When
Several new models have been added to the popular STRIDE family of industrial communication products. As with all of the STRIDE SE3 series, these additions offer low-cost, reliable Ethernet networking solutions with rugged IP30 or IP40 metal housings and Gigabit speed options.
• NEW! PoE++ Ethernet switch provides both power and Ethernet communication to connected devices, allowing even more savings in your network design. This switch will auto-detect the presence of a PoE enabled device and provide up to 240W of DC power along with Fast or Gigabit Ethernet communication speeds to the powered device.
• NEW! SE3 Ethernet media converters provide copper-to-fiber and fiber-to-copper conversions. Converting from copper to fiber allows for faster data transmission, less noise interference, and extended ranges.
• NEW! PoE++ injectors provide a convenient add power to an Ethernet network where needed, convenient for adding PoE enabled devices, including web cameras and Wi-Fi access points, to an existing standard Ethernet network.
injectors a convenient way to add power
No matter how many “ings” your process has, Productivity PLCs can handle them all while providing substantial cost savings. Whether you’d prefer a single controller for complete end-to-end control or a segmented control system with multiple controllers, the scalable Productivity PLC family has what you need for less.
This family offers three series of PLCs each with different I/O capacities but all using the same FREE advanced programming software, so you can easily scale your control hardware up or down depending on the application.
NEW! More discrete and relay I/O expansion modules have been added to the Productivity PLC family for even more affordable control options.
For the Productivity1000 PLC series:
• A 4-channel, high current relay output module with up to 7A/point and four Form C contacts, perfect for applications with higher current loads
For the Productivity2000 PLC series:
• A 6-channel, high current (7A/point) relay output module with both Form A and Form C contacts
• A 16-point low voltage discrete input module and 16-point low voltage discrete output module, ideal for devices that utilize transistor-transistorlogic (TTL) and voltage levels ranging from 3.3 to 5 VDC
Decarbonize with Confidence
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VIEWPOINT
5 | Becoming a leader under 40: the new wave of change in engineering
Age has nothing to do with leadership. It’s all about empowering and elevating
INSIGHTS
6 | How manufacturing experts are utilizing VFD and VSDs in their facility
Variable frequency drives (VFDs) and variable speed drives (VSDs) play a critical role in manufacturing facilities and they are being used in more diverse ways than ever. Learn how from several experts.
10 | Rising to the challenge: Engineering Leaders Under 40, Class of 2024
Discover how these 35 engineering professionals are making a significant impact in automation, controls and beyond.
SOLUTIONS
19 | How to bolster asset management efficiency using analytics platforms
Centralizing field data and leveraging advanced analytics for process insights are essential
SOLUTIONS
23 | Digital valve controller offers detailed asset health insights
Controller uses edge computing capabilities to analyze data in real time, providing diagnostic valve health indications and recommended corrective actions.
27 | Know when, how to implement electrical maintenance in power equipment
Maintenance of electrical systems is a necessary process that often gets overlooked
31 | Modernize, monitor and maintain to make aging switchgear safer
Breathe new life into old switchgear with modernization and see the benefits of improved reliability and safety
36 | Benefits of modernizing manufacturing power, electrical systems
Many organizations are looking to modernize a flexible power system and approach maintenance for their power systems to improve sustainability and efficiency.
When an opportunity for being better or the best at what we do is available, why wouldn’t we take it?
As Engineers, Technicians etc., we should and, need to know what we are doing. Having a better understanding of our role is something that we can accumulate as we perform our jobs, but sometimes things come along that are ‘out of the norm’, just different or more complex than we can educate ourselves on, or perhaps related to a subject you may have only briefly covered during your formal education.
On the job training is only as good as those we are learning from, sometimes we need to seek additional help especially with much of the newer technologies we see today. While we could read books, manuals and these days even watch videos on the subject they often lack the ‘hurdle’ component, that’s the bit where we need additional guidance when something just didn’t make sense.
Training from an expert not only walks us through the process but also enables us to ask questions that may arise while doing so; the ‘hurdle’ effectively need never exist.
While finding time to take advantage of these opportunities may be a challenge, we should take them when we can. Companies such as DEWESoft offer opportunities both in-house and a variety of locations around the country to provide that training from beginner to expert in a variety of different subjects, consider the advantage and ultimate time saving as well as possibly creating local experts so the future on-the-job trainings you give will truly cover the needs of the role.
“ Training from an expert not only walks us through the process but also enables us to ask questions that may arise while doing so; the ‘hurdle’ effectively need never exist. ”
+1-855-339-3669 • sales.us@dewesoft.com • www.dewesoft.com
CliCk or scan QR to learn more
Training session with Dave Gallop, Business Development Training Manager — Dewesoft
CONTENT
CONTENT SPECIALISTS/EDITORIAL
AMARA ROZGUS, Editor-in-Chief ARozgus@WTWHMedia.com
CHRIS VAVRA, Senior Editor
MICHAEL SMITH, Art Director MSmith@WTWHMedia.com
AMANDA PELLICCIONE, Marketing Research Manager APelliccione@WTWHMedia.com
SUSIE BAK, Staff Accountant SBak@WTWHMedia.com
EDITORIAL ADVISORY BOARD
H. LANDIS “LANNY” FLOYD, IEEE Life Fellow
JOHN GLENSKI, Principal, Automation & Digital Strategy, Plus Group, A Salas O'Brien Company
MATTHEW GOSS, PE, PMP, CEM, CEA, CDSM, LEED AP, Senior Vice President, CDM Smith
CONTRIBUTORS WANTED
Are you a subject matter expert in one of these topics? Would you like to write an article on one of the topics below? If so, please submit an idea to: https://tinyurl.com/PlantEngineeringSubmissions
• Compressed air systems
• Emissions reduction
• Expert Q&A: Maintenance
• Expert Q&A: Power ane electrical systems
• EV charging systems
• Lubrication
• Preventive maintenance
• Robotics
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.
* https://tinyurl.com/PlantEngineeringSubmissions 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://tinyurl.com/PlantEngineeringSubmissions
Becoming a leader under 40: the new wave of change in engineering
Age has nothing to do with leadership. It’s all about empowering and elevating
According to Plant Engineering’s most recent salary survey, the average age of this audience is 54 years old. Employees have worked in this industry an average of 26 years. In this study, only 16% of respondents are younger than 40, the age cut-off for the Age Discrimination in Employment Act.
In an industry traditionally dominated by seasoned professionals, a new generation of leaders is making waves. These individuals, under the age of 40, are taking on significant leadership roles in fields like automation, controls, electrical systems, robotics, quality control, cybersecurity and manufacturing operations.
ments is both a challenge and an advantage. These professionals often come from diverse educational backgrounds, equipped with the latest knowledge in quickly advancing fields. This agility, however, can put them at odds with traditional processes and mindsets.
Amara Rozgus, Editor-in-Chief
But being a leader at a young age comes with its own set of challenges and opportunities.
Overcoming age bias and perceptions: One of the first hurdles young leaders face is overcoming the stigma of age bias. Many professionals under 40 often find themselves needing to prove their worth — sometimes to themselves, but often to those around them.
However, the new generation is turning this challenge into an opportunity.
Leading through rapid technological change: For many engineering leaders under 40, the need to navigate rapid technological advance-
Balancing expertise and leadership: Another key challenge young leaders face is finding the balance between technical expertise and leadership. Engineers are often promoted to leadership positions based on their technical abilities, but leading a team requires a different skill set. For professionals under 40, many of whom are still refining their management styles, this balancing act can be daunting. Yet, those who succeed are rewriting the script on what leadership looks like.
