The LS Electric XMC motion controller has numerous state-of-the-art features built into its compact brick-style design. These controllers are optimized for advanced motion control, are available in 8- or 16-axis models, and offer a variety of high-tech capabilities for a price that can’t be beat!
XMC for Xact motion control - XMC controllers utilize the EtherCAT high-performance protocol which is specifically designed for real-time communication and deterministic data exchange, making it ideal for precise motion control applications.
XMC for EtherCAT Xpansion - XMC controllers feature full EtherCAT Master capabilities, meaning they can communicate with and/or control any EtherCAT device including EtherCAT I/O, encoders, AC drives, etc.
MOTION CONTROLLER
XMC for Xtensive automation - Not only can XMC controllers handle numerous EtherCAT devices, they also support G-code, M-code, and programming specific to robot control including Delta3, Delta3R, Linear Delta, and more.
XMC for blazing fast Xecution - The XMC controllers offer extremely fast processing capabilities, with a scan time of 6.25 ns for basic commands, 5ns for motion commands, and 30ns for arithmetic commands. EtherCAT-based high-speed communication cycle times are 0.5/1/2/4ms.
XMC for Xtreme value - The XMC controller provides both highly advanced motion control with EtherCAT communication and built-in PLC functionality for a price well below the competition. By using the powerful XMC controller for your next motion control application, you could save thousands on hardware costs alone, not to mention the FREE software and support!
Dold VARIMETER phase monitoring relays quickly detect fault conditions, such as overvoltage, undervoltage, exceeding voltage range, phase unbalance, phase reversal, and missing or broken neutrals in single- or three-phase AC systems. Easy-to-use single-turn switches simplify setup, eliminating the need for complex menus.
• Up to 575 VAC 50/60 Hz measuring range
• Adjustable voltage, hysteresis, and time delay
• Single- or three-phase AC voltage monitoring
• 5A SPDT output contacts
• Fast fault detection
• DIN rail mounting
Voltage Monitoring Relays
Starting at $110.00 (RL9854AC45-135V)
Dold VARIMETER series voltage monitoring relays protect equipment from damage caused by abnormal voltage fluctuations. These relays continuously monitor voltage levels and trigger a fault when they exceed or fall below a predetermined threshold. Four single-turn switches allow quick setup for a broad range of applications.
• Up to 250 VDC or 300 VAC measuring ranges
• For use in single-phase AC or DC systems
• Overvoltage, undervoltage, or voltage band monitoring
• 5A SPDT output contacts
• Adjustable voltage, hysteresis, time delay, and monitoring function
• Fast fault detection
• DIN rail mounting
Solid State Relays
Starting at $21.75 (GQ-15-24-D-1-3)
• Gefran GQ series “hockey puck” style relays feature contact ratings from 15 to 90A and include thermal mounting pads and overload and thermal protection
Gefran GQ and GRSH series solid state relays are available in DIN rail or panel mounting styles and offer a variety of overload and thermal protection options. Both series provide zero-crossing technology, 100kA SCCR ratings, and IP20 finger-safe protection ratings.
• Gefran GRSH series relays offer contact ratings from 15 to 120A, support for up to 600VAC, and include built-in overtemperature and overvoltage protection
Electro-Mechanical Relays
Components starting at $5.00 (781-1C-24D)
Electro-mechanical relays receive an electrical input that magnetizes an internal coil, causing the relay’s contacts to open or close. Although typically less expensive than solid state versions, they have a shorter lifespan due to the mechanical components.
• Force guided relays
• Square relays/cube relays
• Octal relays
• Power relays
• Hazardous location sealed relays
• Slim/card relays
• Slim interface relays
Experience control at every level –Valmet DNAe Distributed Control System
Valmet DNAe is a next-generation distributed control system. As a fully web-based platform, it delivers an industry-leading user experience and cybersecurity by design.
The system brings the process know-how of the world’s leading experts directly to your control applications and improves efficiency. It provides unique data collection and utilization capabilities, enabling informed decision-making.
Valmet DNAe is a catalyst for sustainable practices, and it sets the stage for autonomous operations and a digitalized future. Empower people to perform at their best, reach and exceed your targets, enable path to autonomous operations and evolve throughout the lifecycle with the new DCS. Are you ready to evolve?
For more information, visit valmet.com/dnae
7 | March and April online article sampling: Refresh of www.controleng.com, more headlines, authors, companies, with links
INNOVATIONS
41 | New Products for Engineers, www.controleng.com/products
Did you vote for Product of the Year, yet?
64-bit automation controller; Smart RTU enhances critical infrastructure cybersecurity; Generative AI software helps asset lifecycle intelligence; Sensor, analytics for rotating industrial assets; Industrial edge IoT edge gateway; stainless steel gear unit; control room strategy; sensor and condition monitoring; advanced encoders; block opencore control transformers; pressure transmitter; tiny photoelectric sensors; supercharger for multicore computing.
44 | Back to Basics: Choosing the best control valve style for your application
With so many control valve options available, it’s important to know how to choose the right body style for a particular application.
NEWSLETTERS ONLINE
CE AI & Machine Learning, March 6
• AI challenges and opportunities at the edge, beyond a system of systems, improving visual inspections with AI, data security, AI savings quantified.
CE Motors & Drives newsletter, March 11
• Robotics accelerator, ethernet technologies, mergers in motion, motion market growth expected, hot topics.
Go to www.controleng.com/subscribe and select newsletters.
Control Engineering eBook series, now available: Spring Edition
u Applied Automation, Feb. 12
Featured articles include:
• Automation system implementation
• Planning for future automation
• Analytics for asset management
Learn more at: www.controleng.com/ebooks
u Global System Integrator Report
Learn more about system integrators and system integration trends, technologies and tools: www.controleng.com/global-systemintegrator-report
u Control Systems eBook, March 12
Featured articles include:
• Distributed control system integration
• Choosing the right controller
• SCADA help from system integrators
More topics at: www.controleng.com/ebooks
u Control Engineering digital edition
Digital edition advantages:
1. Click to more using live links with more text and often more images and graphics. 2. Download a PDF version. 3. Slide bar at bottoms navigates more quickly. 4. Greater sustainability. www.controleng.com/ magazine
Online Highlights
INSIGHTS
uNew backup algorithm for post-quantum encryption - NIST chooses HQC, which is based on different mathematics than ML-KEM.
uEnergy innovation center opens in Houston to highlight AI solutionsSchneider Electric technology facility will support automation and energy sectors in North America.
uNew testbed initiative to drive innovation in digital twin evolutionThe testbed initiative will define digital twin capabilities using measurable KPIs for testing, verification and validation - Digital Twin Consortium (A)
uPID spotlight, part 14: How open loop tuning works in an integrating process - Tuning a new PID controller begins with an open loop step test. What are the steps? What data do I collect? What calculations are required? How well will it work? What problems might I run into? - Ed Bullerdiek is a retired control engineer with 37 years of process control experience in petroleum refining and oil production. (C)
u ProMat 2025: The critical role information architects play in artificial intelligence
How to mitigate the ongoing Salt Typhoon telecom hack: CISA
uSalt Typhoon telecommunication hack is an ongoing exploitation of AT&T, Lumen, T-Mobile, Verizon and other networks, from a state-sponsored hacking group in October 2024, explained as the worst telecom hack in U.S. history by the Cybersecurity and Infrastructure Security
to use fully encrypted text messaging apps to minimize chances of sharing information with the Peoples Republic of China (PRC).
• If possible, conduct business over Microsoft Teams, Webex or other similar platforms
Neal Arnold, cybersecurity advisor – law enforcement liaison, Region IV, Cybersecurity advisor program, Cybersecurity and Infrastructure Security Agency (CISA), explained about the worst and ongoing telecommunications hack in U.S. history, Salt Typhoon, and offered cybersecurity advice at the 2025 ARC Industry Leadership Forum by ARC Advisory Group Feb. 10. Courtesy: Mark T. Hoske, Control Engineering, WTWH Media
Agency (CISA) at the 2025 ARC Leadership Forum by ARC Advisory Group, Feb. 10. The hack gained access to millions of U.S. call detail records, who talk to, how often, at what times and location data, including highly sensitive law enforcement intelligence and law enforcement data, said Neal Arnold, cybersecurity advisor – law enforcement liaison, Region IV, Cybersecurity advisor program, CISA. Arnold said Salt Typhoon is not a traditional compromise because no confirmation has been given that Salt Typhoon has been evicted from compromised networks. Arnold said Salt Typhoon has embedded itself in older, aging network equipment and in niche networking that’s difficult to detect. In addition:
• On Dec. 4, 2024, CISA published guidance specific to the communication infrastructure, providing network engineers and network defenders mitigation information. https://www.cisa.gov/resources-tools/ resources/enhanced-visibility-and-hardening-guidance-communications-infrastructure
• CISA and the FBI urged Americans
• The most sensitive conversations should be in person, including sensitive critical infrastructure and manufacturing-related intellectual property information.
Arnold’s presentation, “Cybersecurity threat landscape: Securing critical infrastructure,” covered industrial cybersecurity from the CISA perspective. He explained that CISA will reach out when operational technology (OT) products have a vulnerability and are being exploited. As with any contact, he recommends verifying and contacting CISA back, though perhaps not via email, which may also be compromised, he said.
Industrial cybersecurity threats
Many of the 16 critical infrastructure sections that CISA has been asked to help use automation, control and instrumentation, including chemical, critical manufacturing, energy and water and wastewater. Cyber threat factors include ransomware; sophistication phishing; internet of things (IoT) malware and vulnerabilities; data theft, fraud and breaches; supply chain attacks; teleworking; insider threats; lack
of protection and policies; and advanced persistent threats (APTs). Supply chain threats include:
• Software service providers and outside contractors through exploitation of smaller, typically less-secure companies with access to networks of larger corporations.
• Mergers and acquisitions: Inheriting the (lack of) security.
• Physical components: Hidden “backdoors” embedded in software or hardware.
• Network services: Do you know the route your digital traffic takes?
• IoT may prioritize time to market over security.
Advanced threats include:
• Social engineering: Scattered spider, SIM swapping, account takeovers, reset passwords and multi-factory authentication (MFA) removal, data exfiltration, extortion and ransomware.
• Artificial intelligence (AI), a program that can sense, reason, act and adapt: Machine learning (ML), algorithms whose performance improve when exposed to more data over time; deep learning, an ML subset where multilayered neural networks learn from vast amounts of data; large language models; generative AI; deepfakes; and artificial general intelligence.
Only about 20% of critical infrastructure cybersecurity incidents are reported. Reporting to CISA is confidential and protected against litigation, sunshine laws and civil litigation. ce
Mark T. Hoske is editor-in-chief, Control Engineering, WTWH Media, mhoske@wtwhmedia.com.
Gain new insights on SCADA trends, applications
TRENDS in supervisory control and data acquisition (SCADA) software include easy-to-use SCADA features, wider SCADA benefits and broader industrial use of SCADA, as explained at the 2024 ScadaFest by Trihedral. This year’s ScadaFest, March 17-21, started with three days of training followed by two days of trends and discussions, including new SCADA features, SCADA integration with industrial communications, SCADA resiliency and load balancing, SCADA software as a service and industrial software development lifecycle.
Additional SCADA topics included best practices for new SCADA systems, massive data sharing, SCADA alarm optimization, SCADA cybersecurity, SCADA use of the new OPC-UA Publisher, SCADA configuration and debugging, smarter SCADA historians, SCADA recipes and awards.
Key 2024 SCADA features in VTScada by Trihedral include scalability for systems of any size, advanced cybersecurity and acceptance for use in critical industries, explained Glenn Wadden, president, Trihedral, a Delta Group company, and Barry Baker, vice president, Trihedral, and president of U.S. Trihedral.
Best practices from Toyota’s SCADA use: For monitoring equipment health, for instance, SCADA software screens can help investigate issues, troubleshoot and develop countermeasures, according to Jesse Daniels, engineering manager-maintenance and spare parts new model, Toyota Motor North America.
Read more. www.controleng.com/ gain-new-insights-on-scada-trends-applications/
Practical advice for automation programmers
u Get “Practical advice for automation programmers” from Control Engineering i n a March 26 webcast (archived for a year); webcast instructors provide programming advice for automation and programmable logic controllers (PLCs) below. The instructors are Braden Hadwiger, mechanical engineer, Huffman Engineering Inc., and Jason Israelsen, PE, senior control engineer, APCO Inc. Tips, tricks and best practices to hone your control system programming skills include programming for PLCs, programmable automation controllers (PACs), industrial PCs, embedded controllers and edge devices. IEC 61131-3 programming languages are discussed, along with practical advice for making controls and automation programming more productive.
Israelsen, in discussing a table based on the principles of programming languages, noted that it can be misleading because it does not account for platform specifics. “Process considerations” are only one item of reference in choosing a programming language. For instance, Israelsen said, also consider details about licensing, the interface and tools. (See more details and graphic with this article online.)
Hadwiger suggests creating a PLC standard for your facility. This can also
shown on the screen is an example of a matching object tied to a function block located in the PLC created for a customer, explained Braden Hadwiger, mechanical engineer, Huffman Engineering Inc. This allows both PLC and HMI/SCADA programming to be deployed much easier and faster and allows changes to be made to templates instead of individual instances. Courtesy: Control Engineering webcasts
be paired with a separate SCADA or HMI standard or can be part of a more comprehensive set of standards documents for your facility. Typically, a PLC standard includes information such as the type of hardware used, how to organize PLC programs, how tags are created, named and organized, and includes a ref-
erence for any pieces of custom code and how they operate and when they should be used. ce
Register for the Control Engineering webcast at https://gateway.on24.com/wcc/experience/ elitewtwhmedia/2927718/4673040/ce.
Figure: The graphic
Annual report details progress in advanced space-based R&D
uThe International Space Station (ISS) National Laboratory reported growth in space-based R&D in its annual report, released by the Center for the Advancement of Science in Space (CASIS). Over the past fiscal year, the ISS National Lab sponsored more than 100 payloads delivered to the orbiting laboratory—the second-highest annual total to date. This year also saw 51 ISS National Lab-related results published in peer-reviewed articles highlighting the ISS National Lab’s contribution to scientific research.
Since 2011, CASIS has managed the ISS National Lab under a cooperative agreement with NASA, enabling access to the space station for research and fostering growth in the low Earth orbit (LEO) economy. This partnership with NASA supports the ISS National Lab’s mission to advance space-based R&D, encourage a sustainable space economy, and support the development of future commercial LEO destinations (CLDs). The ISS National Lab’s annual report for fiscal year 2024 (Oct. 1, 2023-Sept. 30, 2024) updates these initiatives, including:
• Of the 103 ISS National Lab-sponsored payloads launched to the space station, 80% were from commercial entities, reflecting consistent participation by private industry in space-based R&D.
