABLE/GRAPH 6 : To map CO%=PV% (that is, linear), the PID CO% needs to change to match the actual PV% measured. Graph 6 is updated with this added information.
response instead is 75%. A summary of updated findings from Graph 5 is shown in Table 5a.
Since this exercise is attempting to map CO%=PV% (that is, linear), the PID CO% needs to change to match the actual PV% measured. Graph 6 is updated with this added information. ce
Matt Petras is senior control application engineer and author, with contributions from Alireza Haji-Valizadeh Ph.D., technology development director, both with ControlSoft. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com.
FIGURE 5: The process variable PV from formula (4) converts the compressor map into a one-dimensional operating point offset scale from 0 to 100%, where the movement of the mark simultaneously determines the position of the operating point relative to surge and choke. Protecting the compressor in this way allows scaling over the range of compressor operation with ability to select the exact margins of compressor safety.
be the basis for autotuning, which makes it easier to implement adaptive control. Polar coordinate methods aim to implement a new modern control strategy by updating the software and graphical user interface while maintaining the integrity of the input/output (I/O) signals and without the need for hardware and communication upgrades. ce
Roman Bershader is a retired engineer, now consultant, with a bachelor’s and master’s degree in aerodynamics and a Ph.D. in experimental fluid dynamics who worked for Compressor Controls Corp. for more than 30 years. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media and Technology, mhoske@cfemedia.com.
TABLE 5A: Update the valve characterizer curve as table 5a shows.
Industrial cloud, automation
The industrial Internet of Things (IIoT) is being embraced by manufacturers as a natural extension of automation and controls development.
The tide of industrial Internet of Things (IIoT) is gradually receding. Who will be the last among hundreds of IIoT or industrial internet platforms?
Siemens has integrated Mindsphere’s IIoT platform business into its Insights Hub (IIoT as a service solution) and stressed it will use this core of the IIoT ecosystem to better meet customer needs. This transition of Siemens Mindsphere differs from GE’s movement away from Predix a few years ago. Siemens continues to integrate the IIoT industry in a more practical, easy-to-implement way with greater participation in the industrial production system.
More real-time monitoring and control provide means to stimulate the value of the IIoT platform through artificial intelligence (AI), machine learning and other technologies. The Insights Hub is a lowcode IoT solution from Siemens based on Mendix. With Mindsphere integration, customers can use lowcode application development tools to quickly create and integrate personalized IoT applications.
The integration seems to begin to move Siemens’ IIoT business from simple to deep and from virtual to real. The rest of the industrial internet field is “moving from virtual to real” after the initial boom.
IIoT focus shifts to applications
First, IIoT has shifted from focusing on platforms to applications. Advanced technologies survive only by solving production pain points through applications and bringing real value to production.
No matter how good a concept or technology is, if it cannot be applied, it remains a vision.
IIoT enters vertical development
Second, IIoT has entered the vertical development stage of the industry, and platform and application service providers have paid more attention to targeted solutions for different industries.
For example, ABB Ability is not strictly an IIoT platform, but a general term for IIoT solutions in various vertical industries. Schneider Electric’s EcoStrux-
ure is a three-tier architecture of an IIoT platform. Vertical industries have their own solutions and products. Advantech’s IIoT platform Wise PaaS is seeking vertical industry partners to create a “platform and ecology” landing plan.
Industrial control manufacturers embrace IIoT
Third, a large number of native industrial control manufacturers have entered the IIoT field. The Industrial Internet emerged from GE’s Predix, followed by a large influx of IT vendors and manufacturing giants.
Manufacturers of industrial automation controls came late to IIoT, some still seemingly confused by the “invasion” of industrial Internet and related IT technologies. The complexity of industrial scenarios and industrial production shows there is no platform for industrial internet that can be applied universally. Some early industrial internet platforms have retreated from difficulties, while others have shifted to system integration for individual projects. Few industrial internet platform-based products exist.
Automation manufacturers are changing this phenomenon, and the industrial internet has gradually transformed into the “industrial Internet of Things.” IIoT platform examples include those based on configuration software of Asian Control, Force Control and other manufacturers, the IIoT platform integrating IoT touch screen and IoT controller of Fanyi in Shanghai, the IIoT platform based on supervisory control and data acquisition (SCADA) system of Wago and Delta, and the IIoT platform based on sensors of Yifu Men and Kunlun Coast.
Vertical industry needs have prompted adoption. There is a trend to use IIoT to replace the general platforms of major automation manufacturers. 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: Industrial cloud, IIoT platforms for automation LEARNING OBJECTIVES
See how industrial Internet of Things (IIoT) focus is shifting from platforms to applications.
Understand that IIoT is developing vertically to focus on specific industries.
Learn how industrial control manufacturers are embracing and expanding IIoT.
CONSIDER THIS
How are you using IIoT technologies and industrial cloud applications to accelerate manufacturing? ONLINE
https://www.controleng. com/articles/industrialcloud-platforms-need-todemonstrate-value/ www.controleng.com/ international
See more on cloud on p. 45.
Stone Shi, Control Engineering China
CWhat makes an engineering trailblazer?
The 2023 Engineering Leaders Under 40 include 34 rising stars of innovation.
Amanda McLeman, Research Director
FE Media and Technology proudly presents the Engineering Leaders Under 40, Class of 2023 — a cohort of 34 exceptional minds, all hailing from the industrial manufacturing, controls, automation and systems integration professions. These pioneers are reshaping the industries of technology and engineering.
These remarkable individuals have surpassed boundaries and expanding the boundaries of what’s possible. From optimizing industrial processes to engineering seamless automation solutions, their collective achievements have streamlined operations and laid the groundwork for a more sustainable and efficient future. Their varied interests make them talented, quirky and downright fun.
Delve into the stories behind these engineering leaders — their aspirations, breakthroughs and the journeys that have led them to their various careers. Learn about clever problem-solving skills of these young leaders, each a driving force behind the transformative advancements that are shaping the course of engineering, applied creatively across many industries.