The broader impact (or what industry can learn): As more professionals under 40 take on leadership roles, they’re reshaping how engineering is viewed — not as a static field, but as a dynamic space driven by innovation. The lesson for the broader industry is clear: leadership is not about age, but about vision.
The future of engineering will be defined by those who are willing to embrace new technologies and new ways of thinking. And those leaders, regardless of age, are the ones who will push the industry forward. PE
How manufacturing experts are utilizing VFD and VSDs in their facility
Variable frequency drives (VFDs) and variable speed drives (VSDs) play a critical role in manufacturing facilities and they are being used in more diverse ways than ever. Learn how from several experts.
Question: What are some of the current trends for variable frequency drives and variable speed drives (VFDs and VSDs) for industrial and manufacturing facilities?
Richard Barrows: Energy savings are key to their growth. Depending on the application, VFDs offer flexibility. They can turn off and on to tailor the air
power output to your needs at the time.
Eder Matias: Rather than looking at specific VFD types, customers are looking for a VFD platform. This means creating products made to work together and are powerful and versatile enough to solve simple and complex applications without spending lots of money in trainings and costly support fees.
Craig Nelson: To save energy, space and costs, many VFD systems on production machinery are utilizing a common dc bus design. This configuration allows for regenerative energy from decelerating drives to be captured and used to drive other motoring loads. The elimination of a braking resistor to dissipate this energy into wasted heat energy adds to its growing popularity.
Paulo Guedes Pinto: From an application perspective, VFDs are being packaged into IP54+ enclosures and being placed closer to the motor. This avoids the need for space within the electrical cabinet for the VFD and makes maintenance easier. Also related to this trend is the use of quick disconnect cabling, which further allows for fast installation and easier serviceability.
The use of wide-bandgap technologies like gallium nitride (GaN) and silicon carbide (SiC) MOSFETs in consumer electronics, electric vehicles (EVs) and alternative energy inverters (solar & wind) has brought down costs making it more feasible to deploy into industrial VFDs. The benefit of utilizing GaN and SiC MOSFETS in VFDs as compared to traditional IGBTs include improved efficiency, smaller form factor and better thermal management.
Brandon Teachman: Trends in drive technology include reducing heat and putting the drive on a network. Conventional panel-mounted drives can shorten drive life due to heat. Flange-mounted or NEMA-rated drives dissipate heat directly into the environment, reducing energy losses. It is ideal for heat dissipation or space constraints. Drives can process, and the network enables the sending of motor performance data, analytics, and some amount of predictive maintenance. This also allows diagnostics and monitoring for troubleshooting issues remotely.
Atlas Copco's GA VSD product line brings energy efficiency and reliability for industries worldwide. Courtesy: Atlas Copco
Question: What longterm trends do you see for VFDs and VSDs (looking ahead to the next 12 to 18 months)?
Richard Barrows: The market is moving toward using permanent magnet motors to further drive efficiency. These are more efficient than traditional induction motors. They are becoming standard, and they require VFDs in order to operate.
Zack Fowler: One of the long-term trends we have noticed is to move from asynchronous motor to permanent magnet motor.
Eder Matias: It will be a combination of new technology and how it gets implemented. Energy management and storage combined with motion controllers, advanced decentralized VFDs and predictive maintenance are the next areas of industry focus.
Craig Nelson: Utilizing drive-based safety integrated functions has been a growing trend for years, but now more advanced SI functions such as safe limited speed and safe operating stop are being incorporated into new innovative machine safety designs. The secondary effect of utilizing more safety functions in the VFD is the safety signals are migrating from HW safety inputs to a safety channel on the communications network.
Paulo Guedes Pinto: We see the adoption of IP54+ packaging and the use of GaN and SiC continuing to increase over the next 12 to 18 months. In addition, given the reduction in cost of power electronics, we see increasing adoption of active front end (AFE) enabled VFDs. AFE VFDs can provide regeneration, saving money and energy in some applications and reduced total harmonic distortion (THDi).
Question: What are the primary advantages of using VFDs in motor control applications compared to other methods, such as soft starters or direct-on-line starting?
Zack Fowler: VFDs significantly enhance efficiency, resulting in reductions in power consump-
tion. They provide precise control over motor speed and torque, leading to smoother operations and extended equipment life.
Eder Matias: There are several advantages ranging from energy usage to ease of maintenance. In addition, despite all of the technical advantages, customers benefit by having a more flexible system which can easily adapt to different demands rather than running at a constant speed.
Paulo Guedes Pinto: There are several benefits to using a VFD compared to other methods, including energy savings, improved speed or position control, reduced starting current, integration with the control system, and built-in protection.
For centrifugal fan and pump loads, reducing the speed to 80% results in roughly 50% reduction in energy consumption.
In industrial applications such as cranes, elevators and material handling, the operator needs speed and position control. Older methods like soft-starts or direct-on-line starting do not offer this capability.
Participants
Brandon Teachman: VFDs are unique in motor control applications because they can regulate both motor speed and torque. Smooth acceleration and deceleration are possible with VFDs because they provide exact control over motor activities, in contrast to soft starters or direct-on-line starting techniques.
This flexibility is essential to ensure maximum performance and energy efficiency in applications where load circumstances change. Additionally, it enables you to adapt to changes in the mechanical components or process.
Question: How do you select the appropriate size and rating of a VFD and VSD for a specific motor application? What are the key factors that need to be considered in this process?
Zack Fowler, product marketing manager, Atlas Copco, Rock Hill, S.C.
Craig Nelson, senior product manager, Siemens Digital Industries, Alpharetta, Georgia
Brandon Teachman, owner, Automation Coffee Break, Appleton, Wisconsin
Richard Barrows, senior electrical engineer, Hitachi Global Air Power, Michigan City, Indiana
Eder Matias, director of sales, drives, controls & automation, SEW-EURODRIVE USA, Lyman, S.C.
Paulo Guedes Pinto, chief technology officer, infinitum, Round Rock, Texas
The Infinitum Aircore EC motor system. Courtesy: Infinitum
ENGINEERING SOLUTIONS
The MOVI-C automation platform is part of SEW-EURODRIVE’s Industry 4.0 approach and includes VFDs, HMIs, motion controllers, gearboxes, motors, servomotors and encoders, which are designed to work together seamlessly.
Courtesy: SEW-EURODRIVE
Zack Fowler: By knowing the air demand of the customer application and operating pressure while considering pressure drops. Acknowledging the air purity requirements to provide a suitable solution. If they plan to expand its best to offer multiple machines with the VSD as the lead. If it’s a VSD and fixed speed combination, the VSD should be double the fixed speed.
Eder Matias: Several factors to consider are: Environment conditions, motor type, application, safety requirements, panel-mounted, motor-mounted or decentralized, communication with upper-level programmable logic controllers (PLC) or discrete input/outputs (I/Os). Customers also should consider a VFD platform which offers flexibility, regardless of the key factors being considered.
Paulo Guedes Pinto: Infinitum sells a combined motor and VFD system that avoids the need to select the components individually. In traditional applications where these components are sold separately, there's several factors a user must consider including the motor requirements and load characteristics. The application's load characteristics are crucial to understand in selecting a VFD to avoid field issues.
Brandon Teachman: There are few key pieces of information to consider:
• Know your motor: You will want all the information from the nameplate, but the essential item is the motor's full load amps (FLA).
• What is the application? Some applications need the motor to run at a continuously high amp draw. In this case, most manufacturers will have you increase the drive size. Some applications, like a loaded conveyor, will have a higher FLA till they get to speed.