Of the 103 The International Space Station (ISS) National Laboratory-sponsored payloads launched to the space station, 80% were from commercial entities, reflecting consistent participation by private industry in space-based R&D, as reported in the FY24 annual report, released by the Center for the Advancement of Science in Space (CASIS). Courtesy: International Space Station (ISS) National Laboratory
• Nearly 75% of newly selected projects in FY24 were from organizations conducting space-based research for the first time, reflecting the effectiveness of ISS National Lab solicitations in engaging new research participants. Of the 31 selected projects, more than half were awarded through ISS National Lab Research Announcements (NLRAs) focused on technology development, in-space production applications such as tissue engineering and biomanufacturing and workforce development.
Cybersecurity profile for semiconductor manufacturing: Share your feedback
THE SEMI Semiconductor Manufacturing Cybersecurity Consortium (SMCC) and the National Institute of Standards and Technology (NIST) developed a semiconductor industry community profile for NIST Cybersecurity Framework 2.0 (CSF 2.0). Announced in September 2024, the profile provides semiconductor manufacturing cybersecurity guidelines. The comment period is Feb. 27 through April 14. NIST and SMCC seeks input from those involved in semiconductor supply chain security, such as cybersecurity professionals, equipment manufacturers, engineers, architects, operations professionals and professionals from fabs, fabless companies and semiconductor or electronic system providers. NIST expects to release the updated profile in Q3 of fiscal year 2025. Visit the National Cybersecurity
Center of Excellence (NCCoE) website and sign up for updates through the Community of Interest.
“NIST, in collaboration with industry leaders through SEMI and government agencies, has developed and is releasing a comprehensive framework designed to safeguard semiconductor manufacturing from emerging threats and vulnerabilities,” said Sanjay Rekhi, group leader of the Security Components and Mechanisms Group at NIST. “This initiative is part of a broader, multiyear effort to strengthen the security of critical infrastructure.” Read more. www.controleng.com/cybersecurity-profile-for-semiconductor-manufacturing-share-your-feedback Edited by Puja Mitra, WTWH Media, for Control Engineering, from a SEMI news release.
Private 5G network platform to accelerate manufacturing innovation
INDUSTRIAL cybersecurity and wireless communications are advancing in a technology partnership demonstration. Betacom, a provider of private wireless networks, has partnered with Siemens Industries. The companies have deployed a private 5G network platform at MxD (Manufacturing x Digital), the National Center for Cybersecurity in Manufacturing in Chicago. The platform is the first private wireless network to operate behind a Siemens firewall, showcasing secure enterprise solutions.
The platform shows how enterprises can:
• Set up private wireless infrastructure within their firewall
• Manage network operations and connected devices independently
• Support integration of Industry 4.0 applications
• Enhance security across OT and IT environments
Developed for Siemens U.S. manufacturing operations, the solution features:
• CBRS spectrum deployment in the coveted 3.55GHz – 3.7GHz range
• Security framework developed with the MxD Cybersecurity Institute
• Cybersecurity measures based on 3GPP standards
• Compliance with NIST framework and Zero Trust principles
• Betacom AirGap Protection for network segmentation
Industries benefiting from this private 5G solution include manufacturing, logistics, defense contractors and supply chain operations. Read more. www.controleng.com/ private-5g-network-platform-to-accelerate-manufacturing-innovation/
Edited by Puja Mitra, WTWH Media, for Control Engineering, from a Siemens news release.
Second robotics accelerator cohort selected from 130 global applicants
uMassRobotics, an independent robotics hub, has introduced the second cohort of the MassRobotics Accelerator, powered by the Massachusetts Technology Collaborative’s (MassTech) Innovation Institute. Following its inaugural program, the second cohort includes startups such as Haystack Ag, LiftLabs, Mito Robotics, Nexterity, p!ng, Redefine Surgery, ReviMo, Revolute Robotics, Tatum Robotics and Variable Machines.
Over the past two years, $2 million has been awarded to 20 robotics startups through this accelerator program. The program stands out for its equity-free funding model. Each participating startup receives a $100,000 non-dilutive grant from MassTech. The three-month accelerator program has begun, and the cohort will introduce their startups at MassRobotics’ annual
sponsor event. During the program, startups will participate in a curriculum covering topics such as customer discovery, value proposition discovery, manufacturing for excellence, fundraising tactics, and team management.
Since graduating, the 10 companies from the first program engaged with multiple customers, with 80% beginning to generate revenue.
Similar to last year, competition for the Accelerator was highly competitive, with an 8% acceptance rate. More than 130 startups applied from over 25 countries. The selection process was thorough, guided by a selection committee of experienced roboticists, entrepreneurs and academics.
The MassRobotics Accelerator will conclude with an Accelerator Showcase at the Robotics Summit & Expo April 30.
ONLINE/CALENDAR
New patent uses AI to help reduce process safety hazards - ARC Leadership Forum, 2025: Schneider Electric has a patent for artificial intelligence and process safety to help reduce hazards and enhance risk assessments. A Control Engineering interview adds insights. www.controleng.com/new-patent-uses-aito-help-reduce-process-safety-hazards
Control Engineering hot topics: February 2025 www.controleng.com/control-engineering-hot-topics-february-2025
How diamond transistors support high-power applications www.controleng. com/how-can-diamond-transistors-support-high-power-applications
PI North America: New resource lists distributors of automation products www.controleng.com/product/newresource-lists-distributors-of-automation-products
UPCOMING COVERAGE
Watch for more coverage on the following events at www.controleng.com.
• Promat 2025, March 17-20, Chicago www.promatshow.com/home
• Trihedral SCADAfest, Orlando, March 19-21, https://scadafest.com
• Advanced Automation Forum online www.advancedautomationforum.com
• Aveva World 2025, San Francisco, April 7-10, https://events.aveva.com/aw-2025
• Automate, A3, Detroit, May 12-15, https://www.automateshow.com
• Emerson Exchange, San Antonio, May 19-22 www.emerson.com/en-us/automation/events/emerson-exchange/2025/ about-exchange
Read more. www.controleng.com/second-robotics-accelerator-cohort-selected-from-130-global-applicants ce
Edited by Puja Mitra, WTWH Media, for Control Engineering, from a MassRobotics news release.
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Sheri Kasprzak, managing editor, engineering, automation and control, SKasprzak@WTWHMedia.com
Stephanie Neil, vice president, editorial director engineering, automation and control, 508-344-0620 SNeil@WTWHMedia.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
Eric J. Silverman, PE, PMP, CDT, vice president, senior automation engineer, CDM Smith, www.cdmsmith.com Mark Voigtmann, partner, automation practice lead Faegre Baker Daniels, www.FaegreBD.com
WTWH Media Contributor
Guidelines Overview
Content For Engineers. WTWH Media focuses on engineers sharing with their peers. We welcome content submissions for all interested parties in engineering. We will use those materials online, on our Website, in print and in newsletters to keep engineers informed about the products, solutions and industry trends.
* Control Engineering Submissions instructions at https://www.controleng.com/connect/how-to-contribute gives an overview of how to submit press releases, products, images and graphics, bylined feature articles, case studies, white papers and other media.
* Content should focus on helping engineers solve problems. Articles that are commercial in nature or that are critical of other products or organizations will be rejected. (Technology discussions and comparative tables may be accepted if nonpromotional and if contributor corroborates information with sources cited.)
* If the content meets criteria noted in guidelines, expect to see it first on the website. Content for enewsletters comes from content already available on the website. All content for print also will be online. All content that appears in the print magazine will appear as space permits, and we will indicate in print if more content from that article is available online.
* Deadlines for feature articles vary based on where it appears. Print-related content is due at least three months in advance of the publication date. Again, it is best to discuss all feature articles with the content manager prior to submission. Learn more at: https://www.controleng.com/connect/how-to-contribute
Think again about "The State of Industrial Automation," 2025
Spring research report takes a fresh look at industry trends and outlook. Watch for related coverage throughout the year.
The State of Industrial Automation report, spring 2025, analyzes how this dynamic sector is reshaping industries worldwide. This report offers Control Engineering survey results and data analysis, with actionable insights for manufacturers, technology vendors and policymakers striving to thrive in an era of rapid technological change. The automation industry continues to be defined by innovation and pragmatism. Below, see research methods, demographics for the report.
Automation investments
Why invest in automation?
The key drivers (respondents could select up to three) behind automation investments highlight operational efficiency and cost reduction (69%), alongside priorities like product quality and consistency improvements (45%) and safety enhancements (37%). Standards for digitalization, efficiency, interoperability and regulatory compliance (17%) are motivators, along with environmental sustainability (12%) and supply chain resilience (4%), indicating positive business benefits of global climate commitments and the need for robust, responsive operations.
Investments in foundational technologies like sensors and control systems dominate priorities with 52% of survey respondents investing in each as organizations seek operational reliability and real-time data insights. Fewer than 35% of those surveyed are investing in motion control systems, robotics, edge computing, embedded components or mobile devices, at present, perhaps reflecting concerns over return on investment (ROI) and system integration challenges. Vendors can address these hesitations by demonstrating cost-effectiveness and seamless interoperability with existing systems. More than half of respondents (60%) choose moderate, steady adoption of “new automation technologies” with an ROI focus. The 28% characterizing themselves as conservative automation adopters (risk averse, minimal adoption) may see budget constraints and perceived complexity as barriers (see barriers, below). However, the 12% of survey respondents who identify as aggressive early adopters of leading-edge automation demonstrate willingness to accept some risk to achieve competitive advantages.
Methods, demographics
In the January email survey of Control Engineering subscribers, 122 responses were received, including 104 complete responses for a margin of error of plus or minus 8.9%. Respondents include 45% end-user engineers or system integrators, and more than three-quarters were from locations with fewer than 250 people. Chat GPT assisted in shaping this report. ce
Mark T. Hoske is editor-in-chief, Control Engineering, WTWH Media, mhoske@wtwhmedia.com.
With this column online, read more from the Control Engineering “The State of Industrial Automation” 2025 report. Download the full report at https://www.controleng.com/research.
Related trends: Research: Hot topics in Control Engineering for 2024 https://www.controleng.com/ research-hot-topics-in-control-engineering-for-2024
Mark T. Hoske Control Engineering
INSIGHTS
Latest automation mergers, February 2025: AI, robotics, sensors
The Bundy Group reported 15 automation transactions in a February 2025 summary. Acquisitions and reports include Ace Controls, Ati Motors, Motion Industries, RMH Systems and others
Bundy Group, an investment bank and advisory firm that specializes in the automation segment, provides an update on mergers and acquisitions and capital placement activity, with 15 February 2025 report transactions, involving Ace Controls, Bonsai Robotics Inc., Motion Industries, RMH Systems, SensorLogic and Zebra Technologies, among others. Technologies involved include AI, manufacturing robotics, sensing and others. Some follow. See more online.
Motion Industries Inc. has signed a purchase agreement to acquire the net operating assets of Thompson Industrial Supply Inc. The company distributes bearings, gear reducers, motors, hydraulics, industrial automation and pneumatics, along with fabrication, gearbox modification and custom hydraulic hose fabrication.
Rotunda Capital Partners acquires RMH Systems, Feb. 11
Rotunda Capital Partners has invested in RMH Systems, a provider of material handling, packaging and automation solutions. The partnership, formed with the Howard family and existing leadership, positions RMH for accelerated growth and expanded market reach. RMH provides material handling, packaging equipment and consumables, robotics and related MRO services.
McNally Capital acquires Jewett Automation, Feb. 11
McNally Capital, a private equity firm
specializing in founder-, family-, and management-owned businesses in the lower middle market, has announced an investment in Jewett Automation. Jewett Automation is a leading manufacturer of filtration equipment and custom automation solutions, specializing in engineered manufacturing and robotic systems for complex industrial applications.
Bison Ventures funded Bonsai Robotics, Jan. 28
Bonsai Robotics Inc., a leader in physical AI solutions for agriculture, has raised $15 million in Series A funding, led by Bison Ventures with participation from Cibus Capital and existing investors. The funding will support enhancing software, expanding an AI platform, driving original equipment manufacturer partnerships and accelerating commercialization.
Blackford Capital, Ace Controls, Jan. 27
Blackford Capital, a leading lower middle market private equity firm, acquired Ace Controls, that designs and builds industrial control panels. This acquisition expands Blackford’s Industrial Automation Platform, PACIV, to serve a wider customer base.
Walden Catalyst Ventures & NGP Capital, Ati Motors, Jan. 23
Ati Motors raised $20 million in Series B funding led by Walden Catalyst Ventures and NGP Capital, with participation from other investors. Ati Motors specializes in AI, robotics and manufacturing, with hundreds of Sherpa robots deployed across 40 top manufacturers, including Forvia and Hyundai.
Zebra Technologies have acquired Photoneo, a leader in 3D vision and AI robotics. Photoneo specializes in robotic vision sensors and intelligence software, powered by its patented parallel structured light technology. The acquisition enhances Zebra Technologies' portfolio with advanced, high-resolution and fast solutions that integrate seamlessly with many top robotic manufacturers, particularly in robot-arm applications.
Creandum, Point Nine & Air Street Capital, Sereact, Jan. 20
Sereact has secured 25 million euros in Series A funding to advance AI-driven robotics. The round was led by Creandum, with participation from Point Nine, Air Street Capital and other investors.
R.M. Young Company acquires SensorLogic, Jan. 17
Benford Capital Partners and its portfolio company, R.M. Young Company, have acquired SensorLogic Inc., a provider of radar-based sensors for environmental applications. ce
Clint Bundy is managing director, Bundy Group, which helps with mergers, acquisitions and raising capital. Edited by Mark T. Hoske, editor-in-chief, Control Engineering, WTWH Media, mhoske@wtwhmedia.com.
How to mitigate automation risks with a system integrator
Consistent, high-quality automation project outcomes do not happen by accident. The system integrators behind them execute on formalized, documented procedures and methodologies through a project’s progression.
Automation projects undertaken in today’s complex industrial manufacturing environment often carry significant risk. Manufacturers looking to implement new automation or update existing systems face a host of potential system integrators eager to bid on their projects.