ChatGPT was allowed to “read” select entries and suggested some of the introductory wording, which was reviewed and edited by Control Engineering and Plant Engineering editors. Learn more about the program and how to nominate a colleague for 2024 at www.controleng.com/EngineeringLeaders. Nominations open April 1, 2024. (No fooling!) ce
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Andres Aguilar, 39
Lean Six Sigma Black Belt
John Crane
Morton Grove, Illinois
—Andres started at John Crane eight years ago as a reliability service engineer in Colombia and later relocated to Baton Rouge, Louisiana, supporting customers in the Gulf region. He was promoted to a regional service manager for North and Central America to deliver asset management contracts. Adding responsibilities, he led the project management team for major customers in the oil and gas industry, including the company's first methane detection projects that added value to the energy transition journey and enabled agile methodologies for mechanical seal contracts implementation.
Richard Ahlfeld, 33
CEO & Founder
Monolith
London
Fun fact: To encourage camaraderie, Andres organized and leads a soccer tournament pool at John Crane.
Matthew Bailey, 38
Controls Engineer
Hargrove Controls & Automation
Mobile, Alabama
—As a talented and well-respected engineer, Matthew can take small to highly complex projects and ensure successful completion. He is motivated, driven and has diverse engineering experience in system integration of multiple control system platforms. He works hard, guiding teammates to successful outcomes. For clients, he identifies cost and time savings. He maintains the highest ethical standards and understands and meets client needs. He is viewed as a leader by peers and mentors junior teammates.
—Richard has developed artificial intelligence (AI) technology that allows engineers to solve tough challenges and has contributed to the acceleration of electric car adoption and hydrogen fuel cell development. The software has helped make cars safer, gas bills cheaper, reduced the costs of petrol cars and reduced noise pollution. Richard is committed to empowering 100,000 engineers to cut their product development cycle in half by 2026. The scope of applications for AI in the automotive industry is enormous, and it is Richard's mission to invoke greater change and facilitate innovative product development for more engineering teams.
Fun fact: Matthew comes from nine generations of ship captains and collects antique seafaring equipment.
Ioannis Bonis, 39
Senior Engineer in Industrial ControlSystems Dept.
Helleniq Energy
Aspropyrgos, Greece
—Ioannis is a charismatic engineer with a strong technical background and a clear inclination for innovation. He is self-motivated and has the capacity to coordinate the teams he participates in. He has high emotional intelligence and is a team player, which helps produce outstanding results. Ioannis has worked on all major control engineering projects during the past 10 years in Aspropyrgos and Elefsina refineries and is an integral part of the digital transformation program.
Fun fact: Ioannis has served as an expert for the European Climate, Infrastructure and Environment Executive Agency.
Fun fact: Richard plays the piano daily to relax and think.
Chase Beard, 30
Controls & Automation Engineer
Hargrove Controls & Automation
Johns Creek, Georgia
—Chase started at Hargrove as a Controls & Automation Co-Op in summer 2014. He worked at Hargrove while finishing his Chemical Engineering degree at Auburn University.
After graduating in 2017, Chase joined Hargrove full-time as a Controls & Automation Engineer. He mentors multiple engineers in Hargrove's Co-Op program. In 2021, Chase joined Hargrove's Purview talent development program and passed the professional engineer (PE) exam. He works on a variety of controls and automation projects.
Fun fact: Chase enjoys hiking, biking, fishing and other outdoor activities.
Iain Brearton, 30
Senior Controls Engineer
Concept Systems Inc.
Kent, Washington
—Iain is a talented, dedicated engineer who inspires others. He has displayed adaptability by successfully overcoming an ABB robot challenge during 2022 project. He seamlessly integrated it with a third-party press, tackling intricate programming obstacles. Iain played a crucial role in the Fanuc CRX robot demo for the Rockwell Automation Fair. He wrote a comprehensible and accessible operations manual for the engineering and sales teams.
Fun fact: Iain has his own “fan club” at a nearby restaurant who loves listening to fun stories and love for the Wizarding World of Harry Potter.
Control Engineering and Plant Engineering Awards programs
In addition to Engineering Leaders Under 40, CFE Media and Technology publications have awards programs related to new products and system integrators. These include:
• Product of the Year
• System Integrator Giants
• System Integrator of the Year
LEARN MORE AT: www.controleng.com/events-and-awards www.plantengineering.com/events-and-awards.
Andrew Edmondson, 38
Project Engineer
Applied Control Engineering Inc.
Newark, Delaware
—Andrew is a technical expert specializing in distributed control systems (DCS), notably Honeywell TDC, Honeywell Experion and Rockwell PlantPAx. He is the technical lead on DCS projects and has an affinity for modernization efforts. Andrew is leading a customer through the process of replacing an aged DCS with a modern control system, educating the customer on the process and teaching new engineers at ACE skills in the new DCS. Mentoring new engineers is something Andrew has a passion for.
Fun fact: Andrew is learning the guitar, especially the blues. He enjoys the challenge and combining expression with a love for music.
Ashish Garg, 37
Assistant General Manager
Jindal Saw Ltd.
Anantapur Andhra Pradesh, India
—Ashish Garg is a member of the International Society of Automation, a certified Chartered Engineer from The Institution of Engineers India and inspires many industrial automation professionals. Many initiatives include process safety and plant reliability. Under his leadership, more than 90 people were trained for blast furnace operations and maintenance. He wrote a book on instrumentation and represented Jindal Saw at international forums and conferences. With 14 years in automation and instrumentation, he has successfully completed multiple greenfield and brownfield projects.
Fun fact: Ashish is proficient at social and interpersonal skills.
Joseph Dolivo, 35
Chief Technology Officer
4IR Solutions Corp.