• Where is the VFD being placed? This includes the temperature range and enclosure rating (water, dust, etc.). The temperature range can affect the drive sizing.
Question: As VFDs become more widely used in industrial and commercial settings, how do you ensure the compatibility and integration of VFD systems with other control and automation technologies?
Zack Fowler: Ensuring compatibility and seamless integration of VFD systems with other control and automation technologies is achieved through the use of OPC-UA. This communication protocol provides a reliable and secure framework for data exchange, enabling interoperability among various devices and systems, which is essential for modern industrial and commercial applications.
Eder Matias: Compatibility is a factor which should be considered early in the selection process. Selecting a manufacturer that offers motors, servos, gearboxes and drives with standard fieldbus commu-
nication eliminates the guess work and ensures compatibility among these components.
Paulo Guedes Pinto: The use of and adherence to industry standards is critical to interoperability, especially with regard to communication protocols like Ethernet/IP. Some standards, such as Modbus RTU, allow for a lot of interpretation, which occasionally creates issues between vendors.
Brandon Teachman: For a new application, I recommend that the person choses a drive with EtherNet/IP and write their program using the ODVA communication standard. This allows you to switch out a drive with multiple manufacturers. EtherNet/ IP and ODVA are supported by many VFD manufacturers, allowing the end user to prevent supply issues.
Question: With the rise of the Internet of Things (IoT) and Industry 4.0, how do you envision VFDs evolving to become smarter and more interconnected within larger control and monitoring systems?
Zack Fowler: With larger control and monitoring you will have better access to equalize running hours, narrowing pressure bands, more reactiveness to breakdowns which will improve productivity, efficiency and sustainability of products.
Eder Matias: Industrial internet of things is already a reality at SEW-EURODRIVE. Our MOVI-C automation platform is part of our Industry 4.0 approach and includes VFDs, HMIs, motion controllers, gearboxes, motors, servomotors and encoders — all designed to work together seamlessly. Thanks to our single cable technology, MOVILINK DDI, our VFDs enable asset management, motor temperature monitoring, vibration, brake pad wear and can warn the customer before a major failure happens.
Craig Nelson: VFDs are becoming a producer of data giving us insights into our equipment efficiency and mechanical condition. Feeding the motor operating conditions continuously back to edge or cloud platforms for analyzing gives us insight into any anomalies that can result in future downtime way before they happen. Further insights also tell us what can be improved or rightsized in the future.
Paulo Guedes Pinto: VFDs, like most devices at work and at home, are becoming smarter with increasing intelligence and capabilities. I envision VFDs interpreting application and on-device data to provide users with insights into the health of the
asset. Over the past few years, this data has typically been pushed to an on-site edge or off-site cloud server for further analysis. With devices gaining more intelligence, this data could be processed and acted on locally.
Brandon Teachman: I believe VFDs will have the ability to pair with motor sensors directly. This would reduce the hardware needed to implement projects and allow you to get more predictive maintenance of the motor and drive, allowing users to increase the time of their lines.
I also believe that VFDs will add native message queuing telemetry transport (MQTT) Sparkplug B support. This allows for common communication between devices, PLCs, and software. Some VFDs have added MQTT support, but I believe Sparkplug B will become the standard.
Question: What impact will the semiconductor industry have on the VFD market and manufacturing, both short- and long-term?
Richard Barrows: Supply for semiconductors seems to have leveled off from the shortages caused by the COVID-19 pandemic. At the same time, some chips are becoming obsolete, and must be replaced by readily available chips.
Zack Fowler: The semiconductor industry will have a significant impact on the VFD market and manufacturing in both the short- and long-term. As VFDs rely heavily on electronic chips and components in our drives.
Eder Matias: Semiconductors are the core of any industrial power electronics device. As the semiconductor technology evolves, VFDs are becoming smaller and offering higher overload capabilities. PE
Decentralized VFD mounted next to motor. Courtesy: Siemens
IRising to the Challenge: Engineering Leaders Under 40
Discover how these 35 engineering professionals are making a significant impact in automation, controls and beyond.
Amanda Pelliccione, Marketing Research Manager, WTWH Media
n an era of rapid technological advancement and complex challenges, the Engineering Leaders Under 40 program celebrates the achievements of young professionals who are shaping the future of manufacturing and engineering. This year, we honor 35 remarkable individuals whose contributions span a wide range of industries — from automation and cybersecurity to clean energy and robotics. Their innovative solutions, leadership and dedication not only drive success in their fields but also address critical workforce development issues, which are more pressing than ever. Each of these leaders brings a unique blend of technical expertise and visionary thinking, whether it's advancing cutting-edge control systems, pioneering renewable
energy initiatives or revolutionizing manufacturing processes. Their work reflects a deep commitment to excellence, continuous learning and community impact, inspiring peers and setting new standards across the industry.
As we share their stories, we celebrate not just their individual achievements, but also the collective progress they represent in making engineering a more dynamic, inclusive and forward-looking profession. Join us in recognizing these outstanding professionals who are leading the charge in building a stronger, more innovative future for all. Learn more about this program and how to nominate a colleague for 2025 at www.plantengineering.com/ EngineeringLeaders. Nominations open April 1, 2025. PE
Jason Andronic, 37
Senior Controls Project Manager
Quality Design Services
Okemos, MI
—Jason excels as Senior Controls Project Manager for Quality Design Services, having recently contributing to GM's flagship battery plant by coordinating over 250 engineers. His technical expertise in vision systems, programmable logic controllers (PLCs), and robotics, coupled with his leadership skills, drives operational success and fosters growth in junior engineers. Beyond work, Jason applies his skills to home automation projects, maintaining his reputation for innovation and dedication.
Kaleb Baker, 30
Controls & Automation
Engineer
Hargrove Controls & Automation
Mobile, AL
Fun Fact: Jason once repaired 30 alternators in a single day at his parents' shop.
—Kaleb is highly motivated and known for his detail-oriented approach and expertise in control systems and automation technologies. His adaptability and quick learning enable him to deliver high-quality results on various projects, from new installations to equipment upgrades. Kaleb has updated human-machine interface (HMI) screens to enhance usability and collaborated on designing safety control systems. He was crucial in programming and launching a new plant, ensuring a successful startup through close client collaboration.
Fun Fact: Kaleb enjoys working on cars and finding innovative ways to enhance their performance.
Steven Carlberg, 34
Controls & Automation Engineer
Hargrove Controls & Automation
Mobile, AL
—Steven specializes in system migrations, notably transitioning legacy Dow MOD 5 technology to modern distributed control systems (DCS) like DeltaV. His meticulous work in process control has made him an invaluable asset across industries, from oil refineries to pharmaceuticals. Steven's passion for continuous learning and client communication sets him apart as a leader.
Preston Clinemyer, 24
Hardware Design Engineer
Sealevel Systems
Liberty, SC
—Preston rapidly advanced from a repair technician to a hardware design engineer, showcasing his dedication and talent. He has led the development of custom intelligent platform management interface (IPMI) firmware and is involved in artificial intelligence (AI) server product design. His hands-on approach and continuous learning are key to his engineering success.
Fun Fact: Steven aims to visit every national park in the United States.
Ross Dale, 38
Senior Electrical Engineer
Continental Wahpeton, ND
—Ross’s transition from Journeyman Electrician to Senior Electrical Engineer has uniquely positioned him to revolutionize electrical controls at Continental’s Wahpeton facility. His contributions include designing safety systems and improving equipment efficiency. Ross’s hands-on experience and leadership have established him as a key figure in plant engineering.