However, identifying an integrator who can minimize project risks, consistently design and implement solutions that meet or exceed a client’s needs and deliver on time and within budget can be daunting. These three indicators of a project’s overall success — effective, well-designed functionality; timely completion; and remaining within budget — collectively measure the overall quality of the system integrator. Integrators who embed structured quality assurance processes into their workflow are inherently better equipped to reduce project risks and significantly improve the chances of delivering effective solutions to their clients.
Manufacturers might find identifying and selecting a skilled system integrator committed to delivering high-quality results to be a daunting task. But there are essential characteristics of a high-quality project that outlines the fundamental methodologies that effective system integrators embed into their workflows to ensure positive outcomes.
How to define a high-quality project
At its core, a high-quality system integration project delivers the right functionality to fully address the original issues faced by the manufacturer and is strategically designed with future scalabil-
ity in mind. It is delivered on budget and schedule. Conversely, a poor-quality project fails to meet the above results. Instead, the manufacturer faces unmet promises. An inadequate solution won’t resolve the original problem or operate as expected, causing unexpected delays, which may impact production plans and add additional expense due to an expanding project timeline and scope. Code may also need to be rewritten to mitigate unresolved issues.
Manufacturers commonly prioritize a bidder’s overall cost when choosing a system integrator for a project, but it’s more expensive to fix a system that was poorly designed from the start than investing in an integrator equipped to deliver the right solution the first time.
Most manufacturers can identify the markers of a high-quality project delivery. However, identifying the traits of integrators who consistently achieve these results is more nuanced. Consistent, high-quality project outcomes don’t happen by accident. The integrators behind them execute upon their own formalized, documented procedures and methodologies throughout the entirety of a project’s progression. Because they recognize the value of their own quality management programs, these integrators will include verbiage pertaining to quality into their companies’ core values and mission statements.
CSIA-certified system integrator
One overarching way a manufacturer can ascertain that they are working with a reputable integrator is to choose one that is CSIA-certified. The Control System Integrators Association (CSIA) is a nonprofit organization whose goal is to foster the
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KEYWORDS: Automatoin projects, system integration, system integrators ONLINE www.controleng.com/ system-integration CONSIDER THIS Why are you delaying needed automation?
LEARNING OBJECTIVES: Understand the characteristics of a high-quality solution. Learn the key methodologies for consistency. Be able to identify the right partner
ANSWERS
‘Each stage of a project should involve multifaceted reviews to ensure engineers progress towards the intended deliverable.
continuous improvement of the standards of service within the control system integration industry. While all CSIA system integrator members have access to their industry standard CSIA Best Practices and Benchmarks Manual, only those that obtain certification have gone through a rigorous third-party audit process to prove that all facets of their business meet CSIA’s standards for quality, reliability and performance. Auditors review the methodologies a system integrator has both documented and implemented that show the association’s best practices in action. Some of these best practices are outlined below.
Methodologies add quality
There are methodologies used by system integrators that consistently obtain high-quality project outcomes. These are the most important methodologies a prospective client should consider when selecting a partner to complete a project. These include the following.
A consultative approach for the project’s definition
A skilled integrator will act as a partner and consultant to their clients by taking the time to understand the long-term, high-level plans for their operation. With this knowledge, the integrator can design a solution that can later be scaled to meet these future growth plans, maximizing the benefits.
For any project, it is important that both the system integrator and their customer mutually agree on the key markers that define its success. An integrator that is committed to a high-quality outcome will invest a significant amount of time collaborating with the client at a project’s outset to define and detail the functional requirements of the proposed solution. These metrics inform both parties of a project’s scope and ensure that the system designed by the integrator fully addresses the client’s needs.
However, a manufacturer may understand the problem or challenge they face, but they may not always know the full scope of the solution that best addresses it. An integrator who is committed to a high-quality outcome will employ a flexible approach to the management of this type of project. Rather than fixating on the limited project scope they may have been provided, they will ask further questions of the manufacturer to obtain a thorough understanding of their needs. The integrator may hold more frequent review and planning meetings with the client so that both parties agree on the project’s best steps forward.
Regular technical reviews
Each stage of a project’s progression should involve multifaceted reviews to ensure engineers progress towards the intended deliverable. The reviews should involve multiple people, including:
• Those with expertise in the actual systems under design
• Those with expertise in the process to which the control system is being applied
• The entire development team to ensure all aspects of the project remain streamlined and aligned with project goals
Additionally, it’s helpful to include someone in the review process who is not intimately involved in the project. This person is best suited to providing the bigger picture, which helps mitigate the potential issue of tunnel vision that can occur when only those embedded in the project are involved in its review.
Regular project audits
Alongside ongoing technical reviews, project
managers need to regularly audit the project to ensure it remains on track with schedule and budget commitments.
System verification
Integrators who ensure a high-quality outcome have documentation outlining their verification methodology. This documentation will include the platforms and tools that will be used to verify that the project meets internal standards and recognized industry standards established by relevant organizations including the International Society of Automation (ISA), the National Fire Protection Association (NFPA), the International Electrotechnical Commission (IEC) and more. They will also maintain checklists that allow them to ensure rigorous verification of the functionality at different phases of the project.
A skilled system integrator will use simulation tools to perform an internal simulated factory acceptance test (FAT) that fully exercises the functionality of the code they developed, ensuring all aspects of the project’s specifications are met. Once the internal FAT is completed, the client is invited to verify the functionality themselves prior to installation. These steps ensure that once installation occurs onsite, there are few or no surprises. The client’s quality objectives and the specifications of the process are met.
Consistent, open communications
A project’s proposal will include formalized review meetings at specific milestones along its progression. For example, client-integrator review meetings may be scheduled for 30%, 60% and 90% completion. These meetings allow the client to remain fully informed about all facets of its progress, including the timeline, budget and ongoing technical development and challenges. For system integrators, they help ensure their client remains informed and is satisfied through every step of the process. Furthermore, these integrators have structured their personnel such that there is always someone who can provide clear answers to any client questions or concerns.
Technical expertise and training
Reputable system integrators know that high-quality project outcomes require engineers
and project managers with the skillsets and qualifications to implement the solution. They ensure their team has the technical expertise, qualifications, initiative and commitment to complete the work effectively.
Case studies on the integrator’s process
An integrator focused on a high-quality outcome will have examples or case studies of previously completed successful work in addition to client references. The case studies will outline how the integrator’s methodologies effectively result in high-quality outcomes.
Dedication to continuous improvement
It’s important to note that a skilled integrator is committed to continuous improvement. They are always learning and adjusting their methodologies accordingly. When a project doesn’t go as planned, these integrators will conduct detailed reviews to understand why they fell short and how to prevent similar issues in the future, including methods to support established quality practices.
Choosing a system integrator for success
By selecting an integrator who consistently practices their own well-documented procedures — from thorough project definition and regular technical reviews to systematic functional verification — manufacturers set themselves up for reliably successful outcomes. The methodologies outlined above contribute to reducing risk, increasing transparency and ensuring a project’s functionality, timeliness and budgetary integrity.
Manufacturers benefit from partnering with system integrators who employ careful planning, expertise and continuous improvement to achieve high-quality automation outcomes that effectively address their operational needs and deliver real value. ce
Hargrove Controls & Automation is a Control System Integrators Association (CSIA)-certified system integrator.
Jody Poirier, PE, is an engineering leader with Hargrove Controls & Automation. Edited by Sheri Kasprzak, managing editor, Automation & Controls, WTWH Media.
‘
Simulation tools are used to perform an internal simulated factory acceptance test (FAT) that fully exercises the functionality of the code the system integrator developed, ensuring all aspects of the project’s specifications are met.
’
Insightsu
System integrator selection insights
u A high-quality system integration project properly addresses the issues faced by manufacturers and is designed with future scalability in mind.
u It is critical that the system integrator and their customer mutually agree on what defines a project’s success.
ANSWERS
Mark T. Hoske, Control Engineering
New insights: 100-controller ExxonMobil Open Process Automation
ARC Industry Leadership Forum, 2025:
ExxonMobil runs Open Process Automation (OPA) system in a large-scale Lighthouse Project, with 1000 I/O and 100 controllers at a resin finishing plant in Baton Rouge, providing reliable interoperability, without glitches.
AKEYWORDS: Open Process Automation, ExxonMobil OPA Lighthouse Project
LEARNING OBJECTIVES
Explore Open Process Automation (OPA)
ExxonMobil Lighthouse Project, 100 controller, 1000 I/O project, architecture, migration, startup and benefits were described at the ARC Industry Leadership Forum.
Learn about the OPA ExxonMobil Lighthouse Project, architecture, and compare to migrating a distributed control system (DCS).
Understand additional OPA information, timelines, and artificial intelligence (AI) integration.
CONSIDER THIS
Are you requiring Open Process Automation in your next request for proposal?
new ground-up process control system is operating with more than 100 controllers and 1000 input/output (I/O) points at the ExxonMobil Resins Finishing Plant in Baton Rouge, Louisiana, using the Open Process Automation Standard (O-PAS), as described at the 2025 ARC Industry Leadership Forum by ARC Advisory Group. The open architecture, standards-based system and its hardware and software components are “replaceable, interchangeable and interoperable,” said David DeBari, R&D team leader, ExxonMobil (Figure 1), followed by substantial spontaneous audience applause. Ideas for the effort emerged 16 years ago, and the first OPA prototype and test bed was five years ago (Figure 2).
OPA ExxonMobil Lighthouse Project, architecture
In addition to interoperability, O-PAS separates hardware and software, so, like information technology (IT) systems, incremental upgrades can be made over time on the fly, rather than often only during a large-scale distributed control system (DCS) upgrade every 20 to 30 years. Last year, those involved cited a 52% OPA hardware and soft-
ware savings compared to traditional DCS.
The architecture for the ExxonMobil Lighthouse Project resin plant (Figure 3) has a control room operator console, advanced computing platform (infrastructure services, historian, advanced control and optimization, engineering tools, IEX 61499 runtime application and server for the human-machine interface [HMI]), multiple distributed control nodes (DCN) compute resources with IEC 61499 runtime applications all connected to an OPA connectivity framework. A DCN with a local I/O device connects to the OPA connectivity framework and marshalling to field devices. Other network I/O connect to the OPA connectivity framework and to marshalling and field devices also. In the process area, instead of connecting through marshalling, a DCN local I/O device and network I/O each connect to field devices through junction boxes.
Harry Forbes, research director, ARC Advisory Group, praised the OPA efforts and called on more end users to require Open Process Automation in requests for proposals (RFPs).
OPA ExxonMobil Lighthouse Project, architecture
The Lighthouse Project clears the way for more commercial installations of O-PAS, DeBari said, who called it a group effort beyond ExxonMobil because of involvement from Open Process Automation Forum (OPAF; more than 100 members, part of The Open Group), including Shell, DuPont, Yokogawa and Supcon, among others. The implementation timeline and results was rigorous, but not perfect, DeBari said. On Aug. 28, 2024, during an extensive factory acceptance test, it took operators all of six minutes to find the first mistake. Work continued and on Nov. 18 (ahead of schedule), first sold production was produced. Feb. 12,
FIGURE 1: Audience applause followed the announcement that ExxonMobil Resins Finishing Plant in Baton Rouge, Louisiana, is operating using the Open Process Automation Standard (O-PAS), as described at the 2025 ARC Industry Leadership Forum by ARC Advisory Group. From left, ExxonMobil speakers on the “replaceable, interchangeable and interoperable” system are: David DeBari, R&D team leader, ExxonMobil; (Toriano) Tito Jackson, ExxonMobil, operator; Dave Hedge, ExxonMobil technology and engineering; and Kelly Li, ExxonMobil, commercial lead. All images courtesy: Mark T. Hoske, Control Engineering
2025: Stable operation has continued since, and operators are happy: (Toriano) Tito Jackson, ExxonMobil, operator (Figure 6) using OPA in Baton Rouge, was confident enough to leave the plant and get out of town after years of being close by in case a DCS on-site needed help.
OPA differences compared to migrating a DCS
Dave Hedge, ExxonMobil technology and engineering, (Figure 7) who’s worked through 21 process control system conversions, said the project phases using O-PAS v2.1 include preparation, engineering and manufacturing operations experiences (Figure 8). Hedge said OPA transition benefits include:
• Skill building for internal and ecosystem capability
• Cybersecurity – IEC/ISA 62442, role-based access control (RBAC)
• Automating the automation system
• OPC UA for control communications
• Advanced computing platform, an operational technology (OT) data center, small to extralarge, with good, better and best, containerized software.
• IT technology in the OT space – Linux, mesh networks, firewall rules, virtual local area networks (VLANS), and more.
• Ability to install and run controller in less than 20 minutes.
• lug-and-play reality.
Next OPA project for ExxonMobil
Kelly Li, ExxonMobil, commercial lead (Figure 9), with the company for 19 years, said ExxonMobil is working on more commercial deployments of open, secure and standard-based systems. The company is seeking to use commercially available products for the OPA vision. She expects PLC and supervisory control and data acquisition (SCADA) projects next.
Li added: “I’m excited to see the future impacts. I call on other end users, suppliers and system integrators to move into the future to realize the benefits of lower TCO for deployment in field. We need more deployments.”
FIGURE 2: The diagram shows the Open Process Automation architecture (advanced computing, distributed control nodes, networking, I/O and field device connections) for the ExxonMobil Lighthouse Project resin plant at the 2025 ARC Industry Leadership Forum by ARC Advisory Group.
ANSWERS
FIGURE 3: The Open Process Automation Forum Lighthouse Project implementation timeline was rigorous, but not perfect, said David DeBari, R&D team leader, ExxonMobil, at the 2025 ARC Industry Leadership Forum by ARC Advisory Group.
4: Dave Hedge, ExxonMobil technology and engineering, said automation is necessarily changing from closed to open architectures in industrial automation, as he outlined the past, present and future evolution of process automation toward open architectures, at the 2025 ARC Industry Leadership Forum by ARC Advisory Group.
OPA Forum roadmap
Jacco Opmeer, Shell, representing the OPA Forum, outlined other 2024 major achievements in a roadmap. The idea for the standard is that automation should be plug and play, like USB, Opmeer said. Incremental updates will be in edition 2, V2.1, Opmeer said, such as:
• Security, OPC FX
• Architecture and hardware updates
• AutomationML portability
• Orchestration – management of O-PAS components.
How end-users benefit from the ExxonMobil Lighthouse Project
Dave Emerson, Yokogawa, and co-chair of enterprise architecture of the OPA-S working group, said end-users from around the world have been interested in Lighthouse Project benefits because of many commonalities at their facilities, including:
‘Interoperability, interchangeability, modularity and flexibility are key drivers for rethinking process automation applications.’