Bethlehem, Pennsylvania
—Joseph is recognized as a thought leader among peers and maintains a strong technical competency to augment his broad industry knowledge. Joseph envisioned and leads the development of flagship products FactoryStack and PharmaStack, which provide managed operational technology infrastructure. He is wellknown in Inductive Automation's Ignition ecosystem, serving as a Solution Partner and subject matter expert for SAP connectivity, 21 CFR Part 11, Docker containers and the cloud. He helped create and supports an SAP-certified connector module suite.
Fun fact: While in university, Joseph co-founded a game development startup called Stencyl to make programming accessible and fun.
Mercedes Elizalde, 26
Senior Product Owner, Hardware
Rockwell Automation
Mayfield Heights, Ohio
—Mercedes is a dedicated, passionate technical leader within her team and a fast riser within the Rockwell Automation hardware design and development organization. In five years of professional experience, she assumed the role of Product Owner within one of the most complex product design programs in the company, leading a team of 14 engineers with levels of experience from less than one year to more than 25. Her role is to define the technical roadmap for the next two years and remove barriers for peers.
Fun fact: Mercedes recently took up quilting and has fallen in love with the meditative process.
Nick Gigliotti, 30
Group Manager, Customer Success Management (EMEA)
Seeq
Seattle
—Nick has technical expertise and domain knowledge of the chemicals industry and interpersonal communication and relationship-building skills. He helped Seeq land new and grow existing business. He plays a key role in company culture, fostering a collaborative environment by providing best practices across the customer success department and leading his team as a group manager. He engages with key stakeholders, presents and writes content.
Fun fact: Nick is improving his chess skills by attending chess classes and joining a weekly over-the-board chess club.
Pankaj Goel, 36
Instrumentation, Measurement & Control Systems Engineer
ExxonMobil Spring, Texas
—Pankaj is a conscientious engineer eager to use his knowledge and expertise to design a better and safer world. He has contributed to the advancement of technologies and solutions through his research and engineering leadership at a global level. Pankaj published five peer-reviewed manuscripts, presented at conferences, contributed to standard committees as a subject matter expert and worked with key automation vendors to define and develop technology roadmaps.
John Grounds, 34
Plant Engineer
PAC Worldwide
Phoenix
Fun fact: Pankaj previously worked on a team to develop the nextgeneration ocean research vessel, equipped with artificial intelligence and other innovative technology.
Zachary Jones, 29 Director of Engineering
Pigler Automation
Longmont, Colorado
—As a recent college graduate, Zach began working for Pigler Automation in 2017 as a Process Controls Engineer. He was promoted to Lead Controls Engineer and then Technology Manager before becoming Director of Engineering in 2022, where he demonstrates his leadership qualities. Zach is certified in Siemens PA and FA control systems, process safety and Inductive Automation Ignition, with other control system credentials. He has lead projects in industrial gas, food and beverage, automotive, renewables and others.
—Upon his arrival at PAC Worldwide, John began setting the tone within operations by spearheading major scrap reduction projects within operations. Outside of his expertise, John was willing to dig in and learn new processes and equipment while learning the inner facets of the organization. Within six months, PAC began to experience the benefits of John's talent. He oversees an expansion and HVAC project in excess of $5 million, leading efforts to ensure timely projection completion. John is spearheading the next phase of the expansion from facility layout to equipment installation.
Fun fact: John has a passion for off-road racing and flying remotepiloted vehicles.
Justin Katz, 37
Manager of Product Management, Inside Sales & Tech Support
Schmalz
Raleigh, North Carolina
—Justin has much to be proud of during his time at Schmalz, a material handling equipment supplier. He assisted companies with process improvements and helped decrease repetitive stress injuries. He has become an expert on vacuums and materials handling and helped Schmalz grow from a $2.5 million company to a $50 million company. A direct report says Justin is “by far" the best manager to work with, by ensuring employees are well taken care of and able to complete tasks.
Fun fact: Zach and his wife, McKenzie, were high school sweethearts and nominated for Prom King and Queen their senior year.
David King, 29
Lead Analytics Developer
Interstates Inc.
Sioux Center, Iowa
—Through on-site immersion and tackling complex roadblocks, David paves the way for robust solutions. Constantly seeking new use cases, he stimulates innovation and ensures client success. David's team engagement nurtures a collaborative learning environment, fostering skill growth and strong project delivery. His volunteering spirit underlines his commitment to progress. David champions advanced projects, like vision analysis, edge data collection and global software deployment.
Fun fact: He is a hopeful fan of Cleveland's sports teams, cheering for the Cleveland Browns, Guardians and Cavaliers
Fun fact: Justin enjoys vacationing with his loving wife and daughter.
Kristen Kosatka, 32
Product Manager
Rockwell Automation
Mayfield Heights, Ohio
—Kristen helps craft a seamless user experience across all Rockwell Automation products. She is a fierce advocate for customers and users. As an early career manager for Rockwell’s training program, Kristen coached and managed nearly 200 early-career employees, using real-world examples to guide development. Kristen helped employees grasp nuances of customer communication and reshaped soft-skills training. Yellow belt training and certification streamlined workflows, eliminated duplication and minimized waste.
Fun fact: Kristen is dedicated to inclusivity and creating a supporting environment.
Ankur Kumar, 34
Operations Technology Development Lead Linde
Tonawanda, New York
—Ankur made substantial contributions to Linde’s technology stack through award-winning machine learning-based solutions for hydrogen and air separation units. His tool, PlantWatch (for plantwide monitoring), received the 2021 Industry 4.0 Award from the Confederation of Industry of the Czech Republic. Ankur is a passionate digitalization evangelist. He engineered an advanced monitoring solution for cyclic processes and helped with adoption of ML-based MPC. He received 2022 awards for digitalization innovation and for product impact.