Fun Fact: Ross began his career as an intern at the Wahpeton facility while completing his engineering degree.
Fun Fact: Preston has broken both of his arms twice, resulting in a total of 16 casts.
Andrew DeChirico, 36
Engineering Manager
NeoMatrix
Andover, MA
—Andy is an engineering manager and senior automation engineer at NeoMatrix, where he leads complex projects in industrial automation, particularly in the BioPharma industry. His technical expertise and leadership have significantly contributed to the company's success and growth. Andy balances his career with passions for hockey, golf, and homebrewing.
Fun Fact: Andy is an accomplished amateur chef who loves experimenting with new recipes.
Alex Garland, 36
Principal & Enterprise Account Manager
Burns & McDonnell
Atlanta, GA
—Alex is the Global Facilities leader for Burns & McDonnell in the Southeast, recognized for his work in advancing manufacturing facilities, particularly in the food and beverage sector. He led the development of a state-of-the-art "factory of the future," showcasing his blend of technical and leadership skills. Alex’s career is marked by his ability to drive client success and community impact.
Fun Fact: Alex enjoys golfing with his father-in-law, cherishing the quality family time and creating lasting memories on the course.
Michael Grabowski, 37
Senior Electrical Engineer
Salas O'Brien
Dublin, OH
—Michael is known for his exceptional work ethic and commitment to integrating safety into engineering solutions. He holds professional engineering licenses in 11 states and is actively involved in the Institute of Electrical and Electronics Engineers (IEEE) societies. His dedication to continuous learning has shaped him into a valuable asset in the engineering community. Outside of work, Michael is a passionate rock climber, finding joy in both the physical and mental challenges of the sport.
Evan Gonnerman, 29
Portfolio Manager
Concept Systems
Albany, OR
—Evan is an innovative engineer with a passion for finding revolutionary solutions to customer problems. His transition from Senior Engineer to Portfolio Manager has seen him expand a regional team and lead the successful launch of the evriiRobot. Evan is admired for his ability to unite customers and colleagues, fostering a collaborative environment. His dedication extends beyond work, where he enjoys spending time with his family and riding his e-Bike with his daughter, Luna.
Fun Fact: Evan loves complex and challenging board games.
Joshua Heater, 31
Proposal Delivery Manager
Concept Systems
Albany, OR
—Josh has progressed from being Concept’s first mechanical engineer to a respected engineering leader. He has pioneered robotic systems for various applications and is dedicated to mentoring junior engineers. His recent promotion to Interim Proposal Manager highlights his ability to lead and inspire his team. Josh is also active in his community, sharing his robotics expertise with middle school students through volunteer work.
Fun Fact: Michael is a dedicated family man who enjoys spending quality time with his wife, Katie, and their two children.
Joe Jones, 38
Quality Engineer
Rittal North America
Urbana, OH
—Joe excels in diffusing high-pressure quality concerns with logic, facts, and empathy, making him an invaluable team member. His dedication to continuous learning has led to numerous certifications, including a Six Sigma Yellow Belt and ASQCQA, enabling him to advance in his career. Outside of work, Joe is deeply committed to his family, coaching his sons in sports and celebrating their achievements. A former law enforcement officer, Joe transitioned back to manufacturing, driven by his passion for quality and precision.
Fun Fact: Josh is an avid soccer fan, supporting both the Portland Timbers and Chelsea Football Club.
Jacob Kaplan, 31
Engineering Manager
Continental
Lincoln, NE
—Jake leads capital investments and process improvements at Continental, significantly enhancing efficiency and reducing waste. With a strong background in product development and a customer-focused approach, he now manages both Plant Process and Manufacturing Engineering teams. Jake’s leadership has grown his team from two to seven members, and he has earned multiple patents during his career. Outside of work, he maintains saltwater reef aquariums, bonding with his autistic son over their shared love for marine life.
Fun Fact: Joe once earned the Top Gun Award for best accuracy, reflecting his attention to detail.
Fun Fact: Jake earned his private pilot's license while in college and captained the Arizona Shotgun Team.
Aneesh
Karakkat, 38
Staff Application Engineer Woodward
Fort Collins, CO
Aneesh is a leader in developing control applications for turbines and compressors, managing challenging projects across multiple continents. He is recognized for his contributions to cybersecurity awareness, digitalization efforts, and his role in pioneering controls for renewable energy initiatives. Aneesh’s expertise is highly regarded by original equipment manufacturers (OEMs) and global customers alike. Outside of work, he enjoys playing soccer, volleyball, and hiking in Colorado.
Imran Khan, 29 Lead Solution Architect
Pipeline Technologies & Services
Al Khobar, Saudi Arabia
—Imran is a talented engineer known for his technical prowess and strategic business acumen at PipeTech. He played a key role in developing the WaveGuard Leak Detection System and securing major pipeline projects in Saudi Arabia. His contributions extend beyond technical expertise to strategic negotiations with customers. Imran is also an avid painter, finding solace and creativity in capturing nature's beauty on canvas.
Fun Fact: Aneesh is a big fan of classic motorbikes, appreciating their craftsmanship and history.
Jonathan Miller, 35
Automation Engineer
CDM Smith
Columbus, OH
Jonathan is a highly dedicated automation engineer specializing in water and wastewater control systems. As a licensed professional engineer in Ohio, he has held several leadership roles at CDM Smith, including Project Technical Leader and Ohio Region Area Coordinator. Jonathan is also a committed mentor and has obtained his Project Management Professional (PMP) certification, furthering his expertise. His passion for mentorship and dedication to his clients and profession make him a standout leader in the engineering community.
Fun Fact: Painting allows Imran to shift his focus away from work-related concerns and enjoy quality time with his family, who often join him in the creative process.
Kyle Moore, 39
Team Leader & Senior Automation
Controls Engineer
Malisko Engineering
Denver, CO
—Kyle is a senior automation controls engineer with 19 years of experience at Malisko Engineering. As a team leader, he has been instrumental in leading multi-year projects, developing project management processes, and mentoring junior engineers. His technical expertise spans across multiple industries, including pharma, food and beverage, and more. Kyle is also a dedicated mentor and has contributed to Malisko's core values and project execution process. His leadership extends beyond his team, impacting the entire company.
Fun Fact: Jonathan recently traveled to India to mentor senior engineers in CDM Smith’s technical specialist development program.
Tim Mullen, 31
OT Cybersecurity Engineer
Applied Control Engineering
Newark, DE
—Tim leads the operational technology (OT) infrastructure and cybersecurity business at Applied Control Engineering, focusing on developing resilient and secure-by-design systems. His career began in the nuclear power industry, where he became a cybersecurity expert. At ACE, Tim has built a core team supporting OT security, earning his Global Industrial Cyber Security Professional (GICSP) certification and becoming a licensed control systems professional engineer in Maryland.
Fun Fact: Kyle helps maintain his in-law’s family farm, which includes raising chickens, goats, sheep, and cows.
Emily Niemi, 29
Group Manager
RoviSys
Portage, MI
—Emily is a group manager at RoviSys, leading the Life Sciences division with a focus on system integration and client collaboration. Starting as a software developer, Emily quickly advanced, earning certifications in PI System Infrastructure and AI. Her leadership was critical during the Pfizer COVID-19 vaccine project, leading to her promotion. Emily’s authenticity and enthusiasm make her a highly respected leader in her field, and she is passionate about empowering women in engineering.
Fun Fact: Tim volunteers as a bike mechanic at Velocipede Bike Project, a do-it-yourself bike shop in Baltimore.