• Brownfield obsolescence, end of life issues, obtaining new technology value.
• Greenfield: New facilities and new processes need new architectures. Many seek ways to feed artificial intelligence (AI) applications with more content. Applications can create new value with O-PAS to get attention quicker.
• Lowest total cost of ownership (TCO): There’s lot of interest in gaining value over longer time scales.
• Interoperability, interchangeability, modularity and flexibility are key drivers for rethinking process automation applications. ce
Mark T. Hoske, editor-in-chief, Control Engineering, WTWH Media, mhoske@wtwhmedia.com.
FIGURE
No other platform manages redundancy better.
ANSWERS
Claudio Fayad, Emerson
The future of automation lies beyond a system-of-systems approach
An enterprise operations platform evolved from the control system creates efficient and future-proof automation.
Most process manufacturers have approached automation the same way for decades. Following the Purdue Model, implementation teams have isolated the control system on its own layers. The control layers were built, updated and maintained for purpose, with little to no interaction with other layers of operations. In isolation, the distributed control system (DCS) performed its role reliably, but if it could be elevated to a platform that integrates all functionality required to automate industrial operations, it could become the key component of a future-proofed operation.
As industrial process operations have evolved — particularly in the last decade — many organizations have seen their current strategy stall their ability to digitally transform operations. When isolated, the DCS does not scale well, nor does it pair as well as it could with other critical automation solutions.
Moving beyond a DCS
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KEYWORDS: Open automation, beyond DCS ONLINE
For related links, see: https://www.controleng.com/ the-future-of-automation-liesbeyond-a-system-of-systemsapproach
CONSIDER THIS Whats important in your next process control system?
Implementing new technologies and strategies requires either breaking into the control layer or finding a way to push data out of that layer to other systems and solutions. It can be done, but it takes lots of time and money, as well as a deep bench of dedicated, expert personnel to engineer and maintain the automation system.
This increasing complexity has brought the DCS to an inflection point. As new automation innovations continue to emerge, with an increasing need
to consume data from across the automation stack, automation solution providers and process manufacturers alike have discovered a need to develop enterprise operations platforms that enable data handling across a wide array of applications. There are two primary ways to implement such a platform: as a system of systems with each component connected to each other in a web of interfaces and protocols or by evolving the DCS into the enterprise operations platform.
System-of-systems approach
Today, many organizations follow the system-of-systems approach to developing an enterprise operations platform. These teams select efficient and cost-effective solutions for each automation function and integrate them after the fact. Modern protocols such as Open Platform Communication Unified Architecture (OPC UA), Message Queuing Telemetry Transport (MQTT) and others have made this easier in recent years.
This solution, although feasible, comes with several drawbacks. Such systems can be tremendously difficult to scale. When an engineer makes a change to the DCS — adding a new sensor, replacing or upgrading equipment, implementing new alarms and alerts, etc. — those changes have cascading effects across the system of systems. The engineer may need to reconfigure OPC UA, adjust alarm management, reconfigure a connection to the historian, update asset models to account for new parameters and perform other time-consuming tasks.
In many cases, engineering teams don’t feel the changes are worth the additional work, so unless organizations are highly motivated to continuously digitally transform their operations, system-of-system solutions often stagnate for years or decades.
Moreover, even if teams stay on top of their changes, the data coming out of the DCS for use in other systems is often low- or no-context data. Therefore, teams need to do even more manual work in the individual systems to rebuild context and make the data useful.
Beyond a system-of-systems approach
In contrast to the system-of-systems approach, an emerging strategy for building an enterprise operations platform is evolving the already natively integrated DCS to create a more efficient solution. When the control system evolves into a seamlessly integrated operations platform, its functionality shifts. Process control is simply one function of the platform, as are advanced control, data historization, alarm and event management, reliability, data analytics, safety, compressor controls and more. Instead of being focused on process control, the center of the enterprise operations platform is data integrity, availability and security (Figure).
Such a system offers more seamless integration and easier management. The DCS — the largest container of data in the automation platform — is positioned to be seamlessly integrated with all other automation solutions as they are added. New solutions will connect out of the box, with data moving efficiently and effortlessly between them. With a built-for-purpose enterprise operations platform evolved from the DCS, context is preserved as data moves from one system to another. Critical information can be consumed at every level and then used to generate actionable insights for innovation, maintenance, efficiency and sustainability improvements and more.
Integrated automation benefits
Moreover, because the systems are seamlessly integrated, a single change anywhere in the operations platform does not require hours of engineering effort to maintain integration. Solutions designed as part of the platform are integrated out of the box and changes will seamlessly cascade across the environment as part of its core functionality.
This new approach will also need to account for connecting legacy automation to the new enterprise operations platform to protect existing investments. This integration will likely still require some custom engineering, potentially aided by AI agents, as such solutions were not designed with seamless automation integration in mind.
Once the process is complete, replacing old technologies (and adding new ones) with modern technology will no longer require replacement of the core automation infrastructure. New technologies will be add-ons and seamlessly integrated into the enterprise operations platform stack.
How to futureproof automation
As organizations modernize their automation stack to pave the way for new technologies like artificial intelligence (AI), Ethernet-Advanced Physical Layer (APL) and more, they are seeking ways to futureproof their investments. Ideally, these efforts would capture the benefits of the newest technologies and eliminate the need to rip and replace infrastructure as new solutions emerge. The enterprise operations platform is an ideal path to that futureproofed automation stack, especially if it is developed as an evolution of the DCS. The traditional system-of-systems approach to platform design will increasingly show limits as new technologies become critical enablers of competitive advantage. A platform evolved from the DCS will continue to evolve, providing teams with more integration and efficiency and increased operational excellence, with less engineering effort. ce
Claudio Fayad is vice president of technology of Emerson’s Process Systems and Solutions business. Edited by Sheri Kasprzak, managing editor of Automation & Controls, WTWH Media, skasprzak@wtwhmedia.com.
FIGURE: In an enterprise operations platform built around the distributed control system (DCS), the focus is on is data integrity, availability, scalability and security Courtesy: Emerson
‘
Seek the benefits benefits of the newest technologies, while eliminating the need to rip andww replace infrastructure as new, critical solutions emerge.
’
Insightsu
uAutomation solution providers and process manufacturers need to develop enterprise operations platforms that enable data handling across a wide array of applications.
uA system-of-systems approach is incredibly difficult to scale.
uAn enterprise operations platform is an ideal path to a futureproofed automation stack, especially if it is developed as an evolution of the distributed control system.
ANSWERS
Ed Bullerdiek, process control engineer, retired
PID spotlight, part 15: Open loop tuning of near integrating processes
Slow, self-limiting processes can be very time-consuming and difficult to tune. However, a self-limiting process with a high lag/deadtime ratio looks a lot like an integrating process. We can tune these processes as if they are integrating processes, treating them like nearintegrating processes.
How can we use integrating process open loop tuning methods to tune certain self-limiting processes, so called nearintegrating processes?
step testing time up to 90%.
There are some caveats. Since we don’t determine a process gain or process lag, the tuning constants we calculate can be poor estimates, which is why we have heuristic methods to trim up the tuning. However, the increase in speed at getting results can be a good tradeoff. This process only works on high lag/deadtime ratio processes. High lag/deadtime ratio processes are stable even if the controller gain is five, 10 or more times the baseline controller gain (the inverse of the process gain). Since we don’t know the process gain, we cannot know what the controller gain stability limit might be. Therefore, we should only use this on a process where it is unlikely we will cause instability.
Open loop tuning method for near-integrating processes
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KEYWORDS: PID, open-loop tuning
ONLINE
Link to PID spotlights, parts 1-14 and a webcast with this article online... www.controleng.com/pidspotlight-part-15-open-looptuning-of-near-integratingprocess
...starting with “Three reasons to tune control loops: Safety, profit, energy efficiency.”
CONSIDER THIS
Can we speed up the tuning of a slow self-limiting process by pretending it is an integrating process? Why does this to work? What are the potential pitfalls? How much time can we save?
What is a near-integrating process?
A near integrating process is a self-limiting process with a high lag/deadtime ratio. Processes with a high lag/deadtime ratio are often very slow. Lag times can be many minutes or hours. These are difficult to tune using self-limiting process open loop tuning methods. It takes a lot of time for the process to come to steady state after a step test, and there is a high likelihood that a process disturbance will ruin the step test. Getting good step test results is time-consuming and prone to error, therefore there is a strong incentive to develop a faster method. This is where using integrating process open loop tuning comes in handy. A slow, high lag/deadtime ratio self-limiting process looks a lot like an integrating process in the short term. We only need to run the step test long enough to get the initial slope of the process response, which can shorten
The open loop controller tuning method is done with the controller in manual mode. This is when a controller is in manual it is operating in open loop.
The method is:
• Place the controller in manual.
• Step the controller output (OP) up or down 2-10%.
• From trends estimate the
• The change in OP (ΔOP – %).
• The slope of the process variable (PV) after the change (ΔPV/time – %/minute).
• The apparent deadtime (Dt – minutes).
• Calculate the tuning constants using your favorite calculations.
We are assuming the effect of any process lags can be ignored. We are only interested in the effective deadtime that any lags create.
The instructions are like open loop tuning of an integrator. The one difference is the PV slope before stepping the OP is zero; the process is at steady state. If you believe that another step is necessary, you should wait until the process has come to steady state.
What an open loop step test looks like
Figure 1 shows an open loop step test of a self-limiting process with a process gain (Kp) of 2, two lags of 10 seconds, one lag of 180 seconds and no deadtime. This has a high lag/deadtime ratio and therefore can be treated as a near integrating process. We are only looking at the first three minutes of the step test because that is all we need to gather the information required for our calculations.
The near integrating process open loop tuning method uses this procedure.
STEP 1: Place the controller in manual.
STEP 2: Verify the process variable (PV) is moving in a straight line.
STEP 3: Step the controller output (OP).
STEP 4: Estimate the change in PV slope and deadtime from the process reaction curve (read them off the trend).
STEP 5: Write down the ΔOP, the maximum ΔPV/ minute rate and the deadtime (Dt):
• ΔOP = 5%
• Max ΔPV/min = 2.5%/min
• D t = 0.25 minutes.
STEP 6: Calculate the near integrator process gain (Kp):
K p = Max ΔPV/min / ΔOP
K p = 2.5 / 5
K p = 0.5%/min
From here we can calculate a pseudo fill time (Tfill):
Tfill = 1/Kp
Tfill = 1/0.5
Tfill = 2 minutes/%
FIGURE 1: Estimating the three parameters required for near integrator open loop tuning of a high lag/deadtime ratio self-limiting process with a process gain (Kp) of 2.0, three lags (T1, T2, T3) of 180, 10 and 10 seconds each and no deadtime (Dt). Note multiple lags create an apparent deadtime of 15 seconds. All graphics courtesy: Ed Bullerdiek, retired control engineer
STEP 7: Calculate and test.
Calculating tuning constants
A concept critical to several loop tuning methods is arrest time (λ). Those of you who have worked with lambda tuning will recognize the Greek letter λ. Lambda is used in multiple tuning methods to allow controller response to be customized. With integrating processes, lambda is the time to stop a process upset (in the time scale the control system uses for tuning, which for us is minutes). Table 1 contains the lambda tuning rules for integrating processes.
Key to using any of these tuning methods is understanding the limitations on λ. You can’t arrest
‘A slow, high lag/ deadtime ratio self-limiting process looks a lot like an integrating process in the short term.’
Insightsu
Near integrating process controller tuning insights
uSlow self-limiting processes with high lag/ deadtime ratios (aka nearintegrating processes) can be tuned using open loop integrating process tuning methods. This can reduce loop tuning time up to 90%.
uThe open loop tuning method for near integrating processes is nearly identical to the method for integrating processes. The one difference for near integrators is the process must be at steady state before starting the test.
uThe (pseudo) fill time to deadtime ratio must be checked to verify the calculated tuning constants will be stable.
uThe calculated tuning constants may not be ideal and require further modification to achieve best response.
ANSWERS
the effects of a process disturbance faster than the process deadtime or for some time after the deadtime has passed. Therefore, there is a limitation on λ:
λ >= 3 * D t
You may choose to go higher but setting λ lower risks controller instability.
The self-limiting process gain (Kp) isn’t used to calculate the tuning constants. The implicit assumption is that lag dominant processes can accommodate a controller gain higher than any we will calculate using this method.
Validating the calculation method
Since we step tested a process with a pseudo fill time of 2.0 minutes/% and an apparent deadtime of 0.25 minutes, let’s see how the calculations turn out. The minimum permitted λ is:
λ = 3 * 0.25
λ = 0.75
This is the most aggressive setting. We should expect the tuning to minimize the disturbance arrest time but at the cost of a strong response to setpoint changes, oscillation and potential instability.
1: Lambda integrating process PI tuning constant calculations for proportional-integral (PI) controllers.
TABLE 2: Calculating aggressive lambda integrating process PI tuning constants for a near integrating process with a pseudo fill time (Tfill) of 2.0 minutes/% and an apparent deadtime (Dt) of 0.25 minutes.
The calculated tuning constants are shown in Table 2:
Another thing we should do is calculate the fill time/deadtime ratio to verify that we should not expect stability issues. In this case the ratio is:
Tfill/Dt = 2.0 / 0.25
Tfill/Dt = 8.0
From PID spotlight part 13, in Figure 1 it looks like the process will be stable with a controller gain up to about 10. The controller gain for disturbance rejection tuning will be in the vicinity of 5. Therefore, we shouldn’t expect any stability issues with a controller gain of 3.5.
We would be remiss if we didn’t estimate the time savings we achieved by treating this as a near-integrating process. The step test in Figure 1 yielded all the information we needed in about two minutes. The time for an open loop step test to come to steady state is nominally four times the dominant lag, which in this case is three minutes (T1 = 180 seconds). It would have required a minimum of 12 minutes to estimate the process gain. We saved at least 10 minutes or about 85% of the time to perform a full open loop step test.
The only question remaining is: Do these tuning constants work? In figure 2 we see that the controller tuning is aggressive but stable. Not surprisingly a controller gain of 3.5 causes the controller output (OP) to hit 100% on a setpoint (SP) change. The remainder of the response to the setpoint change is oscillatory. The response to a load disturbance is very quick. It appears the "arrest time" is a little more than 0.75 minutes after the deadtime has passed, which is the chosen value of λ.