Kaleigh Linton, 23
Industrial Engineer, Simon & Schuster
Riverside, New Jersey
—Kaleigh’s first project at Simon & Schuster was to analyze the usage of the automated sortation technology being used in the warehouse and figure out how to improve its output. Through studies, observation and research, she has nearly doubled output with the automated sortation device. Before starting the project, the company’s output was around 13,000 to 15,000 units per day across three shifts and now the average is between 20,000 and 23,000 units daily. Kaleigh has played a role in reestablishing labor standards at the company, with increases in productivity and efficiency.
Fun fact: Ankur joined Vibha, a USA-based nongovernment organization that raises funds to educate underprivileged children.
Derrick Marlow, 28
SCADA Engineering Manager
Tesco Controls
Sacramento, California
—Derrick is a self-taught automation professional and a mentor of high-performing teams. He turned his passion for automobiles and electronics into a career in industrial automation. He devotes his talents and energy to preserving precious water resources. He rapidly advanced from SCADA Engineer to Supervising SCADA Engineer, and, in June 2023, to leading the SCADA department of more than 30 engineers. Derrick has a positive outlook, unrelenting work ethic, outstanding leadership and can solve complex challenges.
Fun fact: Kaleigh is an avid skier and has been social chair of Penn State’s Ski Club, allowing her the opportunity to travel for her winter hobby.
Chad McDowell, 34
Technical
Resource Director
Concept Systems Inc.
Albany, Oregon
—Chad leads challenging automation system integration projects. When Concept established a mechanical engineering team and entered the robotic work cell market, Chad was promoted into management. He helped develop most mechanical work cells deployed by the company. As the automation team manager, he led the company's largest single project, a multirobot, multimillion-dollar custom palletizing system. As Technical Resource Director, he leads company strategy on technology portfolio and resource skill development.
Fun fact: Derrick is an active home brewer who has used his skills to invent a sensor retrofit lid with apps to monitor keg levels.
Megan McIntosh, 29
Controls Engineer
Hargrove Controls & Automation
Mobile, Alabama
—Megan has led several small projects at Hargrove Controls & Automation and has played a highly technical role in larger projects. She is versed in Rockwell and Emerson DeltaV in continuous and batch control applications. Clients praise Megan's attitude and knowledge, requesting her by name on projects. She takes part in extracurricular activities in her community and the organization, and she’s an active leader as a mentor to high school students and co-ops. She has twice been awarded Teammate of the Quarter at Hargrove.
Fun fact: After earning his private pilot’s license, Chad purchased a kit airframe, to build a plane himself.
Bradley Meissner, 35
Engineering Manager
Neomatrix Inc.
Andover, Massachusetts
—Bradley possesses a deep understanding of engineering principles and concepts. He exhibits exceptional leadership qualities, such as the ability to inspire and motivate a team of engineers, provide guidance and effectively manage resources. Bradley has experience in coordinating and organizing engineering projects, setting goals and ensuring successful project execution. By leveraging expertise in automation technologies, Bradley has played a pivotal role in helping various industries by enhancing productivity, efficiency and reliability.
Fun fact: Megan loves to spend free time fishing in Mobile Bay and Baldwin County and has recently learned to clean and cook the fish.
Fun fact: Bradley is an adventure seeker and avid skier who plans annual ski trips with friends.
Elliott Miller, 35
Controls & Automation
Technical Consultant
Hargrove Controls & Automation
Johns Creek, Georgia
—Elliott provides strong leadership and guidance to his peers at Hargrove Controls & Automation. As a collaborative colleague, he is willing to share knowledge and experience, such as multiplatform expertise in DCS and programmable logic controllers, to uplift and educate teammates. Elliott provides practical solutions to clients. He acquired his professional engineer license. He is learning more about information technology, OT and cybersecurity.
Seth Purk, 30 Quality Engineer/Supervisor
Rittal North America LLC
Urbana, Ohio
Fun fact: Elliott recently picked up sailing and got his bareboat charter license this past year.
Jackson Redline, 29
Engineered System Solutions
Project Manager
Rogers Machinery Co.
Portland, Oregon
—Jackson started as an Inside Sales Engineer with Rogers and quickly moved from Outside Sales to Project Manager and sales leader with product sales responsibilities for the electronics industry. He is the primary resource among peers to help solve problems. Diligent and cheerful, he provides leadership to many colleagues and contributes a keen understanding of control logic to complex engineered solutions.
Fun fact: Jackson participated in a research project for studying ceramic coatings for an artificial ACL replacement in college and tore his ACL during the project. Coincidence?
Zach Sample, 33
Global Digital Enterprise Consultant
Emerson
Round Rock, Texas
—Zach has been engaged in the larger industry, serving the local chemical engineering community in the St. Louis chapter of AIChE, holding positions as Secretary, Treasurer and YP Chair. He presents at conferences about the value of a well-thought-through enterprisewide software deployment and use plan. Zach has been a lead engineer, managed projects, lead sales teams and consulted with customers on enterprisewide digitalization solutions to ensure success.
Fun fact: With an Emerson-donated simulation system at Missouri University of Science & Technology, Zach helped to enhance unit operation and controls lab for the chemical engineering department.
—During his first year at Rittal, he was promoted to the Quality Supervisor for the department and continued as the Quality Engineer in the fabrication department. He took leadership and management courses through a local college, and he is progressing into a management position. He is working to achieve his ASQ certification as a Quality Engineer and taking several quality-related courses. A big achievements includes implementing Rittal’s first automated robotic weld cell to improve the product quality and productivity.
Fun fact: Seth has coached high school football, basketball and baseball for more than 10 years.
Carlos Rodriguez, 32
Engineering Manager
MartinCSI
Plain City, Ohio
—Carlos has become the go-to engineer for technical questions from other engineers. This led to Carlos taking over the training program for new hires. He makes it easy for younger engineers to understand, makes everyone comfortable and unafraid to ask questions and connects on a personal level. He took an outline for a formal engineer training program and put it into useful practice. Carlos mentors younger engineers and assists them in developing career paths.
Fun fact: Carlos loves to cook. He and his friends gather monthly for themed cooking parties where they create new dishes and enjoy being together.