Fun Fact: Emily is highly active and competitive, participating in various physical races and competitions each year.
Robert Phillips, 37
Automation Manager Interstates
Sioux Center, IA
—Robert is an automation manager at Interstates, specializing in soybean processing and refining. Starting as an entry-level programmer, he has advanced to managing client accounts and leading an automation delivery team. Robert is known for building strong, long-term relationships with clients and mentoring young professionals. His contributions to digital transformation and his leadership within the industry make him a trusted advisor and a rising trailblazer.
Mohamed Poptani, 38
Automation Engineer
CDM Smith
Boston, MA
—Mohamed has made significant contributions to municipal water and wastewater treatment projects, specializing in control systems design and construction oversight. As the Automation Design Area Coordinator for CDM Smith’s Northeast Region, he mentors young professionals, develops telecommunications standards, and ensures project delivery standards. His expertise and leadership extend to advancing telecommunications systems in newer markets, making him a pivotal figure in his field.
Fun Fact: Robert enjoys hunting and fishing, particularly for the strategy and adventure involved in the process.
Angelo
Rabano, 29
Controls & Automation Engineer
Hargrove Controls & Automation
Birmingham, AL
—Angelo is recognized for his innovation in optimizing complex systems, particularly through his Six Sigma Yellow Belt certification. He led a team that significantly improved process modeling software implementation, reducing deployment time across multiple plants. Angelo is also known for his initiative in addressing critical equipment issues during plant outages, enhancing operational safety and efficiency.
Fun Fact: Angelo is developing a mobile game that will be an adaptation of a board game he played with his college roommates.
Vidyadhar Rangojoo, 39
Principal Engineer
Fluence Energy
Arlington, VA
—Vidyadhar is a leader in the clean energy sector, known for integrating machine learning with battery energy storage systems to enhance operational efficiency and predictive maintenance. His work has set new industry standards, significantly reducing operational costs while advancing renewable energy technologies. Vidyadhar's contributions have made a lasting impact on sustainable energy solutions.
Fun Fact: Mohamed has visited over 30 countries, with Tanzania, Tokyo, and Andalusia among his top recommendations.
Olajide Rabiu, 38
Project Manager
Salas O'Brien
Dublin, OH
—Olajide excels in automation and controls with extensive experience in power substation design and engineering. A certified PMP, he has delivered cost-effective, technically sound solutions, saving clients substantial procurement costs. Olajide is also a mentor, fostering continuous improvement and innovation among emerging engineers, making a lasting impact on the industry.
Fun Fact: Olajide enjoys watching English Premier League soccer and is active in community service through his local church.
Jason Rhodewalt, 39
Partner
Barry-Wehmiller Design Group
Roseville, CA
—Jason has made exceptional contributions to industrial automation, particularly in developing a manufacturing execution system (MES) for the world’s fastest beer can line. As a Partner at Barry-Wehmiller Design Group, he leads complex automation projects and has pioneered a new market offering in data center automation. His leadership extends beyond his company, elevating the field of industrial engineering.
Fun Fact: Vidyadhar enjoys traveling and learning about global sustainability practices.
Fun Fact: Jason is a rugby coach and board member for his local rugby club.
Nicole Riddle, 32
OT Cybersecurity Engineer
Applied Control Engineering
Newark, DE
—Nicole has been pivotal in building ACE’s OT cybersecurity division, creating standards and training materials, and assisting clients with cybersecurity vulnerabilities in industrial control systems. She is a key contributor to ACE’s Cybersecurity Committee, developing templates and standards while leading major cybersecurity projects. Nicole also supports new engineers and helps customers maintain robust cybersecurity programs.
Tyler Robillard, 37
Director of Engineering & Manufacturing Operations
Feldmeier Equipment
Syracuse, NY
—Tyler progressed from Design Engineer to Director at Feldmeier Equipment, leading a team in developing innovative products and earning multiple patents that enhance product cleanability. His contributions to improving efficiency and innovating within the company have earned him recognition, including the Innovator of the Year award by the Manufacturers Association of Central New York.
Fun Fact: Nicole is a blue belt in Brazilian Jiu-Jitsu and trains regularly, aiming for her black belt.
Aleandro Saez, 30
Process Engineer
Champion Cooler
Denison, TX
—Aleandro has significantly advanced Champion Cooler’s robotic systems, developing ergonomic solutions that improve safety and designing innovative evaporative coolers that enhance energy efficiency and performance. His commitment to excellence and creativity positions him as a leader in engineering.
Fun Fact: Aleandro is an avid painter, transforming discarded materials into Picasso-inspired artworks.
Fun Fact: Tyler enjoys camping with family and has a permanent site at a local campground.
Matthew Schoendorf, 31
Head of Joining Technologies
Brose North America
Auburn Hills, MI
—Matt leads Brose North America's welding technologies, driving cost-saving innovations and process improvements across multiple locations. His leadership has advanced laser welding technologies and fixture designs, significantly enhancing operational stability and efficiency. Matt's proactive approach to new technologies and his leadership within the welding team have been instrumental in the company’s success.
Fun Fact: Matt enjoys home renovations and dog training, which enhance his creativity and leadership skills.
Bruce Slusser, 35
Digital Transformation Practice Director
Actemium-Avanceon
Exton, PA
—Bruce founded Actemium-Avanceon's DataOps division, leading digital transformation efforts that optimize infrastructure and enhance operational efficiency. His expertise in supervisory control and data acquisition (SCADA) design and MES application development has been critical in helping manufacturers achieve their digitization goals. Bruce’s commitment to equipping teams with accurate data has driven innovative solutions across various industries.
Anthony Soellner, 35
Electrical Development Engineer
Innomotics
Norwood, OH
Fun Fact: Bruce recently designed and managed a complete home remodel using an architecture software program.
—Anthony is an expert electrical development engineer with 12 years of experience designing high-efficiency motors for heavy industrial applications. He plays a pivotal role in shaping industry standards through active participation in National Electrical Manufacturers Association (NEMA) technical committees and IEEE working groups. Anthony's work includes authoring technical papers and pending patents on motor heating, and he has conducted extensive training on motor operations. Outside of work, he enjoys hiking, biking, and kayaking with his family.
Fun Fact: Anthony, who is fluent in both English and Spanish, is the first in his family to attend and graduate from a university.
Geno Triana, 38 Automation Engineer CDM
Smith
Dallas, TX
—Geno is an accomplished automation engineer with expertise in SCADA system design and cybersecurity for water and wastewater treatment facilities. His diverse background in industrial robotics, pollution control, and automation makes him a key asset to the industry. A licensed professional engineer in 10 states, Geno is dedicated to improving infrastructure performance and reducing cybersecurity risks for his clients. He is actively involved in the American Water Works Association. Outside of work, Geno enjoys running and has run several marathons and an Ironman triathlon.
Dru Vitale, 35 Controls & Automation Engineer Hargrove Controls & Automation
Baton Rouge, LA
—Dru is a versatile controls and automation engineer with extensive experience leading projects, commissioning systems, and solving complex challenges in real-time. His ability to learn and master outdated systems is crucial for successful migrations, making him a valuable resource on any project. Dru’s on-the-ground expertise and forward-facing client roles ensure smooth operations and successful project completions. Outside of engineering, Dru recently fulfilled a lifelong dream by visiting Greece, inspired by his childhood fascination with Greek mythology.
Fun Fact: Geno recently joined a Toastmasters club to improve his public speaking skills, becoming a more effective speaker and listener.
Caidey Whatley, 27
Controls Engineer
Hargrove Controls & Automation
Mobile, AL
Fun Fact: Dru is passionate about cooking and baking, often bringing his culinary creations to the office for teammates to taste.