The method looks like it works reasonably well even though we do not have a process gain or lag time constant to work with. This looks close to disturbance rejection tuning. If we were looking for critically damped tuning, we would use heuristics to estimate new tuning constants.
Open loop tuning, near integrators
Slow control loops should have a flow cascade secondary. The flow secondary will eliminate flow disturbances and will eliminate poor controller performance caused by valve problems. If there isn’t a
TABLE
secondary flow controller, it’s important to check for valve problems before tuning the controller. You won’t have an opportunity to stack the recommended three steps close together because the process, for best results, should be permitted to line out after each step. This eliminates the potential time savings from using the integrating process open loop tuning method.
Open loop tuning limitations
Bad valves will warp the results. Estimated process gain can be wildly inaccurate, especially with small step sizes. Deadtime may also appear variable based on valve response.
Lambda, near-integrating processes
Treating a very slow lag dominant self-limiting process like an integrator can reduce tuning time by up to 90%. The tuning method does not identify the steady-state process gain (Kp) or the dominant lag time (T1). Instead, it relies on the fact that the controller gain can be much larger than the baseline controller gain (K >> Kbase) and that a deadtime dominant self-limiting process looks very much like an integrating process to a PID controller. The concept of tuning controller response was introduced using lambda (λ). This adds the ability to tune response to meet the process needs but adds
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PID series from Ed Bullerdiek, retired control engineer
a level of complexity. You now must decide what kind of response is required. If you don’t like it, you can change response by recalculating using a new λ or tweak the constants using heuristic methods. There are multiple paths to the desired result. ce
Ed Bullerdiek is a retired control engineer with 37 years of process control experience in petroleum refining and oil production. Edited by Mark T. Hoske, editor-in-chief, Control Engineering, WTWH Media, mhoske@wtwhmedia.com.
Part 1: Three reasons to tune control loops: Safety, profit, energy efficiency https://www.controleng.com/articles/ three-reasons-to-tune-control-loops-safety-profit-energy-efficiency PID spotlight, part 2: Know these 13 terms, interactions https://www. controleng.com/articles/pid-spotlight-part-2-know-these-13-terms-interactions PID spotlight, part 3: How to select one of four process responses https://www.controleng.com/articles/ pid-spotlight-part-3-how-to-select-one-of-four-process-responses/ PID spotlight, part 4: How to balance PID control for a self-limiting process https://www.controleng.com/articles/ pid-spotlight-part-4-how-to-balance-pid-control-for-a-self-limiting-process/ PID spotlight, part 5: What does good and bad controller tuning look like? https://www.controleng.com/articles/ pid-spotlight-part-5-what-does-good-and-bad-controller-tuning-look-like/ PID spotlight, part 6: Deadtime? How to boost controller performance anyway https://www.controleng.com/articles/ pid-spotlight-part-6-deadtime-how-to-boost-controller-performance-anyway/ PID spotlight, part 7: Open-loop tuning of a self-limiting process https://www.controleng.com/articles/ pid-spotlight-part-7-open-loop-tuning-of-a-self-limiting-process/
FIGURE 2: Integrating process PI tuning of a near integrating process. Tuning constants are K = 3.50, Ti = 1.75 minutes/repeat, Dt = 0 minutes.
PID spotlight, part 8: Closed-loop tuning for self-limiting processes https://www.controleng.com/articles/ pid-spotlight-part-8-closed-loop-tuning-for-self-limiting-processes
PID spotlight, part 9: Heuristic tuning for a self-limiting process (part A on heuristic tuning) https://www.controleng.com/articles/ pid-spotlight-part-9-heuristic-tuning-for-a-self-limiting-process PID spotlight, part 10: Heuristic tuning in a self-limiting process https://www.controleng.com/articles/pid-controller-tuning-insights/ PID spotlight, part 11: How a PID controller works with an integrating process https://www.controleng.com/articles/ pid-spotlight-part-11-how-a-pid-controller-works-with-an-integrating-process/ PID spotlight, part 12: What does good and bad controller tuning look like? https://www.controleng.com/articles/ pid-spotlight-part-12-what-does-good-and-bad-level-controller-tuning-look-like/ PID spotlight, part 13: Deadtime: what’s the best that I can do? https://www.controleng.com/ pid-spotlight-part-13-deadtime-whats-the-best-that-i-can-do/ PID spotlight, part 14: Open loop tuning of an integrating process https://www.controleng.com/ pid-spotlight-part-14-how-open-loop-tuning-works-in-an-integrating-process/
ANSWERS
Allan Kern, Lin & Associates Inc.
APC 2.0 spotlight, part 1: What is APC 2.0?
For better understanding of what’s possible in advanced process control (APC), learn what APC 2.0 is about and why it is important. Explore APC agility and importance of APC technology mastery for control-loop optimization. This starts an APC 2.0 series.
controleng.com u
KEYWORDS: Advanced process control (APC), multivariable control and optimization
LEARNING OBJECTIVES
Exploring APC 2.0, what it is and why it is important.
Learn about APC agility and loop intervention analysis
Understand why mastering APC technology is required, not optional.
CONSIDER THIS
Are you attending to control loops too often?
ONLINE
For more insights from Allan Kern, see: Understanding the critical role of metrics for advanced process controls www.controleng. com/understanding-thecritical-role-of-metrics-foradvanced-process-controls Understanding APC limits and targets www.controleng.com/ understanding-apc-limitsand-targets
The idea behind “APC 2.0” is that the conventional advanced process control (APC) paradigm of the last 40-plus years, which could be called “APC 1.0,” is due for an overhaul. Most people would probably agree with this, but they may not yet know the specifics of APC 2.0 – what it includes, what’s different, how it solves past challenges, how it helps move APC forward again and why it is important.
An updated APC paradigm is especially important because one of the lessons learned during the APC 1.0 era – possibly the most important and basic lesson – is that multivariable control and optimization is not a specialized or optional capability. Rather, multivariable control and optimization is a fundamental aspect of nearly every industrial process operation. Without APC technology, multivarible control and optimization is carried out manually (or open-loop) by operating teams. With APC, it is automated (or closed-loop). Either way, with or without the aid of APC technology, operating teams must master multivariable control & optimization to become effective, safe and reliable top-tier operators.
Importance of multivariable constraint control, optimization
If you observe any industrial process operation, you will see multivariable control and optimization in action. It takes the form of console operators
making setpoint and output changes; field operators making equipment adjustments; process engineers pushing to maximize optimization potential; and myriad communications and ancillary activities. All these activities have the common aim of multivariable constraint control and optimization, that is, keeping the process in a safe and reliable condition while maximizing the capture of optimization potential.
APC can help automate multivariable control, optimization
Obviously, to the extent multivariable control and optimization can be automated by the use of APC technology, it provides an advantage. Many processes, including large complex processes where APC has traditionally been applied, and relatively small processes where APC has traditionally been overlooked – sometimes called the application gap – will find themselves handicapped when it comes to achieving their modern automation and optimization goals, if they do not find the time and vision to master APC technology.
If multivariable control is an inherent part of every process operation, and every operating site must master it to the extent possible, then it follows that APC technology must become a more agile and owner-friendly technology. This is a lesson from APC 1.0 – a technology is only as effective as it is reliable, cost effective, and as its tools are easy to use. To thrive in a process operation environment, any technology (or any equipment) must be affordable, flexible and reliable.
What’s involved in APC 2.0 and why
APC 2.0 incorporates many changes and lessons-learned that serve this end. APC agility means (among other things) costs that fall within normal operating budgets, so that it doesn’t break the bank or have to wait for funding; it means time frames that allow new opportunities to be captured and problems to be solved as they arise within a reasonable operational time frame – not a year or two down the road; it means APC work that can be included within projects, not as separate follow-on projects, without becoming critical path items; it means applications that are set-and-forget and do
PROBABLY the easiest and most common way to talk about advanced process control is to call it “APC” and by that to mean “multivariable control and optimization.” Many other terms have been used, such as MPC (model-predictive control), MIMO (multiple-input-multiple-output), and MLC (multi-loop control). But APC is the most commonly used term.
Within APC, the terms manipulated variable (MV) and controlled variable (CV) are almost universally used, even if they can be counterintuitive at first. MVs are the control system “handles” that are directly manipulated by APC. Usually they are single-loop controller setpoints or outputs. CVs are the control system dependent variables that are indirectly controlled, by virtue of the MVs, such as various temperatures, pressures or stream qualities.
APC is shorthand for multivariable constraint control and optimization. In APC, MVs are manipulated within limits to keep CVs within limits (to the extent possible). This is multivariable constraint control. Secondarily, after constraint control, MVs are further manipulated to bring MVs and CVs to their most optimal values (to the extent possible). This is optimization.
not require continuous support – or that fall apart without continuous support; and it means technology that can be effectively owned and operated by on-site control personnel without dependence on off-site specialists.
In APC 2.0, these characteristics of agility come about from a combination of lessons learned and new ideas that are sometimes novel and sometimes just common sense from process control and process operation points of view. The figure illustrates many of the main aspects of APC 2.0 that will be discussed in upcoming installments of this series.
In the APC 2.0 era, the central focus of APC will become closing multivariable loops, just like the focus of base-layer control has always been closing single loops. It’s fundamentally the same. If console operators have to intervene frequently to adjust outputs or setpoints – perhaps so frequently that they are sometimes overwhelmed – then something is missing. It could be a problematic single loop or – quite often – the root cause will be found to be a missing multivariable loop, so that the operator is actually serving as a manual multivariable con-
What are the specifics of APC 2.0?
troller, a job that could be automated via APC to close the related multivariable loops. Closing loops brings the universal automation benefits of more timeliness and consistency, fewer alarms and trips and greater optimization.
Are you intervening too often with control loops?
In APC 2.0, this fundamental aspect of operation – how often console operators have to intervene in control loops – is readily measured and managed using loop intervention analysis and the loop intervention metric. The loop intervention metric is also called the bad actor loop metric, because it is similar to the bad actor alarm metric from alarm management. If operators have to intervene too often, it needs to be addressed to assure safe and effective operation. In many or most cases, as the series intends to explain, an automated multivariable controller, that is APC, is the appropriate solution. ce
Allan Kern is principal APC Consultant with Lin & Associates Inc. Edited by Mark T. Hoske, editor-inchief, Control Engineering, WTWH Media, mhoske@wtwhmedia.com.
FIGURE: APC 2.0 includes lessons learned from APC 1.0 plus many novel and common-sense innovations. Courtesy: Lin & Associates Inc.
Insightsu
Explore advanced process control (APC) 2.0 specifics, insights uBegin by exploring the specifics of APC 2.0, what it is and why it is important.
uLearn about APC agility.
uUnderstand why mastering APC technology is required, not optional.
ANSWERS
Felipe Sabino Costa, Sc, MBA, PMP, CCNA, CISA-US DHS, Moxa Americas Inc.
How generative AI helps industrial networking
The integration of generative AI in industrial networking is reshaping how security frameworks, such as IEC 62443, are implemented and maintained.
Is generative AI improving your industrial networks?
LEARNING OBJECTIVES
Understand the potential role of generative artificial intelligence (AI) may have in industrial networking and how it can contribute to cybersecurity.
Explore how AI-powered programming can aid in International Society of Automation/International Electrotechnical Commission (ISA/IEC) 62443 compliance and risk mitigation.
Gain insights about potential applications of generative AI in industrial control systems (ICS) security.
ndustrial networks form the backbone of critical infrastructure, supporting sectors like energy, manufacturing and transportation. However, with the increasing convergence of information technology (IT) and operational technology (OT), cybersecurity threats are growing at an alarming rate. The International Society of Automation/International Electrotechnical Commission (ISA/IEC) 62443 standard provides a structured approach to securing industrial automation and control systems (IACS), but security adoption requires constant monitoring, configuration and adaptation.
Generative AI — an advanced branch of artificial intelligence that can create content, generate code and predict patterns — has emerged as a powerful tool in supporting different solutions to address these challenges. In industrial networking, AI-driven programming opens a new horizon, transforming cybersecurity by supporting and automating some processes of threat detection, enhancing anomaly detection and ensuring compliance with stringent security frameworks like ISA/IEC 62443.
What is generative AI?
Before we can understand generative AI’s role in industrial networking, it’s important to define the technology. Generative AI a type of artificial intelligence that can create new content. The technology works by generating new data from existing data and reusing existing knowledge to solve new queries. This technology is most used in chatbots, product development and media creation.
Generative AI, industrial networking
Generative AI is revolutionizing industrial networking by enabling:
• Automated network configuration, optimization - AI can generate optimized network configurations to align with IEC 62443 security zones and conduits, reducing human error and adding efficiency.
• Threat detection and response - AI models can analyze large datasets in real time, identifying anomalies and generating insights to respond to actions that mitigate security risks.
• Self-healing networks - AI-powered systems can detect communication failures, generate remediation scripts and provide automated insights to reduce downtime and improve current configurations.
• Compliance and audit automation - Generative AI can generate security documentation, verify configurations against IEC 62443 requirements and assist in auditing processes.
Two ways IEC 62443 and AI help cybersecurity
IEC 62443 provides a framework for securing industrial automation systems by defining security levels (SLs), access controls and risk assessment methodologies. AI-driven programming enhances compliance in the following ways:
1. Risk identification and threat modeling
AI can generate threat models based on historical attack patterns and predict the most likely vulnerabilities considering the specifics of each network. While visibility tools remain important, companies can perform additional analysis to feed their internal knowhow and double-check the identified patterns.
2. Security patch management
AI can suggest patches dynamically, ensuring that maintenance teams are more actively looking into system vulnerabilities.
‘AI can generate optimized network configurations that align with IEC 62443 security zones and
conduits.
’
AI helps industrial control systems (ICS) security
Generative AI goes beyond enhancing cybersecurity compliance and enhances industrial control systems (ICS). There are two significant ways in which generative AI accomplish this:
1. AI-assisted network configuration for secure zones and conduits - In industrial networks, defining security zones and conduits per IEC 62443 is crucial. Generative AI can:
• Analyze network traffic to recommend specific AI models (mathematical models) that are best suited to respond and suggest optimal security segmentation based on network data patterns.
• Propose firewall rules and access control lists.
• Simulate potential attack vectors and recommend network hardening strategies.
2. Intelligent intrusion detection and incident response - Traditional IDS (intrusion detection systems) rely on signature-based detection, which often fails against zero-day attacks. Generative AI improves this by:
• Analyzing real-time network traffic and providing additional insights to detection tools to identify behavioral anomalies.
• Supporting the creation of response playbooks tailored to the nature of the threat and ICS characteristics.