Darren Schlemm, 24
Associate Process Engineer
Dart Container Corp.
Leola, Pennsylvania
—Darren is known for dedication and contributions to the ongoing success of the corporate utilities engineering team, which is critical to the manufacturing processes at Dart Container. He designed and managed various installation projects at different facilities and is responsible for creating, updating and monitoring utility process control plans at many plants, assuring the equipment critical to production is running optimally, allowing for greater longevity and less downtime. Darren completed trainings including boiler room training.
Fun fact: Darren's diverse interests include fitness and weightlifting, engineering and leadership.
Chris Shomin, 39
Manager - Site Automation
Merck Animal Health
De Soto, Kansas
—Chris with almost a decade in process controls in diverse industries, rose from team member to manager, leading an expanding team of engineers and technicians. Chris prioritized cybersecurity, obtaining certifications and devising a more than $6 million modernization plan for production networks, SCADA and more. Connecting with management and shop floor personnel enhances contributions to vision and troubleshooting efforts. Chris’ efforts in barcoding for SAP and manufacturing execution system integration are being considered globally.
Fun fact: Chris has crafted furniture, including a walnut kitchen table. He is restoring a classic Ford pickup with his three sons.
Gayland Waindim, 33
Staff Systems Integration Engineer
Twist Bioscience
Wilsonville, Oregon
—As a staff software integration engineer at Twist Bioscience, Gayland demonstrates expertise and dedication and consistently elevates operations and advancements in DNA manufacturing. His adeptness in seamlessly integrating software systems has led to heightened efficiency and streamlined processes. Gayland facilitated the installation of multimillion-dollar photolithography machines worldwide, improved safety protocols and played a key role in DNA synthesis machine implementation. Sustained efforts in plant instrument software and hardware maintenance underscore his lasting impact on engineering.
Fun fact: Gayland recently learned how to weld and is taking courses in systems science and computer science.
Justin Wengatz, 35
Lead Product Manager
Rockwell Automation
Mayfield Heights, Ohio
—Justin's forward-focused approach consistently seeks long-term solutions by addressing root causes. His receptivity to customers' unique problems and ideas drives innovation at Rockwell Automation. Beginning as an Engineer-in-Training in 2013, he progressed to Project Controls Engineer, integrating PlantPAx solutions. Leading major releases for Studio 5000 Logix Designer, Justin’s expertise has propelled him to Lead Product Manager, guiding a team and shaping the strategic direction of Rockwell Automation’s control software.
Fun fact: Justin’s profession began in pharmacy. He transitioned to engineering due to its alignment with his problem-solving mindset.
Chris Thompson, 39
Project Engineer
Applied Control Engineering
Newark, Delaware
—Chris is a skilled and fun-loving control engineer at Applied Control Engineering. His troubleshooting prowess, coupled with a positive and curious demeanor, makes him a valued team member and customer favorite. Chris has contributed many projects, including chemical processing and NI LabView systems for semiconductor research. Background includes optoelectronic research, utility-scale solar and semiconductor degradation studies, with published works. Expertise extends to complex electrical systems. Eagerness to learn and teach new technologies defines his control engineering career.
Fun fact: Chris finds joy in sailing sailboats on the upper Chesapeake Bay, embracing the excitement of competition and camaraderie.
Engineering Leaders Under 40
Know someone who qualifies as an Engineering Leader Under 40? Help give them the recognition they deserve.
The Engineering Leaders Under 40 program recognizes manufacturing professionals under the age of 40 who are making a significant contribution to their plant’s success, and to the control engineering and/or plant engineering professions. Our research shows that finding, training and retaining workers is the biggest issue facing manufacturing today. The goal of the Engineering Leaders Under 40 program is to call attention to these successful young engineers in manufacturing and to show how manufacturers are recruiting and developing the next generation of manufacturing professionals.
See past leaders online at the page above, going back to 2010.
Remote wireless devices connected to the Industrial Internet of Things (IIoT) run on Tadiran bobbin-type LiSOCl2 batteries.
Our batteries offer a winning combination: a patented hybrid layer capacitor (HLC) that delivers the high pulses required for two-way wireless communications; the widest temperature range of all; and the lowest self-discharge rate (0.7% per year), enabling our cells to last up to 4 times longer than the competition.
Looking to have your remote wireless device complete a 40-year marathon? Then team up with Tadiran batteries that last a lifetime.
ANSWERS
Diego Grassi, Byline Affiliation
What’s new in wireless, RFID for IoT asset tracking?
Recent innovations have been good for tracking technology providers and end-users; what’s in the pipeline seems likely to provide additional industrial benefits.
Just a decade ago, from the moment a valuable shipment left the supplier until it was added to your inventory, it was all but impossible to know exactly where it was and what state it was in. Today, such lack of visibility is increasingly considered poor practice, wasteful or downright irresponsible and multiple technologies, including wireless and radio frequency identification (RFID) are being applied to make industrial applications.
they serve. Device size, positioning accuracy, power autonomy, update frequency, required message sizes, latency, scalability, solution complexity, maintenance requirements, upgradeability, service availability and cost are just a sampling of the many competing constraints device manufacturers need to balance when developing tracking solutions.
FIGURE 3: Via a combination of different networking technologies, indoor and outdoor tracking can be used together to effectively monitor the location and status of goods in motion. Courtesy: u-blox.
Enabled by the widespread adoption of GNSS (Global Navigation Satellite Systems)-based tracking devices — in our cars, our phones and on our wrists, but also throughout corporate logistics chains — IoT trackers have made it possible to keep tabs on everything you value, all the time. It has paid off: Tech-savvy businesses have been quick to translate the visibility the tracking devices provide into increased efficiency and revenues.
IoT trackers come in all shapes and sizes and leverage a growing portfolio of enabling technologies to meet the specific constraints of the use cases
With the right expertise, today’s device developers can select from a growing bag of technological tricks to build smaller, better hardware options, speed up and simplify integration to back-end cloud IoT platforms and reduce the total cost of ownership of the products while growing their margins.