—Caidey has rapidly advanced her career, becoming proficient in three DCS platforms and earning recognition for her reliability and leadership potential. She plays a key role in recruiting efforts, representing her firm at various colleges. Caidey has received quality awards for her dedication, obtained her Engineer In Training certification, and continues to expand her technical expertise. Passionate about mentoring, she has been instrumental in developing a summer high school intern program to inspire future engineers.
Garrison Wilfert, 25
Senior Engineer
Concept Systems
Albany, OR
Fun Fact: Caidey read 115 books last year and recently started learning bookbinding.
Joanna Zinsli, 37
Group Product Manager
Seeq
Seattle, WA
—Joanna’s expertise in the oil and gas industry has made her an invaluable asset at Seeq, where she leads product development with a customer-focused approach. Her career began as a process engineer at Valero Energy Corp., and she now serves as a Group Product Manager at Seeq, driving the success of key product rollouts. Joanna is also a co-chair of Women of Seeq, where she champions professional development for women in technology. Outside of work, she cultivates a miniature urban farm with her family.
Fun Fact: Joanna enjoys making jams and pickles from the harvest of her urban farm.
—Garrison is a rising star in automation and controls, known for his innovative solutions and strong leadership. He rapidly advanced to Senior Engineer at Concept Systems, where he tackles complex projects in various sectors, including aerospace for the U.S. Department of Defense. His engineering journey began with a senior project that developed affordable breathing devices during the COVID-19 pandemic. Garrison is a team player who fosters collaboration and values integrity in all aspects of his work.
Fun Fact: Garrison enjoys playing tabletop games like Pathfinder and Magic: The Gathering with his colleagues.
Engineering Leaders Under 40
Know someone who qualifies as an Engineering Leader Under 40? Help give them the recognition they deserve.
The Engineering Leaders Under 40 program recognizes manufacturing professionals under the age of 40 who are making a significant contribution to their plant’s success, and to the control engineering and/or plant engineering professions. Our research shows that finding, training and retaining workers is the biggest issue facing manufacturing today. The goal of the Engineering Leaders Under 40 program is to call attention to these successful young engineers in manufacturing and to show how manufacturers are recruiting and developing the next generation of manufacturing professionals.
Nominate someone at: https://www.plantengineering.com/events-and-awards/ engineering-leaders-under-40/
See past leaders online at the page above, going back to 2010.
around the pump motor was time-consuming — and it failed to yield a root cause.
What is the main thing?
John Watwood, Motion
nance work list for the next planned shutdown, a proactive maintenance approach that is expected to eliminate unplanned shutdowns due to this failure mode.
Insightsu
Advanced analytics insights
Throughout your life, you hear many sayings. One of my favorites is, “Keep the main thing, the main thing.” I first heard this during college, and it stuck with me—probably more so than some of my class studies. It is credited to Stephen Covey, but I heard it first from a shift manager at my job delivering pizzas.
A process engineer at the refinery took an alternative approach, using an advanced analytics platform to rapidly locate the five most recent shutdowns and subsequent restarts — planned and unplanned — from decades of historical process data. With timedissection tools, they focused on shutdown and startup time periods and overlaid all events, presenting abnormalities in the discharge pressure profile of the two most recent startups (see Figure 2).
Upon further investigation, the engineer also identified early warning signs on the motor amperage signal. Without a method to view the startups back-to-back, the motor degradation had gone unnoticed by operations.
Making advanced analytics work for you
Accurate process manufacturing predictions rely on in-depth knowledge of past equipment behavior and outcomes. By using advanced analytics platforms to combine retrospective with predictive analytics, process experts and data analysts can easily build robust models, capable of predicting plant maintenance needs and risk-mitigating procedures.
I often remind my kids of this simple way to cut through the noise of a fast-paced, complicated world to understand where they should focus. Entire companies exist to help other companies answer the question, “What is the main thing?” through various management techniques, strategy sessions and workshops. I think we all can agree that it’s important to know what the main thing is.
As a result of this root cause analysis, the process engineer implemented a monitoring solution to identify and flag future motor degradation to prevent similar unplanned shutdowns. When an out-of-tolerance value appears, the compressor motor is now immediately added to the mainte-
At Motion, there is no question about what we need to do. An account rep might help diagnose an issue at a customer’s location at night, a customer service rep might determine how to get a product from the West Coast to the East Coast the same day, or a
skilled technician might stay late at a service center to finish a hot repair. Whatever the obstacle, the Motion team goes to work knowing that keeping our customers operating is our main thing.
uAdvanced analytics, employing sophisticated methods like machine learning and artificial intelligence, empower organizations to convert historical, real-time and predictive data into actionable insights, thereby significantly enhancing decisionmaking processes.
So you can spend more time on your “main thing,” Motion is committed to helping you reduce costs, minimize downtime and improve production with the broadest mix of industrial products and unparalleled expertise. Get started and reach out to us today. █
With the right tools in their digitalization toolbox, process manufacturers can build better models to provide vast plant insights and project issues before failure so personnel can optimize maintenance schedules and prevent costly downtime. PE
uThis proactive approach allows manufacturers to anticipate potential issues and implement timely measures, ultimately improving operational efficiency and minimizing unexpected downtime.
John Watwood is Motion’s Senior Vice President – Solutions. He is responsible for the company’s Southeast and Southwest groups plus its businesses of Motion Automation Intelligence, Motion Conveyance Solutions and OEM Solutions. Watwood has over 20 years of experience in various sales and operations roles in both manufacturing and distribution—including with Motion since 2008.
Joe Reckamp is an Analytics Engineering Group Manager at Seeq Corp.
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How to bolster asset management efficiency using analytics platforms
Centralizing field data and leveraging advanced analytics for process insights are essential for effectively managing enterprise assets and maximizing operational efficiency
The enterprise industrial landscape is digitizing and evolving rapidly and asset management is no area of exception.
Reminiscing with any seasoned process engineer is likely to recount how they used to “feel the vibration of the pump” in their feet, “hear the hum of the compressor” to assess operating efficiency or “waft the air in the mechanical room” to detect overheating motors.
While these sensory — and often acutely accurate, depending on the engineer’s experience and expertise — methods of monitoring equipment health were relevant within recent decades, they are outdated in a world that is undergoing a tremendous digital transformation. Industry has installed sensors everywhere, built data warehouses and established remote technical facilities for centrally locating engineers and other personnel, collectively subject matter experts (SMEs).
Additionally, the intersection of information technology (IT) and operational technology is becoming increasingly important and complex. Now, instead of relying on human senses to determine process health, artificial intelligence (AI) is tasked with continuously inspecting incoming field data. The promise is faster, more reliable, earlier and more accurate anomaly and upset detection. Furthermore, the unceasing global increase in automation, paired with the ongoing struggle to hire enough skilled labor to meet demand, is necessitating that SMEs maintain responsibility for more industrial assets than in the past. The only way to successfully accomplish this is to rely on automated
technologies, such as AI, to operate efficiently and maintain industrial equipment effectiveness.
Leveraging AI is dominating the conversation of process analytics and manufacturing optimization and major manufacturing corporations are eager to understand and leverage AI to operate in a more environmentally friendly manner, enhance safety and increase profitability. These companies are investing millions and even billions of dollars in the race to realize these benefits.
However, for most organizations, the promise of AI has yet to be fully realized.