• Simulating potential attack paths and recommending insight for mitigation strategies.
3. AI-powered compliance auditing and reporting - IEC 62443 compliance involves detailed documentation and continuous auditing. AI can:
• Support the creation of compliance documentation based on real-time network data.
• Analyze logs for deviations from IEC 62443 guidelines.
• Recommend remediation actions to address compliance gaps proactively.
Generative AI: challenges, considerations
While generative AI offers significant benefits, its adoption in industrial networking must address key challenges:
• Explainability and trust: AI-generated security policies and configurations must be transparent and understandable for operators.
• Integration with legacy systems: Many industrial environments rely on outdated infrastructure that may not support AI-driven automation.
• Cybersecurity risks of AI itself: AI models can become targets for adversarial attacks, requiring additional security measures.
• Decision-making in industrial control systems: AI should not make automated decisions on industrial control systems but instead offer powerful insights to the asset owner, increasing response time and digitizing large quantities of data to facilitate human decision-making. ce
Felipe Sabino Costa, Sc, MBA, PMP, CCNA, CISAUS DHS, is the senior product marketing manager of networking and cybersecurity for Moxa Americas Inc. Edited by Sheri Kasprzak, managing editor, Automation & Controls, WTWH Media, skasprzak@wtwhmedia.com.
FIGURE: AI-powered systems can help organizations with automated insights to reduce downtime and improve current configurations. Courtesy: Moxa
Insightsu
Generative AI insights
uGenerative AI is a branch of artificial intelligence that can create, generate code and predict patterns.
uGenerative AI is evolving and plays an important role in industrial networking.
uSecurity remains a challenge for generative AI in industrial networking.
Akiba Saeedi, IBM
These three priorities are critical for data security
Manufacturing and other industrial sectors are among the most targeted by cybercriminals and shoulder some of the highest costs resulting from a data breach.
Factory floors, plant control rooms and other industrial engineering settings are growing smarter each day, highlighting the need for more intensive data security. Industrial engineers are eager to enhance their control systems and operational technology with the latest digital capabilities, like generative AI.
Smarter settings mean more efficiency, insights and control — all enabled by more data. But as industrial settings grow more data rich, critical data is often left unprotected. For the third year in
Cost of data breach by industry
a row, the IBM X-Force Threat Intelligence Report ranked manufacturing as the most-attacked industry by cybercriminals.
And cyberattacks are just one issue: There’s also the possibility of insider threats, human error and compliance failures. These carry a significant price tag. Industrial organizations see some of the highest data breach costs — an average of $5.6 million — according to IBM’s annual Cost of a Data Breach Report.
Data security in a sensitive sector
This shouldn’t be surprising. The industrial sector has always been an attractive target for bad actors due to its coveted IP like proprietary designs and sensitivity to downtime. For example, automakers can lose over $20,000 per minute of unplanned downtime.
Nor should these trends be a reason to eschew emerging technologies. Innovation has always been the lifeblood of industrial engineering.
However, these trends make clear the importance of data security in industrial engineering. Especially at this moment in time, as compliance grows more complex and as three major digital transformations — hybrid cloud, generative AI and quantum computing — upend the traditional data security paradigm.
Amid these rapid changes, cybersecurity professionals in the industrial sector should approach data security with three key priorities: laying a strong foundation; meeting emerging risks; and preparing for future risks.
Laying a strong foundation: data security basics
While the data security paradigm is transforming, there are still long-standing best practices that security professionals should always employ. These are the nuts-and-bolts of data security that
FIGURE 1: Data breaches in the industrial sector are among the most expensive. Courtesy: “Cost of a Data Breach Report 2024,” IBM.
‘Security professionals need unified controls that grant visibility across teams and surface areas.’
date back to the days when data was only stored in mainframes on-premises.
Data security professionals should have robust answers to a few important questions: Do you know where your most sensitive data is stored? Is that data being actively monitored? Do you have a plan in place – e.g. containment, notification, improvement — for when a data breach occurs? It’s when a breach occurs, not if. The industrial sector should anticipate the worst-case scenario. The IBM X-Force Threat Intelligence Report found data theft and data leakage to be the most common incidents.
Protecting data throughout its full lifecycle — from collection to storage and processing to disposal — is fundamental. This means being diligent about discovering and protecting data and then analyzing and responding to risks and threats in real time.
Comprehensive identity and access management (IAM) is also a requirement. Determining who or what can access your systems — and data — is especially important in the industrial sector, where a vast array of technicians, machines, edge devices and IoT tools have varying degrees of access to data across multiple clouds.
Hybrid cloud adoption and generative AI proliferation
Once industrial engineers have a strong data security foundation to build upon, they can expand their work to address newer risks and threats. Right now, those surfaces are hybrid cloud and AI — particularly generative AI.
The days of data being stored solely on premises are gone due to hybrid cloud and AI transformations. Industrial engineers’ data now lives across multiple clouds and within large language models. This has major upsides, empowering engineers to optimize supply chains, predict asset maintenance needs and enhance quality control.
These upsides also come with risks, however. It’s easier than ever to lose sight of where data is stored, who has access and how it is protected. “Shadow data” like this significantly escalates the likelihood of a breach. Likewise, the use of generative AI introduces more potential attack surfaces: the training data, the model and the model’s usage. Generative AI like large language models also presents entirely novel vulnerabilities, like prompt engineering, jailbreaks and “shadow AI.” Shadow AI are unsanctioned models operating within a business’s digital ecosystem, often introduced by negligent staff, that elude governance. Recent research by IBM revealed that only 24% of current generative AI projects are being secured. If industrial engineers are using generative AI, they must protect the entire AI pipeline: secure the data, secure the models and secure the usage.
How should security professionals in the industrial sector pursue this type of comprehensive protection? The wrong way to go about this is with a patchwork of isolated point solutions: one piece of software for this surface area, another piece of software for that surface area. A fragmented approach inevitably leads to silos, limited visibility and breaches. Instead, security professionals need unified controls that grant visibility across teams and surface areas. The need for this unified experience was a guiding force behind the newest data security software. We heard repeatedly from security professionals in the industrial sector and others that they need one package with multiple capabilities: data monitoring and compliance, data and AI security
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KEYWORDS: Industrial cybersecurity ONLINE www.controleng.com/ industrial-cyber-security CONSIDER THIS
Do you have visibility into cybersecurity tools? LEARNING OBJECTIVES Understand data security fundamentals.
Discover how to protect data from emerging hybrid cloud and AI risks.
Learn how to protect data from security risks with post-quantum cryptography.
FIGURE 2: Data security in the generative AI era needs to span the entire AI pipeline: the data, the models and the usage. Courtesy: IBM
ANSWERS
FIGURE 3: Data security professionals need unified controls, not a patchwork of point solutions. Courtesy: IBM Guardium Data Security Center
‘Experts predict quantum computing could challenge present-day encryption by the end of the current decade.’
posture management, data detection and response and cryptography management.
Insightsu
Cybersecurity insights
uComprehensive data security is more important than ever as hybrid cloud, generative AI and quantum computing emerge.
uSecuring data is important since technicians, machines, edge devices and IoT tools have varying degrees of access to data across multiple clouds.
u To mitigate data security risks, industrial engineers need “crypto agility,” the ability to quickly switch between different encryption mechanisms that protect sensitive data.
Preparing for future risks: quantum-safe cryptography
While cybersecurity professionals acclimate to hybrid cloud and generative AI impacts on data security, another technological transformation is just over the horizon: quantum computing.
Quantum computing carries immense potential in industrial engineering, like discovering new materials and tackling other complex problems that classical computers struggle with. But bad actors with quantum-powered technology may one day be able to break today’s encryption. Experts predict that quantum computing could challenge present-day encryption by the end of the current decade.
This scenario presents current dangers, too. The notion of “harvest now, decrypt later” can place industrial organizations’ IP and other sensitive data at risk right now. Bad actors could potentially harvest encrypted data now and years later decrypt it using cryptographically relevant quantum-powered
attacks. This can pose a real problem in industrial engineering, where proprietary designs and trade secrets have long shelf lives.
To mitigate these risks, industrial engineers need “crypto agility,” the ability to quickly switch between different encryption mechanisms that protect sensitive data. This requires visibility into all encrypted assets and also the ability to transition from traditional encryption techniques to newer, post-quantum cryptography like the standards recently set by NIST.
Prioritizing data security in industrial networks
Data security should always be a top priority, especially in industrial engineering. The field’s innate qualities — like its complexity and its importance — mean security professionals need a comprehensive and proactive approach to the data security trade. By laying a strong foundation, expanding to protect emerging risks and then finally preparing for risks on the horizon, security professionals in industrial engineering can ensure their critical work and innovations remain safe. ce
Akiba Saeedi is the vice president of product management data security and cloud/service providers with IBM. Edited by Sheri Kasprzak, managing editor, Automation & Controls, WTWH Media, skasprzak@wtwhmedia.com.
Unlock the Future of Circuit Protection with the Time-Fault Circuit Interrupter (TFCI)
Revolutionize your circuit breaker offerings with the Time-Fault Circuit Interrupter (TFCI), an innovative solution designed to enhance protection, reliability, and efficiency for electrical systems.
Why Choose the TFCI Breaker?
1 2 3 4 5
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Unlike traditional breakers, the TFCI incorporates advanced timing mechanisms to distinguish between transient fluctuations and sustained fault conditions. This ensures only necessary interruptions, reducing unnecessary downtime and enhancing system reliability.
Protect Sensitive Equipment
Perfect for circuits powering sensitive loads, the TFCI’s time-delay function allows systems to self-correct minor faults without triggering a shutdown. Ideal for industrial machinery and residential applications.
Advanced Motor Monitoring
The TFCI goes beyond standard breakers by electronically monitoring the runtime of motors such as well pumps and air compressors. It detects excessive or continuous operation caused by leaks, pipe bursts, or other issues and shuts off electricity before catastrophic damage occurs.
Versatile Applications
Designed for both commercial and residential use, the TFCI is a game-changer for industries prone to transient faults or requiring precise protection for critical systems.
Enhanced Selectivity & Coordination
With time-dependent operation, the TFCI coordinates seamlessly with other protection devices, ensuring optimal system performance and targeted fault response.
Easy Installation, Maximum Impact
The TFCI is user-friendly, simple to install, and compatible with a wide range of systems. By integrating this breakthrough device into your product lineup, you’ll offer customers the ultimate peace of mind.
Stand Out in the Market
Partner with us to bring the TFCI to your customers and redefine the future of circuit protection. With its blend of cutting-edge technology and practical utility, the TFCI is set to be a market leader in safety and innovation.
CONTACT: Kevin LaFuente or Sam Tringali today to learn more about integrating the TFCI into your product offerings. EMAIL: tfcibreaker@yahoo.com
‘
ANSWERS
Thomas J. Burke, CLPA, Ravenna, Ohio
These emerging technologies are coming to the industrial ethernet
Advancements are coming to industrial Ethernet, including emerging technologies like Single Pair Ethernet (SPE) and more established Ethernet with Time-Sensitive Networking (TSN).
Emerging industrial automation technologies like Single Pair Ethernet (SPE) and Ethernet with Time-Sensitive Networking (TSN) are set to redefine industrial communication and connectivity. Single Pair Ethernet allows devices to transmit data and power over a single twisted pair of wires, significantly simplifying connectivity for compact devices and sensors in smart factories and industrial settings.
TSN Ethernet provides a versatile, high-performance solution for industries needing precise, real-time control, typically in motion-related applications.
’
This technology reduces wiring complexity, enabling more efficient and scalable networks across a wide array of devices. Ethernet with TSN, on the other hand, enhances Ethernet’s capability to handle real-time data by adding timing synchronization and prioritizing data packets. This enables precise, low-latency communication critical for applications like robotics, automation and autonomous systems. Together, SPE and Ethernet with TSN facilitate seamless, fast and reliable data exchange in Industry 4.0 environments, providing flexibility and efficiency in automated industrial operations.
Although SPE holds significant potential to streamline network infrastructure, especially for
compact devices and sensors in industrial environments, it’s still a newer specification. Industry experts suggest that it may take some time before SPE-based products and solutions are widely available across sectors.
Unlike SPE, the specification for TSN over Ethernet is fully developed and adoption has already been underway. TSN provides enhanced Ethernet capabilities with precise timing and synchronization, allowing deterministic data transfer that is essential for real-time industrial applications like robotics, autonomous systems and factory automation (see Figure 1).
How TSN impacts real-time data transmission
With TSN, various industries have started implementing reliable, low-latency communication solutions, benefiting from the now standardized protocols that ensure interoperability across devices and systems. The maturity of the TSN standards enables manufacturers to deploy it in settings where precise timing and minimal latency are critical, giving it a considerable head start over SPE in terms of real-world application. This rapid adoption of TSN Ethernet demonstrates its readiness and immediate impact on industrial automation. Ethernet with Time-Sensitive Networking (TSN) brings specific technical attributes to Ethernet that enable real-time data transmission with high reliability and precision. Key attributes and benefits include:
Deterministic data transmission: TSN ensures that data packets are delivered predictably within strict timing windows, which is crucial for applications requiring synchronized operations, such as robotics and automated machinery in industri-
al environments. Determinism is achieved through time synchronization and traffic scheduling protocols, allowing TSN-enabled devices to manage data flows precisely, even under high network load.
Time synchronization: TSN uses protocols like IEEE 802.1AS to provide high-precision clock synchronization across networked devices, maintaining microsecond-level timing accuracy. This feature is essential for coordinated, latency-sensitive processes in automation, such as motion control and vision systems, where timing discrepancies can disrupt operations.
Traffic prioritization and Quality of Service (QoS): Through mechanisms like IEEE 802.1Qbv, TSN assigns priority levels to different data types, ensuring high-priority, time-sensitive data reaches its destination without interruption. This QoS approach allows for a mix of data types—such as control, video and general information — over a single network, enhancing operational efficiency and reducing the need for separate infrastructures
Interoperability: As TSN is built on Ethernet, it seamlessly integrates with existing Ethernet-based networks, allowing for flexible and scalable solutions. This interoperability supports Industry 4.0 goals by connecting diverse devices and systems across manufacturing and industrial environments without requiring specialized cabling or network structures.
These features make TSN Ethernet a versatile, high-performance solution for industries needing precise, real-time control, typically in motion-related applications.
TSN is invaluable for automating complex manufacturing processes that involve real-time, coordinated operations. It ensures low-latency and synchronized communication between sensors, controllers and actuators, essential in assembly lines and robotic systems where split-second timing impacts quality and efficiency.