Accurate real-time insight into the what, the when and the where of people and assets can help keep them safe and protected, detect and address inefficient processes and improve planning.
Tapping into this value with IoT tracking technologies requires a suite of components:
• Tags: All assets being tracked need to be equipped with tags capable of sensing data required to determine their location using a positioning system.
• Positioning system: The positioning needs to cover the target area. It can, for example, be made up of orbiting satellites as used by global navigation satellite systems (GNSS). Other variants use existing cellular network base stations, Wi-Fi access points or locally deployed beacons. The positioning system can be supported by additional services, noted later.
• Positioning engine: The positioning engine translates physical measurements made by the tags or the infrastructure as well as additional information into an accurate location estimate. The positioning engine can, for example, run on the tag, on a local processor or on the cloud.
DIVE INTO DIGITALIZATION
WAGO’s new IoT Box is your introduction to digitalization, from signal acquisition to cloud connectivity. A network of inputs and gateways provide monitoring and reporting capabilities to help solve unique application challenges. With flexible hardware and software that remains scalable, no-code configuration, as well as encrypted cloud communication for reliable security, this plug-and-play device requires no engineering experience.
ANSWERS
FIGURE 5: Technological progress on the supply side continues to enable ever more sophisticated high-performance use cases for IoT tracking. Courtesy: u-blox
• Wireless communication to the cloud: For the location data to be useful to the end-user, real-time IoT tracking technologies require a wireless communication channel to the local or cloud-hosted tracking software. Depending on deployment, tags can transmit data directly to the cloud or can relay it via a mobile phone or locally deployed wireless gateway.
IoT trackers need optimal energy efficiency in their main hardware components paired with an open-standard, secure, scalable and portable low-power wireless communication channel to the cloud.
Trends in IoT tracking technology
IoT tracking technology has made huge advances over the past decade. Technological progress on the supply side continues to enable ever more sophisticated high-performance use cases. At the same time, it is driving up customer expectations on the demand side. Demand-side trends are:
• Demand for broader coverage, geographically and in mixed indoor-outdoor environments,
• Improved accuracy and reliability,
• lower power requirements for longer battery autonomy or smaller end device size,
• Tighter integration with a shorter bill of material and fewer suppliers in the supply chain,
u
Online
controleng.com
KEYWORDS: IoT, asset tracking, wireless
LEARNING OBJECTIVES Learn how advances in GNSS, 5G and other networking technologies are expanding the capabilities of asset tracking devices.
ONLINE
With this article online, review use cases and possible future uses.
CONSIDER THIS
What efficiencies could you gain by deploying IoT-based asset tracking technologies?
• Faster time to market,
• Lower total cost of ownership.
Innovation is apace on the supply side, with coverage, performance, power requirements and technological integration improving with each new generation of the technology.
Outdoor location coverage has been improving with the introduction of multi-constellation GNSS receivers that see a greater number of satellites than standard GNSS receivers, even when they are surrounded by tall buildings in a deep urban canyon. Assisted GNSS has cut the time it takes for the receiver to achieve a first position fix to mere seconds. Cellular fingerprinting techniques have
essentially eliminated zero-position scenarios. Indoor location coverage has been improved with the growing adoption of Bluetooth direction finding and indoor positioning as well as ultrawideband technology.
Wireless connectivity solutions are offering increased coverage, with low-power wide-area networks offering enhanced reach over standard consumer 4G LTE networks, while mesh-based short-range solutions extend the range of the transmission across trains, containerships and different forms of load carriers used in warehouses.
Positioning performance has increased, driven by the mainstreaming of multi-band, multi-constellation GNSS receivers, high precision positioning solutions, such as real-time kinematics and more of GNSS augmentation services for centimeter-level positioning.
Dead reckoning technologies that fuse inertial and vehicle sensor data with the GNSS receiver output and vehicle-specific dynamic models reduce the impact of multipath effects and GNSS signal interruptions.
Power autonomy developments include more sensitive antennas, lower-power components used to design GNSS receivers and 4G LTE cellular radios. Cloudbased positioning is opening new avenues toward ultra-low power GNSS positioning for applications that only need to sporadically determine their location. Innovations such as multi-constellation GNSS and assisted GNSS shorten the time the GNSS receiver needs to spend in the power-hungry signal acquisition mode before switching to the lower-power tracking mode. Tighter integration is another trend enabled by the emergence of powerful dual-core MCUs capable of hosting a computing controller and the Bluetooth low energy, Wi-Fi or cellular software stack.
The move from complex architectures with a stand-alone application MCU and radio technology stacks on separate processor cores to a simpler architecture integrating everything on a dual-core MCU offers opportunities for reduced time to market, fewer components, fewer suppliers and shorter development times. ce
Diego Grassi is senior principal application marketing – industrial and consumer IoT, u-blox. Edited by David Miller, content manager, Control Engineering, CFE Media and Technology, dmiller@cfemedia.com.
INSIDE PROCESS: SAFETY ANSWERS
Mark Breese, Yokogawa
Five steps for driving safety culture excellence
While regulations, equipment and appropriate training remain vital to bolstering workplace safety, establishing a culture of safety is still the best frontline defense.
The ILO (International Labor Organization, a United Nations agency) estimates that 2.3 million women and men succumb to work-related accidents or diseases every year, which is the equivalent of over 6,000 deaths per day. Worldwide, there are around 340 million occupational accidents and 160 million victims of work-related illnesses annually. Smarter, safer working culture requires attention to safety culture, equipment, regulations, training and documentation, among other factors.
By actively committing to safety culture excellence from the top down, companies can gain the advantages of greater productivity and profitability by embracing safety as a way of life and not just a regulatory requirement.
Safety culture excellence and control of work
Control of work risks are those associated with work conducted during routine operation of plants and processes or those conducted during maintenance, turnaround or construction across all forms of industry.