Asset management jobs
Recently at a major multinational oil and gas company, teams conducted numerous efforts to derive business value from increasingly digitalized data. Operating in a large global corporation with hundreds of thousands of assets, the primary objective was to optimize plant operations worldwide. Historically, experts were stationed at individual plant sites. While this was highly beneficial for the immediate plant site — ensuring an experienced SME was always on hand to address issues and teach plant personnel directly — it limited the sharing of knowledge across similar sites regionally or globally. Leadership teams recognized this shortcoming and, leveraging newfound digitalization trends, began creating a centralized team of experts to collaborate and support operations globally.
The immediate challenge was sharing learnings throughout the enterprise, answering, “How can we leverage our expertise and scale it world-
• Understand conventional challenges of maintaining and scaling thousands of assets.
• Recognize the ways advanced analytics platforms help organize asset structures and improve operational and maintenance efficiency.
• Explore the use of modern AI-equipped tools to accelerate model creation, simplify analysis and drive insight depth.
Rupesh Parbhoo, Seeq
ENGINEERING SOLUTIONS
1: Seeq’s Asset Group Editor provides an intuitive interface for organizing and adding calculations in analyses. Courtesy: Seeq
They organize physical locations, pieces of equipment and data on said equipment into a hierarchical structure.
When structuring assets, several issues can impede teams' abilities to scale and derive value from their data. The five main challenges are:
1. Differing equipment ages
This is a problem in many plants regardless of age, ranging from brand-new facilities to those more than a century old. Management often thinks, "a pump is a pump is a pump," but unfortunately, engineering design and equipment evolve over time, so one-size-fits-all approaches do not work. Some equipment is fully “sensored,” while other similar assets have no instrumentation onboard.
Notably, one offshore plant consisted of only five data historian-connected sensors. Plant personnel were responsible for measuring all other recorded parameters with handheld pressure gauges and other instruments.
FIGURE 2: Seeq enables superimposing process data and customized calculations to help plant personnel derive a holistic picture of plant performance with context. Courtesy: Seeq
wide?” Energetic and expert engineering and IT teams were eager to tackle this knowledge-scaling challenge. Instead of stationing an SME at each site, the team combined them at one location, relying on data connectivity, video-conferencing and other technologies to bridge the gaps with the sites.
However, the field data itself was not structured in the way working teams needed it to be. Correcting all the imbalances and asymmetries in the data frequently required human intervention and these data-cleansing efforts took years in several cases to remediate. In the end, the company’s grand idea of co-locating key SMEs panned out, but it unearthed a rampant issue in the interim regarding how data was collected and managed.
Problem with asset structures
Before delving into the major challenges, it is important to briefly describe asset structures, which are foundational tools used to harness the full analytic capabilities of software platforms.
Even at new largescale facilities with modernized network infrastructure and data connectivity, project design and construction periods sometimes take place over extensive periods and/or designs change multiple times. These and other factors often result in different variations of similar-type assets.
2. Incorrectly mapped sensors
Major manufacturing facilities can have tens of thousands of sensors, making it challenging to connect and centralize them correctly. Over time, instead of correcting errors, teams sometimes develop simple organizational workarounds, such as proceeding with the knowledge that “sensor XX-1A actually means XX-A1,” which can cause inefficiencies and potential inaccuracies and other errors.
3. Sensor failures
One new cryogenic facility was built with the expectation not to shut down ever in the first five years. When a sensor broke shortly into the plant’s operation, engineers used other process data to calculate a "soft" sensor reading in place of the failed physical sensor to avoid an operational halt, without intending to replace the field sensor until the next planned shutdown. While evading downtime, this calculation did not provide the same accuracy of the original sensor, inherently decreasing operational efficiency potential. Additionally, were the
FIGURE
team to “blindly map” the broken sensor into an asset tree, it would provide inaccurate data.
4. Different design choices
There is persistent tension between project and operations teams within industrial organizations. Project divisions strive to meet requirements with maximum cost efficiency, while operations groups desire the extras that enable improved situational awareness and simplified optimization. This can result in corner-cutting during design and commissioning to save costs, such as omitting contractually nonrequired sensors that operations teams may view as essential. These types of decisions and miscommunications can have long-term operational efficiency and data accuracy implications.
5.
Use case dependency
Asset trees might be structured by equipment type, process flow or plant area, but different analyses require different structures. For instance, control loop performance monitoring may require one structure, while pump health analysis requires another. In one case, a manufacturing company’s IT department attempted to build one asset hierarchy to rule them all, but it failed to recognize the need for different structures for different analyses. As any industrial SME could predict, this effort ultimately failed.
These are some of the leading difficulties for rapidly deploying and scaling asset structures. Fortunately, modern advanced analytics platforms are helping manufacturers overcome these challenges.
Advanced analytics tools for asset management
When ill-equipped, there is a temptation to give up after struggling through constructing one asset hierarchy, but this leaves significant value on the table.
Another occasional pitfall is deploying Python or another programming language to structure data, but this skillset is typically confined to data science groups. Because it is not readily available to all teams, this can lead to maintenance and sustainability challenges of the code as time goes on.
The solution is enabling personnel to build asset hierarchies using point-and-click tools or by ingesting a CSV file, making the procedure accessible to almost anyone capable of operating a computer. AI-equipped advanced analytics platforms facilitate
this, empowering SMEs and other users to experiment and iterate freely with asset groups.
Organizing data into an asset tree in these types of software platforms empowers users to:
• Use asset swapping to rapidly create identical visualizations for different pieces of equipment.
• Write high-value calculations for components, then scale them across all similar components in the tree.
• Automatically generate scalable content and custom analyses.
• Reference the tree as a starting point for roll-ups, calculations, displays, dashboards and reports.
Point-and-click tools: As mentioned previously, there are many challenges to creat ing successful asset structures and SMEs working with structures not fit for their purpose can experience significant hindrances. Point-and-click tools, however, enable SMEs to build and iterate quickly without IT involvement, which can be time-consuming and require numerous approvals.
By empowering plant personnel to create asset structures at the operations level, teams can iterate rapidly on what works and distribute this to the entire operating unit efficiently. This method prioritizes business value over striving for the "one size fits all" asset structure.
When reviewing and selecting tools, teams should consider the ease at which calculations can
FIGURE 3: With just a few lines of Python code, subject matter experts can build out massive asset structures within Seeq, based on entry in a CSV or other spreadsheet-based text file. Courtesy: Seeq
‘ When structuring assets, several issues can impede
teams' abilities to scale and derive value from their data.
’
ENGINEERING SOLUTIONS
nance decision-making.
Courtesy: Seeq
be added. In many analyses, signal data alone is not enough. Effective tools provide simple ways for adding calculations that can be replicated at scale. Figures 1 and 2 show a tool that empowers the operations team — without IT — to build out calculations quickly and efficiently to enhance analyses. Template files (CSV): For use cases that are too large to manage efficiently with point-and-click tools, using a spreadsheet program to create asset structures can be beneficial. With a few lines of Python code, advanced analytics platforms can ingest a spreadsheet-based text file — such as a CSV — and build the asset structure within the platform.
This approach provides significant benefits for iteration at scale, enabling manufacturers to quickly build large asset structures, deploy them, evaluate their effectiveness and make necessary adjustments (see Figure 3).
Insights
Asset management insights
uSubject matter experts are tasked with monitoring equipment, and artificial intelligence can be added to improve asset management.
uThis article will explore common barriers that hold manufacturers back, and how to navigate and progress past the barriers to realize artificial intelligence benefits.