Industry-specific TSN applications
In robotics, TSN's precise timing and low latency ensure seamless operation between robotic arms, sensors and controllers. TSN supports coordinated multi-axis motion control and complex robotic movements, which are critical in high-speed packaging, welding and pick-and-place applications.
TSN is used in automotive applications for safety-critical communication between electronic con-
trol units (ECUs), particularly in autonomous vehicles. It enables reliable data exchange among sensors, cameras and AI processors, which are essential for real-time decision-making and safe navigation in autonomous and advanced driver-assistance systems (ADAS).
How network standards will influence the path
to TSN adoption
Vendors adopt Ethernet with Time-Sensitive Networking (TSN) by implementing TSN-compliant hardware and software into their industrial communication solutions. Adoption often includes upgrading network components — such as switches, controllers and network interface cards — with TSN capabilities like time synchronization and traffic prioritization. This requires manufacturers to align with IEEE standards (e.g., IEEE 802.1AS for time synchronization and IEEE 802.1Qbv for traffic scheduling), ensuring interoperability across TSN devices from different vendors. Adopting TSN allows vendors to deliver solutions that meet the high reliability and low-latency requirements of industries that demand real-time data exchange, such as automotive manufacturing and process automation.
The CC-Link Partner Association (CLPA) plays a crucial role in facilitating TSN adoption by setting interoperability standards and providing a collaborative platform for vendors to test and certify their TSN-enabled products. CLPA's CC-Link IE TSN protocol is one of the first open industrial networks to integrate TSN technology. It extends Ethernet with TSN’s real-time communication capabilities, supporting seamless data exchange and coordination across production lines. By offering certification for TSN-compatible products, CLPA
FIGURE 1: Time-Sensitive Networking (TSN) allows multiple industrial systems to communicate on a single wire. Courtesy: CLPA
Online
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KEYWORDS: Industrial networks, TSN Ethernet, motion control ONLINE
www.controleng.com/ industrial-networking CONSIDER THIS Are your networks serving your high-speed automation needs?
LEARNING OBJECTIVES
Discover how Single Pair Ethernet (SPE) and TimeSensitive Networking (TSN) can work together for optimal network connectivity. Learn the benefits of TSN for applications like robotics, automotive and packaging – those that require precise timing and minimal latency. Understand how TSN can be readily incorporated into network control systems, by working with standards organizations like the Institute of Electrical and Electronics Engineers (IEEE).
ANSWERS
2: Mitsubishi Electric’s Melsec iQ-R series of servo system controllers serve complex operations in one network.
Courtesy: CLPA
helps ensure that devices from different vendors can work together reliably, accelerating TSN adoption across industries (see Figure 2).
SPE and TSN are transforming industrial automation
Insightsu
Industrial Ethernet insights
uSingle Pair Ethernet (SPE) simplifies connectivity for compact devices by reducing wiring.
uTime-Sensitive Networking (TSN) enhances Ethernet’s real-time capabilities with precise timing and low latency, benefiting applications like robotics and automation.
uAdoption of TSN over Ethernet already underway.
The TSN Industrial Automation Conformance Collaboration (TIACC) is a joint initiative by major industrial organizations like the CC-Link Partner Association (CLPA), Avnu Alliance, ODVA, OPC Foundation and Profibus & Profinet International. Its purpose is to create a unified conformance test plan for devices using Time-Sensitive Networking (TSN), specifically aligning with the International Electrotechnical Commission (IEC)/IEEE 60802 profile. This effort aims to enable interoperability between TSN-compatible products from different vendors, ensuring they can operate seamlessly on the same network infrastructure in industrial environments.
The TIACC collaboration directly impacts the adoption of TSN by standardizing testing processes and providing assurance that TSN-based devices will work together reliably, regardless of manufacturer. This collaboration is crucial for industries aiming for network convergence, where various industrial and IT protocols can coexist on a single network, enhancing efficiency and simplifying network management. By validating interoperability, TIACC enables industries like automotive, pharmaceutical and food and beverage to confidently integrate TSN for applications that require high precision and real-time performance, supporting Industry 4.0 and smart manufacturing goals.
In summary, emerging technologies like Single Pair Ethernet (SPE) and Ethernet with Time-Sensitive Networking (TSN) are transforming industrial automation by improving connectivity and real-time communication capabilities. While SPE promises simplified wiring and scalable networks, particularly for compact devices in industrial settings, its adoption is expected to take time as the technology matures. Conversely, TSN's specifications are fully established, enabling deterministic, low-latency communication essential for automation and robotics applications.
Already seeing wide adoption, TSN allows for interoperable, high-precision networks supporting synchronized data transmission across various devices and industries. Initiatives like the TSN Industrial Automation Conformance Collaboration (TIACC), led by organizations including the CC-Link Partner Association (CLPA), are driving industry-wide standards for interoperability, helping to accelerate TSN adoption. This collaborative approach supports the integration of industry 4.0 technologies across sectors, fostering efficient, reliable and scalable industrial operations for the future. ce
Thomas J. Burke is the global strategic advisor for CC Link Partner Association (CLPA). Edited by Sheri Kasprzak, managing editor, Automation & Controls, WTWH Media.
FIGURE
Felipe Sabino Costa, ISA, EC-Council instructor; Moxa
Potential of single-pair ethernet (SPE) for industrial networks
Single-pair ethernet uses twisted-pair cable, reduces cabling complexity and maintains high-speed data transfer.
The evolution of industrial networking has been driven by the need for higher-speed, deterministic, and scalable communication. Traditional fieldbus systems are rapidly being replaced by industrial Ethernet, but challenges such as complex cabling, power limitations, and environmental complexity persist. Single-Pair Ethernet (SPE) is emerging as a transformative technology that simplifies Ethernet connectivity while enabling seamless integration across industrial environments.
SPE enables full-duplex Ethernet communication over one twisted pair, reducing wiring costs, weight and installation complexity. This advancement helps for applications in process automation, factory automation and industrial IoT (IIoT), where space constraints and long-distance communication are critical.
More
SPE details, benefits
SPE supports speeds ranging from 10 Mbps to 1 Gbps over distances of up to 1,000 meters, depending on the application. Traditional Ethernet typically uses four or two pairs; SPE enables device-to-device communication with minimal infrastructure. Benefits are:
1. Network simplification and cost reduction
• Reduces cabling requirements by up to 75% compared to traditional Ethernet.
• Lowers installation costs by reducing the need for gateways and complex infrastructure.
2. Extended reach for industrial environments
• SPE’s ability to support up to 1,000 meters surpasses the 100-meter limitation of standard Ethernet.
• Ideal for large industrial sites, such as oil and gas facilities, power plants and smart buildings.
3. Seamless industrial IoT (IIoT) integration
• Supports edge computing and real-time monitoring by connecting sensors and actuators directly to Ethernet networks.
• Reduces the need for legacy fieldbus systems while maintaining industrial-grade reliability.
SPE and cybersecurity, IEC 62443
While SPE has the potential to facilitate secure practices within an industrial network, it is not a security mechanism. SPE enables the adoption of better security practices, and its implementation can align with IEC 62443 when combined with proper security controls.
1. Fewer attack vectors
SPE enables more efficient network segmentation, helping to reduce the exposure of critical devices if implemented with proper security measures.
2. Enhanced access control
SPE facilitates the convergence to standardized Ethernet networks, allowing the application of network segmentation and secure authentication through appropriate security protocols, aligning with IEC 62443-3-3 requirements.
3. Anomaly detection, monitoring improvements
SPE enables continuous data transmission from industrial devices, making it possible to leverage advanced monitoring and anomaly detection tools, which are essential for IEC 62443 compliance. ce
Felipe Sabino Costa is a cybersecurity director and an official ISA/IEC 62443 industrial cybersecurity instructor at ISA and EC-Council. He is the senior product marketing manager at Moxa Americas.
KEYWORDS: Ethernet SPE, twisted-pair ethernet
ONLINE
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CONSIDER THIS
How can SPE expand industrial ethernet use?
LEARNING OBJECTIVES
Understand the fundamentals of Single-Pair Ethernet (SPE) and how it differs from traditional Ethernet technologies.
Explore the benefits of SPE for industrial applications, including network simplification, cost reduction, and extended reach.
Learn how SPE aligns with industrial standards and cybersecurity frameworks such as IEC 62443 to ensure secure and scalable deployment.
ANSWERS
Association for Advancing Automation (A3)
Revised industrial robot safety standards now available
The new ISO 10218 parts 1 and 2 clarify functional safety requirements, simplifying compliance.
After nearly eight years of work, the Association for Advancing Automation (A3) announces the publication of the revised ISO 10218, a key international standard for industrial robot safety. This is its first major revision since 2011, providing an important update to safety guidelines for robotics in industrial environments.
“Working alongside hundreds of global experts, A3 played a pivotal role in shepherding this update to publication, to refine safety requirements in response to evolving automation technologies and workplace demands,” said Jeff Burnstein, A3 president. “This effort reflects A3’s ongoing commitment to enhancing robotic safety and supporting the widespread adoption of automation.”
ISO 10218 consists of two parts. Part 1: Safety requirements for industrial robots (manufacturers) AND Part 2: Safety requirements for industrial robot applications and robot cells (system integrators). Courtesy: Association for Advancing Automation (A3)
The new ISO 10218 parts 1 and 2 include updates that make functional safety requirements more explicit rather than implied. These changes enhance clarity, helping manufacturers and integrators comply more easily. In North America, ISO 10218 was adopted as ANSI R15.06 in the United States and CSA Z434 in Canada. Efforts are in progress to adopt the new 10218, with updated versions of R15.06 and Z434 planned for release later this year.
Key updates in ISO 10218
(2025)
ISO 10218 consists of Part 1: Safety requirements for industrial robots (manufacturers) and Part 2: Safety requirements for industrial robot applications and robot cells (system integrators). Both parts have been updated to reflect new safety requirements and technologies, including:
• Clearer functional safety guidelines for compliance and risk management.
• Added safety guidance for manual load/unload procedures and end-effectors, merging content from TR 20218-1 and TR 20218-2.
• New robot classifications with related safety requirements and test methods.
• Cybersecurity requirements for industrial robot safety.
Carole Franklin, director of standards at A3 Robotics, said, “With automation evolving at an unprecedented pace, it is essential that safety standards keep up with the latest advancements. This is a critical step in ensuring that as automation grows, worker safety remains a top priority. These revisions provide clearer guidelines and new classifications that will help manufacturers and system integrators implement the latest technology for safer robotic solutions.”
Roberta Nelson Shea, global technical compliance officer at Universal Robots and convenor of ISO TC 299 Working Group 3, said, “This set of safety standards has immense global acceptance, but updates were needed. This is a pivotal moment for industrial robotics. With automation advancing at lightning speed, we need safety standards that keep pace.” ce
Edited by Puja Mitra, WTWH Media, for Control Engineering, from an Association for Advancing Automation news release.
Control Engineering subscribers are invited to vote until April 30. The Control Engineering Product of the Year program highlights some of the best new control, instrumentation and automation products as chosen by Control Engineering’s print and online subscribers. Qualified subscribers are asked to select products based on technological advancement, service to the industry, and market impact. Use your vote wisely.
Control Engineering 2025 Product of the Year Voting Ballot https://survey.alchemer.com/s3/8206433/f8132b621423
New 64-bit automation controller has 2GB RAM, extensive cybersecurity
The Wago PFC300 is a multi-protocol controller with cloud integration and advanced cybersecurity, as explained in a new product news conference at the Wago North American headquarters in Germantown, Wisconsin, Feb. 25. The PFC300 Controller supports multiple fieldbus protocols including EtherNet/IP Adapter and Scanner, EtherCAT master, Profinet, Modbus TCP and Modbus RTU. Industrial internet of things (IIoT) protocols OPC UA and MQTT can be enabled for connection to cloud servers. By using the controller’s web-based management system and programmed with CoDeSyS 3.5 software, system configuration is easy. The USB-C service port provides direct access for programming, configuration and firmware updates. It has TLS encryption, VPN capabilities and a built-in firewall. Wago, www.wago.com/us/f/pfc-300#product
Smart remote terminal unit (RTU) enhances critical infrastructure cybersecurity
Schneider Electric announced new (operational technology) OT cybersecurity functionality for Schneider Electric SCADAPack 470i and 474i during the 2025 ARC Industry Leadership Forum. Critical infrastructure customers can securely manage RTU access in harsh environments as easily as they can manage employees’ email access. Cyber threats to water and oil and gas pipelines continue to grow. Controlling access to RTUs in remote and harsh environments is vital to OT security. Using the SCADAPack 470i or 474i provides a smart device for remote control and computer operations so customers can securely manage RTU access using standard IT tools, such as Active Directory, in OT security, including water security and pipeline security. One Linux-based device can host edge services, protocols and applications for efficient remote control and computer operations. Schneider Electric, https://www.se.com/ww/en
How new generative AI software helps asset lifecycle intelligence
Hexagon’s HxGN Alix, an AI-powered assistant to help industrial enterprises digitally transform heavy asset operations, offers data security, privacy, accuracy and accessibility to enterprise asset management (EAM) customers on edge or on the cloud, said Tom Kurtz, Hexagon vice president EAM portfolio strategy, at the 2025 ARC Industry Leadership Forum by ARC Advisory Group. The Hexagon AI assistant supports how to use HxGN EAM features, simplifies code generation and advises on industry processes, regulations and specifications. Hexagon, https://hexagon.com/products/ hxgn-alix
Sensor, analytics for predictive maintenance of rotating industrial assets
The Nanoprecise MachineDoctor is a six-in-one sensor for vibration, acoustic, mag flux, speed, temp and humidity that sends information to data storage and cloud computing. The Nanoprecise MachineDoctor VibAnalyst Agent finds the cause behind data using artificial intelligence (AI) and a predictive analytics algorithm supplies custom outputs in an application programming interface (API) to provide alerts and populate a dashboard, with a more than 50% increase in accuracy over six months ago, to find and correct energy wasting issues. Nanoprecise, www.nanoprecise.io
INNOVATIONS
Industrial IoT edge gateway has edge computing capabilities, second-stack expansion
Advantech launched the Uno-2271G V3, expanding its Uno-2000 modular IoT gateway series. Featuring Intel Atom x7211RE processor and modular design, this compact solution provides edge computing capabilities with second-stack expansion options. The device enables diverse industrial applications from equipment connectivity to process visualization and environment management, meeting Industry 4.0 demands for real-time analytics. It has a compact design (100 x 70 x 40 mm) and modular architecture, offering three stackable expansion options supporting PoE PD, COM ports and iDoor modules. The device supports multiple mounting options, including DIN rail, rear DIN rail, stand, wall and VESA mounting. Advantech, www.advantech.com/en
Stainless steel gear unit has temperature stability
The SEW-Eurodrive WES Series stainless steel gear unit is a compact and hygienic drive designed for temperature stability during continuous use. The WES Series features SEW-Eurodrive Spiroplan right-angle gearing, reducing heat buildup compared to traditional worm gear units. Designed for food, beverage and hygienic applications, the WES Series is corrosion-resistant, easy to clean and rated for high-pressure washdowns. It has no cooling fan, reducing contamination risks in clean environments.