The risks themselves will vary, but at its core, Control of Work, which is sometimes known as “permit to work” or the permitting process, consists of three main elements that should always be linked and equally represented to ensure the best possible work safety:
• Risk assessment – an analysis of the risks associated with the task being conducted, taking into consideration the conditions and the tools being used
• Isolation management – the safe isolation of all forms of energy, power or motion and locking
out of devices, known as lockout / tagout (LOTO) processes
• Permit to work – The document containing a description of the work and the approvals and associated documents necessary so that final authorization to work can be given. This is issued to the work team before beginning work.
Safe working practices have differing standards of enforcement around the world depending on the country or location where the work is being done. Control of work (CoW) practices may be driven by company, national or international guidelines, standards or regulatory bodies such as OSHA or the UK or European Health and Safety Executive (HSE) as examples.
Failures to control working practices, particularly those related to health and safety are behind many of the major incidents, fatalities and fines seen in high hazard industries.
Human factors and leadership for industrial safety
Human factors and leadership within an organization will always be key drivers of both the importance and success of any safe working practices.
Management system improvements such as ISO 45001 and the increasing levels of controls and fines applied by regulatory bodies such as OSHA are influencing safety, but improvements can be slow to take effect.
ISO 45001 is an international standard for occupational health and safety which is globally used and is applicable to all organizations no matter their size, industry, or type of business.
controleng.com
KEYWORDS: Safety, workforce LEARNING OBJECTIVES Understand how workplace injuries and fatalities not only exact a human toll, but damage a business' bottom line.
Explore ways that leadership can incentivize a culture of safety.
Discover methods for challenging how work is conducted to promote safety improvements.
ONLINE
With this article online, see a section on An introduction to industrial safety with 2 more graphics.
CONSIDER THIS
How can you challenge the status quo within your organization to improve safety outcomes?
Discover methods for challenging the way work
ANSWERS
1: Among Top 10 most-cited standards cited for OSHA violations, falls, respiratory protection and ladders were the top three. Lockout/tagout was seventh. Machinery and guarding was tenth. Graphics courtesy: Yokogawa RAP
Key within it is section 5.1 Leadership and Commitment:
This states that those who lead an organization must promote risk-based thinking and that top management is required to demonstrate leadership and to promote the importance of safety to be in conformance with the operational health and safety (OH&S) requirements, to be effective in achieving results, and to be continually improving.
To achieve this and to drive safety culture excellence, the leadership of an organization must,
as Figure 2 shows, act as role models, ensure safety is a key topic, establish the conditions for safety, support tools for improvement, and continue to challenge status quo.
The path to continuous cultural improvement means leaders throughout the organization must be encouraged to challenge existing ways of working to drive towards a consistent aim of zero harm.
Methods used to challenge the status quo include:
• Ensuring that accountability is built right through the culture
• Workshops to engage teams in the processes of safety and build workforce positivity
• Leadership having a passion and commitment to the momentum gained
• Sensible metrics to reinforce compliance and to understand the need for consistency
• A willingness to listen and make use of worker’s past experiences and knowledge
• A willingness to spend appropriately to ensure the process works.
The main safety benefit of challenging the status quo is the drive towards the goal of no incidents or accidents that it engenders, but many other benefits can also be derived from the resulting consistency in culture and the fundamental way of working that comes from the overall effort.
Support, encouragement and tools help the safety culture
In summary, the path to continuous safety improvement to ensure an effective safety culture is only possible with the active support and encouragement of effective leadership within an organization, and with an emphasis on the human factors that underly current ways of working.
This is only possible if the emphasis is on driving cultural safety improvement (Figure 3) as opposed to short-term key performance indicator (KPI) goals that may change regularly. ce
Mark Breese is head of sales, Yokogawa RAP. Edited by David Miller, content manager, Control Engineering, CFE Media and Technology, dmiller@ cfemedia.com.
FIGURE 2: A safety culture must be leadership-driven in five ways.
FIGURE 3: Yokogawa has a 5-step process to drive continuous safety culture improvements.
FIGURE
Bryon Hayes, Grantek
Embrace the industrial cloud
With automation vendors' turn-key applications, the industrial cloud is easier.
As manufacturing organizations adopt the tenets of Industry 4.0 across the enterprise, they are turning to cloud computing as a major pillar to support their efforts. A PricewaterhouseCoopers (PwC) survey indicates 72% of manufacturing companies are investing in cloudbased platforms and applications to support Industry 4.0 strategies. Some major automation platform providers have cloud-enabled applications to help.
Rockwell Automation’s FactoryTalk Design Studio software is bringing programmable logic controller (PLC) programming to the cloud. The design studio is designed as a multi-user, multicontroller platform. It leverages the object-oriented programming concepts from the software world to enhance modularized automation application development and uses the Git platform under the hood. Aveva System Platform enables collabora-
tion and enterprise-wide scalability with its cloud and hybrid-cloud development tools. Inductive Automation’s Ignition Cloud Edition leverages the cloud’s elasticity to drive user scalability. Cloud providers such as AWS and Microsoft Azure are responding to the growing needs of the manufacturing space with a safe and secure infrastructure on top of which industrial automation platform providers can deploy applications.
As cloud adoption travels down the ISA-95 stack, from Level 4 and Level 3 down to Level 2, the operational and financial benefits for manufacturers will keep increasing. ce
Bryon Hayes, director of consulting – life sciences, Grantek. Edited by David Miller, content manager, Control Engineering, CFE Media and Technology, dmiller@cfemedia.com.