SEW-Eurodrive, www.seweurodrive.com
New control room strategy targets distractions, fatigue, ergonomics
Winsted’s new control room solutions address challenges that impact operations and personnel, including distractions, acoustics, traffic, lighting, ergonomics, communication issues and fatigue. The design process improves workflow, enhances accuracy and boosts operational performance. Design integrates ergonomic standards and guidelines for control room systems to prioritize the comfort and physical health of personnel, which is vital for continuous operations. Designs align operator needs with the latest tools and facilitates efficient interactions. Winsted, www.winsted.com
Sensors, condition monitoring improve food line reliability
Dodge’s Optify is a condition monitoring platform designed to improve efficiency and reduce costs in industrial operations. The platform combines Dodge Industrial internet of Things (IIoT) products with data analytics and product expertise. Optify features advanced sensors, breathers, automatic lubricators and gateways, aiming to transform how manufacturers manage operations and help improve operational excellence. One of the Optify platform’s key features is its ability to provide real-time data, enabling informed decision-making. Dodge Industrial, https://dodgeindustrial.com
Advanced encoders have metallic code disk, IIoT integration
The Kübler Sendix encoder is designed for durability and precision using selected materials. It includes incremental and absolute encoder options, enabling accurate position and speed measurement for machinery, automation systems and motor control. Kübler provides measurement, transmission, and evaluation solutions for various applications. The new Kübler Sendix K58 and K80 encoders feature advanced sensor and electronics technology, designed to meet current standards and integrate with IIoT systems. The 58 mm and 80 mm sizes follow standardized housing designs, available in incremental, single-turn and multi-turn variants. This consistency simplifies installation and mounting choices for designers. Kübler refined its material selection, safety lock technology, and EMC shielding while reducing the number of components. The K58 and K80 encoders use a new sensor system with a metallic code disk, offering resolutions of up to 36,000 ppr and improved accuracy over glass disk systems. Kübler, www.kuebler.com/en/home
The Trafag AG 8271 CMP Pressure Transmitter features a small and rugged construction, making it suitable for harsh environments and demanding applications. For applications requiring enhanced durability, an optional fivefold overpressure resistance provides robust protection against pressure spikes. The thin-film-on-steel measuring principle delivers high accuracy and excellent long-term stability in pressure measurements. Accuracy is ensured with ±0.5% FS typ. or ±0.3% FS typ. @ 25℃, providing precise pressure readings for critical applications. Trafag AG, www.trafag.com/en/cmp-8271-canopen-miniature-pressure-transmitter
Subminiature photoelectric sensors, high-accuracy, compact barrel or block style
Idec Corp. is expanding its photoelectric (PE) sensor portfolio with the new SA1N series of space-saving subminiature PE sensors. The SA1N series provides high accuracy and performance, and it is available in compact barrel and block form factors. Both versions are all-in-one devices with built-in amplifiers and sensitivity adjustment control. The barrel-mount version has a 3 to 50mm sensing range, while the block-type can detect over a 5 to 30mm sensing range. Both models are available in NPN or PNP light-on configurations, and both provide a rapid 0.5msec maximum response time. Idec Corp., https://us.idec.com
Supercharger for multicore processing power
With TwinCAT Core Boost, Beckhoff is supercharging its proven TwinCAT 3 runtime and robust multicore processing power with turbo mode. TwinCAT Core Boost increases the computing performance of individual real-time or user-mode cores by up to 50%. Now, systems can achieve maximum performance, adapt to unique application requirements, and possibly use lower cost CPUs while tapping into extra performance for specific tasks as needed. TwinCAT Core Boost enables users to configure the clock frequency of individual processor cores. The clock rate per core can be defined for real-time transmission and user-mode applications. Beckhoff Automation, www.beckhoff.com
Block open core control transformers
AutomationDirect Block CT and USTE series open core control transformers can step down a wide range of voltages from 208 to 600 VAC. The Block CT series is made in the USA and offers a rugged design engineered for isolation, lighting or signaling systems. It is available with a 240/480 or 600 VAC primary and a 24 or 120 VAC secondary. Ratings range from 50 to 2500 VA. Fused versions are available. The Block USTE series allows OEMs and system integrators to save time and reduce costs by standardizing on one model. Available in ratings from 40 to 3200 VA, they feature low inrush current, tool-free push-in wire terminals, and 13 jumper selectable primary inputs from 208 to 600 VAC. The transformers are RoHS-compliant and CE-marked. AutomationDirect, https://www.automationdirect.com/open-core-transformer
TK Arasu, Emerson
Choosing the best control valve style for your application
With so many control valve options available, it’s important to know how to choose the right body style for a particular application.
Choosing the right control valve for a specific application can be a daunting task. There is a wide range of body styles with most of these offering a broad selection of body and trim sizes, flow characteristics, packing options and a multitude of body, internal and seal materials.
The details of control valve sizing and the art of material of construction selection is a vast topic. But it’s important to understand the various control valve body styles to help end users make the right choice for their application.
Understanding control valve applications
The first step in valve selection is to fully understand the application. The process conditions will drive the selection of construction material and normal and abnormal flows, and pressure drops will drive the valve sizing calculations, but there are other fundamental requirements that drive selection of the body style itself. Some points to consider include:
• What kind of pressure drops will the valve encounter? Will pressure drop for vapors or gases approach critical flows or sonic velocity? Will liquid processes tend to cavitate or flash through the valve?
• How good is the valve control rangeability or turn down? Must the valve provide control through a wide dynamic range of flows, or will it usually operate within a relatively narrow band?
• What is the required flow characterization of the valve: linear, equal percentage or quick opening? This is generally determined by the requirements of the process being controlled.
• What is the nature of the process fluid and piping arrangement? If the fluid is a slurry or highly viscous or has scaling potential, a different style or valve must be chosen. Similarly, piping requirements like end of line or change in piping orientation will require a different kind of valve.
Before we get into details of selecting a valve type, let’s look at the main valve body styles.
Understanding control valve body styles
Control valve body styles come in two
FIGURE 1: Butterfly control valves come in a wide range of sizes up to 72”, including the Fisher Control-Disk Rotary Valve. All images courtesy: Emerson
FIGURE 2: The Fisher A11 High-Performance Butterfly Valve.
3:
major categories: sliding stem control valves where the stem rises and falls to throttle flow and rotary valves where the shaft turns (usually 90 degrees) to throttle flow. Each style has inherent strengths and limitations that play into valve selection.
Butterfly rotary control valves
Butterfly control valves use a rotating flat disc to control flow (see Figures 1 and 2). Butterfly valves are the least expensive of the options, owing to their simplistic design, particularly in large sizes. In very large pipe sizes, a butterfly valve may be the only available option.
Butterfly valves may exhibit a linear or equal percentage flow profile depending on the design of the disc and they offer very limited turndown and less control range than the other valve styles. Butterfly valves are also not suited to high pressure drops and flashing and/or cavitation conditions due to the high recovery pressure profile discussed later in this article.
Ball rotary control valves
Ball control valves rotate a full ball with a hole or a segment of a ball to throttle flow (see Figures 3 and 4). Ball control valves are offered in full-ported versions to provide an unrestricted and piggable flow path for pipeline applications. Ball valves are typically limited to line sizes up to 24”. Most ball valves have an equal percentage characteristic, though a few models offer linear as an option. Ball valves have limited turndown like butterfly control valves, but some versions do offer anti-cavitation and low noise options not available with butterfly valves.
Like the standard ball valve, the V-ball control valve rotates a ball with a hole in it to throttle flow. It’s offered in full port versions, and it has high noise and cavitation options (see Figure 5). However, the V-ball uses a ball with a V-shaped notch in it to better modulate low flows and to provide significantly higher turndown and better control. The V-notch also enables a shearing action making them suited for pulp and slurries. Line sizes are generally limited to 24” or less. V-ball valves usually have equal percentage characteristics.
Sliding stem control valves
FIGURE 4: V-ball control valve models have a V-shaped notch to provide higher rangeability and tighter control.
In a sliding stem control valve, the throttling element moves vertically to control the flow of the process fluid. Sliding stem globe control valves come in a vast array of designs with different trim offerings (see Figure 8), allowing a specific model to have quick opening, equal percentage or linear flow characteristics. They often have higher throttling resolution than rotary valves and they have advanced internal designs specifically fabricated to handle very high pressure drops, noise, flashing and cavitation. However, they have a lower-rated capacity than a comparable rotary design due to the nature of their construction. Sliding stem globe valves are the most complex to manufacture, making them more expensive than other types, but they also offer the most customization options.
What are control valve selection criteria?
Now what we’ve looked at the main control valve body styles, let’s look at some of the selection criteria.
Pressure drops
Taking a pressure drop is one of the key functions of a control valve. Even if the inlet and outlet pressures are identical, the internal pressure can differ significantly between sliding stem globe and rotary control valves. Globe valves of all types, including sliding stem, are classified as low recovery. Rotary valves, such as butterfly valves and standard V-balls, are high recovery. As shown in Figure 7, high-recovery valves experience much lower internal pressures, which can lead to issues like cavitation and noise. Consequently, butterfly valves
FIGURE 5: Sliding stem control valves can be made in globe here or angle (as seen in Figure 6) designs to match with piping requirements.
FIGURE
Ball control valves come in sizes up to 24 inches and offer full port models.
BACK TO BASICS
FIGURE 6: Sliding stem control valves can include highly engineered trims, like Fisher Dirty Service Trim, capable of handling over 4000 psi pressure drops with entrained particulates.
FIGURE 8: Relatively recent introductions allow some rotary ball and v-ball valves to incorporate anti-cavitation and lownoise trims. One of these introductions is the Fisher Cavitrol Hex Trim shown.
FIGURE 7: This graph compares the vena contracta pressures of a high recovery (ball, butterfly) valve versus a low recovery (globe) valve for the same process conditions. Notice the vena contracta pressure in a high recovery valve is significantly lower, increasing the likelihood of cavitation.
and standard V-balls are not ideal for high-pressure drop applications.
Turndown and control range
From a control valve standpoint, it's essential to understand how much of the valve’s throttling range can provide an ideal gain. Too little gain can make the control process sluggish, while too much gain can cause the process to swing wildly and potentially lead to system upsets. The gain of a control valve is therefore crucial for effective throttling and maintaining tight control over the process. This refers to how much the flow changes with a change in valve position. Ideally, the gain of the control valve would be 1, but that's not practical.
EnTech’s Control Valve Dynamic specification recommends a gain between 0.5 and 2 for maintaining good process control.
• A butterfly rotary valve exhibits a significant change in flow area during initial opening, resulting in very high gain and a much lower change in flow area at the top end of its travel range, resulting in very low gain. Therefore, the range where the gain is ideal is limited to the mid-portion of the disc's travel, typically 25 to 60 degrees.
• This range is better in a ball rotary valve. A V-Ball valve excels in rangeability, offering a wide range of controllable control valve coefficient (Cv) due to significant changes in flow area. However, as a V-Ball reaches the top end of its travel range, the change in flow area diminishes, leading to inefficient throttling capabilities. Therefore, we typically limit the openings of a ball valve to around 70 to 75 degrees for effective throttling. For emergency flow dumps, the valve can open to 80 to 90 degrees.
• A sliding stem valve is characterized by the design of the cage openings or plug contour, offering great flexibility and precision in flow control. The flow area changes and resultant flow rate change can be controlled more precisely, allowing the sliding stem valve to provide a wider throttling range where the gain is optimal.
Understanding sliding stem versus rotary valves
For very large line sizes or basic flow control within a limited dynamic range, a cost-effective butterfly or ball valve is usually sufficient. When improved rangeability is needed, a V-ball valve may be the better choice. Slurry applications are best managed with specially modified V-ball models. For precise control over a broad dynamic range or in cases of very high pressure drops, investing in a sliding stem valve is likely worthwhile.
However, a rotary style valve will provide a significant savings, particularly if the application requires only basic flow control. Rotary valve designs generally don’t handle cavitation or high noise conditions well, although recent designs do allow some ball and V-ball valves to incorporate noise and cavitation reduction trims (see Figures 8 and 9).
Other control valve selection considerations
Using a low-quality actuator and/or positioner on a control valve will render the best body style ineffective. A well-designed rotary control valve will instead incorporate an oversized shaft with spline connections to eliminate slippage and backlash.
A quality sliding stem valve will have a stiff stem adequately supported along its length, complemented by a high-quality actuator that is appropriately sized, with a strong spring to ensure reliable
‘A rotary style valve will provide a significant savings, particularly if the application requires only basic flow control.’
control throughout its operating range.
Both body styles should incorporate a high-resolution positioner with tightly coupled or linkage less feedback. For critical applications, users should consider a positioner capable of delivering realtime health status of the valve, adding an extra layer of reliability.
The importance of understanding the capabilities and limits of control valves
The wide range of options can make control valve selection overwhelming. End users must first fully understand the application and its specific requirements. Armed with that knowledge and an understanding of the capabilities and limitations of
each valve style, they can choose the right solution for a specific application.
However, there are a broad range of options that can be difficult to negotiate, so spending time discussing specific application requirements and control valve solutions with your control valve partner is a worthwhile endeavor. The valve specification and selection process can be complex, but choosing the right solution will yield big dividends in controllability, process reliability and performance. ce
TK Arasu is global industry sales manager for Severe Service with Emerson. Edited by Sheri Kasprzak, managing editor, Automation & Controls, WTWH Media, skasprzak@wtwhmedia.com.
Robust Ethernet Networks
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• Single mode and multimode ber optic switches and media converters
• Diagnostic switches for network troubleshooting
• PoE switches, mid-span splitters and injectors
• Wired and wireless IP routers for secure remote access
• Custom con gurations and outdoor-rated options available
FIGURE 9: The Fisher Whisper NXV.
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