MEDIA SHOWCASE FOR ENGINEERS
controleng.com
KEYWORDS: Industrial Cloud, digital transformation
LEARNING OBJECTIVES Learn how OT professionals can begin leveraging the benefits of the industrial cloud. ONLINE www.controleng.com/ digital-transformation/ virtualization-cloud-analytics/
Innovations
LTE4 cellular router protects against cyber threats
The Moxa OnCell G4302-LTE4 LTE cellular router offers high-speed performance and reliable communication between FTUs and FRTUs at substations, enabling immediate detection of issues or anomalies in the system. It also provides protection against potential cyber threats to ensure system security. The OnCell G4302 offers advanced security features based on an IEC 62443-4-2 certified OS, thus supporting cybersecurity for IP-based cellular architecture. Moxa, www.moxa.com/en
Wireless access point, client bridge
L-type magnets for the industrial market
Arnold Magnetic Technologies Corp., a subsidiary of Compass Diversified, offers L-Type Laminated magnets for high efficiency industrial applications such as high speed power generation, high speed magnetic bearings, high speed motors and others. In using L-Type magnets for motors, having more power doesn’t need to mean more heat production. Arnold reduces eddy current losses to ensure efficiency. Arnold Magnetics, www.arnoldmagnetics.com
Angle seat valves to control liquid and gas flow
ATO angle seat valves are fluid control devices used to control the flow of liquids or gases. It’s named from the angled design, in which an angle, usually 90 degrees, is formed between the valve body and the direction of fluid flow. This design allows angle seat valves to control fluids with a high degree of accuracy and stability. Sizes are 1/2, 3/4, 1, 1-1/2, 1-1/4, 2, 2-1/2, 3 and 4-inch thread port pneumatic angle seat valves. Ato Agle Seat Valves, www.ato.com/angle-seat-valves
Electronic position indicators for rotating shafts
AutomationDirect has added electronic position indicators from Elesa. These indicators are designed to accurately measure and display the position of a rotating shaft. They consist of a rugged polyamide housing, suitable for applications requiring frequent washing, with a clear and easy-to-read display and are attached directly to a rotating shaft.
AutomationDirect, www.automationdirect.com
Antaira Technologies is providing a secure, cost-effective way to extend wireless networks with the launch of its AMY-5133-AC-PD wireless access point/ client bridge. It supports net data rates up to 867Mbps.
Antaira Technologies, www.antaira.com
Small radiometric thermal camera
The Teledyne Flir Lepton 3.1R is the world’s first radiometric thermal camera module with a 95 degree field of view, 160 x 120 resolution and a scene dynamic range of up to 400° Celsius. The 3.1R model has compact and low-power form factor and is a drop-in enhancement for existing Lepton-based products. Flir, www.flir.com
Programmable temperature transmitter
MIK-ST500 Head Mounted
Smart Temperature transmitter from Meacon Automation can be used with multiple sensor types, including resistance thermometer and thermocouple inputs. It is simple to install with improved measurement accuracy over wire-direct solutions. Meacon Automation, www.meacon.cn
Back to Basics
PROJECT MANAGEMENT
Benefits of upgrading legacy PLCs, HMIs
A system integrator was asked to upgrade legacy hardware and software for a water well expansion project. Learn how the PLC and HMI upgrades happened.
Outdated systems have the potential to transform assets into liabilities. It is important to know the signs and risks of using outdated systems, and when it is the right time to modernize. This was a challenge faced by a company specializing in environmental management services that operated 11 water well sites in a fivemile area. These sites were being controlled by legacy programmable logic controllers (PLCs) and human-machine interfaces (HMIs) and relied on slow serial radios for communication, posing several risks such as high maintenance costs, poor HMI responsiveness, and limited scalability due to the outdated equipment.
well upgrades in parallel with the legacy system. The team installed the new PLCs to run concurrently with the legacy PLCs, and configured messaging between the controllers so the main legacy PLC was unaware of the upgrades.
involved experts network design, radio config coding
The customer recognized how the outdated system negatively affected productivity and efficiency which prompted requests for engineering support. The company worked with a system integrator to deploy a modern solution, which included upgrading PLC, HMI and radio controls as well as install another water well.
Upgrading existing PLC, HMI, wireless hardware
Before installing the water well, the project team focused on updating the customer’s existing hardware, which included the PLCs, HMIs and radio controls. The integrator worked with a company that specialized in radio controls to investigate how to implement a modern Ethernet communications protocol for the customer with minimal disruption to operations. The research concluded the best order to implement the upgrades was in two phases. The first phase was to upgrade the access point (AP) radio at the customer’s control office, and then upgrade the remote radios that communicate to the AP and the main control PLC. With this information, the system integrator began developing the updated system.
The project team upgraded legacy controllers for newer controllers and terminals and programmed them. The application integrated a supervisory control and data acquisition (SCADA) system, which provided an operation and management overview of the wells status to local and corporate customer offices.
The project team set up an intermediate infrastructure at the customer’s control office that could run the water
The team then upgraded the customer’s networking communications from serial radios to Ethernet radios with a more powerful antenna. The project team also decommissioned the legacy PLC and converted the water wells to run exclusively on the upgraded system. The integrator resolved challenges with remote customer water wells which faced poor connections from antenna height limitations. The team implemented a store-and-forward capability for the remote radios, which transmitted data to a closer radio station and then forwarded to the main AP radio to improve data connectivity. After modernizing existing water wells, the new water well was installed and commissioned.
Expanded infrastructure
The project, including the design and control panel construction for the new water well, was completed in a few months. The integrator supported modernization of the customer’s system by assigning subject matter experts in network design, radio configuration, PLC/HMI coding and conversions.
controleng.com
KEYWORDS: system integration, project management
LEARNING OBJECTIVES
The implementation of the new system resulted in significant speed and reliability enhancements for the customer. Real-time data are available on a per-second basis instead of waiting for minutes, creating more trust about data value. ce
- This originally appeared on Automation Group's website. Automation Group is a CFE Media and Technology content partner. Edited by Chris Vavra, web content manager, CFE Media and Technology, cvavra@cfemedia.com.
Learn how a system integrator worked on upgrading water wells connected to legacy equipment. Learn the project process, results. ONLINE
See diagram with this article online. https://www.controleng. com/system-integration/ project-management/
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