Monitoring solutions
Customizable asset structures within analytics platforms provide business value for scaling analyses across similar assets enterprisewide. This also facilitates faster creation of customized calculations when applicable, which enhance process efficiency. Outputs, such as dashboards, enrich monitoring and streamline decision-making processes, especially combined with AI-based anomaly detection and triggers (see Figure 4).
By prioritizing ease of use and scalability, AI-equipped advanced analytics platforms empower organizations to leverage their data effectively,
driving smarter decision-making and maximizing process efficiency.
Innovate asset management to drive productivity
In the dynamic landscape of manufacturing and industrial analytics, managing complex asset hierarchies effectively is paramount for optimizing plant operations and deriving actionable insights. From the varying ages of equipment to the need for flexible solutions that empower engineers at the operations level, the complexities of asset structures demand innovative approaches.
Point-and-click tools enable rapid iteration and deployment, placing business value at the forefront of decision-making. Additionally, platforms integrated with Python scripting capabilities provide efficiency at scale, enabling quick creation of large asset structures.
As industry continues to digitize, leveraging AI-equipped advanced analytics platforms to support overextended SMEs is critical for revealing data-driven insights, increasing operational safety and maximizing process efficiency and productivity. By prioritizing ease of use, scalability and the ability to adapt to diverse use cases, these software platforms empower manufacturing leaders and plant personnel to navigate the complexities of asset hierarchies with confidence. PE
Rupesh Parbhoo is a Principal Analytics Engineer at Seeq, where he helps connect people with the right advanced analytics solutions.
FIGURE 4: Dashboards provide at-a-glance asset health monitoring, fostering informed operations and mainte-
Digital valve controller offers detailed asset health insights
Controller uses edge computing capabilities to analyze data in real time, providing diagnostic valve health indications and recommended
corrective actions.
Control and on-off valves are installed throughout process plants and facilities to regulate the flow of liquid and gas media, often in critical applications. Because these valves frequently change position and are in constant contact with process media, wear and tear is inevitable, so their performance and condition must be carefully monitored to ensure proper operation and anticipate any issues.
To address issues with control and on-off valve monitoring and provide other functionality, digital valve controllers were first introduced to the market back in 1975, with improved versions following over the past few decades, culminating in the Fisher DVC7K, recently introduced by Emerson.
Edge computing enables advancements
This digital valve controller is built on 30 years of proven field-tested innovation (Figure 1). Data and information from the controller can be used to improve the performance, reliability, and uptime of both on-off and control valves, and by extension an entire process plant or facility.
The controller interprets data to create an optimized path to action by combining patented technology, experience-based algorithms, and continuous real-time analytics with flexible connectivity and easy integration.
It uses real-time and onboard edge computing to analyze issues and create actionable information, providing real-time awareness of valve health by analyzing data locally via its on-board diagnostics. If analysis reveals a problem, an alert is created,
which can be viewed locally or remotely, providing the information required to create streamlined and efficient work processes. All alerts include recommended actions to fix the problem.
All information can be viewed at the controller’s local user interface, nearby via secure Bluetooth, or remotely after it is transmitted via a wired digital network to a host, such as a distributed control or asset management system. The local user interface provides indication of valve health at a glance via LEDs, and users can drill down from the interface home screen to find more information. Secure Bluetooth enables access to one or more digital valve controllers at distances up to 30 ft from any device capable of supporting Bluetooth, such as a smartphone or tablet. Whether the information is viewed locally, nearby or remotely, plant personnel can use it to drive awareness of valve health.
With more opportunities for remote connectivity and advice at the device, flexibility increases, providing the information needed for fast decisions and quick action to address arising issues. The DVC7K digital valve controller can be specified for all new valve purchases, and it can be retrofitted to most existing valve installations, in either case quickly and easily commissioned via the local user interface.
Control valve applications
With the controller’s always-running, onboard diagnostics, diagnostic data is now automatical-
Continued on pg 26
FIGURE 1: The Fisher FIELDVUE DVC7K is the industry's highest performing and most reliable valve controller, and the first to include embedded prognostics, communicated locally via Advice at the Device.
Courtesy: Emerson
• Understand the role control and on-off valves play in process plants and facilities.
• Learn how edge computing is improving and enhancing valve operation and maintenance by giving users better and faster insights.
Josh Grosvenor and Preston Schaaf, Emerson
Excellence in every WELD. Dependability in every BEND.
ENGINEERING SOLUTIONS
Continued from pg 23
Insights
Control valve insights
uThe Fisher DVC7K by Emerson employs edge computing for real-time analysis, improving valve performance, reliability and uptime for critical applications.
uWith secure Bluetooth and wired digital network transmission, the controller offers viewing options locally, nearby or remotely, enhancing awareness and enabling quick, informed decisions for valve health.
ly captured at the time an event occurs, and it is stored and managed onboard the instrument. This new feature allows the instrument to constantly monitor valve operation, and it provides users with access to the most recent and relevant information so they can review and analyze their control valves installed in critical applications.
On-off valve applications
Users with critical isolation valve applications can use the controller when changing from solenoid control to a digital positioner with on/off diagnostics. Stroke time measurements with stroke time degradation tracking, and partial stroke testing, provide monitoring and testing of on/off valves, giving users the ability to address problems before they impact operations. The controller provides these new features, along with other diagnostics, in a new offering specifically designed for high criticality on/off
LEARNING
valves. Along with the added diagnostic data features, the controller also greatly improves reliability as compared to solenoid control, which is often a weak point for these types of applications.
Valves perform critical roles
Control and on-off valves carry out critical functions in process plants and facilities worldwide, so their performance and condition must be closely monitored. New digital valve controllers provide this functionality, along with other tasks, improving the operation and uptime of these valves. These controllers also enable optimization of maintenance activities by predicting failures well in advance, allowing for proactive instead of reactive actions. PE
Josh Grosvenor is the OEM industry manager on the Global Industry Sales team for the Emerson Flow Controls business unit in Marshalltown, IA. He holds a BS degree in Business Economics from Iowa State University. Preston Schaaf is a senior sales engineer for Emerson’s Flow Controls business unit in Marshalltown, IA. He holds a BS degree in Materials Engineering from Iowa State University.
ENGINEERING SOLUTIONS
Know when, how to implement electrical maintenance in power equipment
Maintenance of electrical systems is a necessary process that often gets overlooked
Maintenance of electrical systems — despite significant evidence showing that is important not only for protection of personnel and equipment, but also for reducing total operating costs — has often been one of the first processes to be disregarded, forgotten about, considered not worth the cost or otherwise left for tomorrow that never arrives.
Though in recent years the importance of electrical testing and maintenance has appeared to increase and the practice be taken more seriously within the electrical industry, it is still often considered a want instead of a need. With the upgrade and adoption of NFPA 70B: Standard for Electrical Maintenance in 2023, the importance of electrical testing and maintenance has been effectively codified, becoming a requirement instead of a suggestion.
NFPA 70B has been in publication for almost 50 years as a recommended practice, but is not the only source requiring, recommending or otherwise discussing the electrical maintenance (and testing). IEEE provides guides on how to perform testing — including general test procedures for various types of equipment, calibration requirements for test equipment and other such documentation. Equipment manufacturers provide detailed instructions on the types and frequency of maintenance that should be performed on their specific types of equipment.
However, there are two overarching publications that guide the overall maintenance of electrical systems: NFPA 70B and American National Standards
Institute (ANSI)/International Electrical Testing Association (NETA) Maintenance Testing Specifications (MTS) for Electrical Power Equipment and Systems. NFPA 70B approaches maintenance from a consideration for personnel and equipment, while MTS strives to ensure that electrical testing and maintenance is conducted correctly. The two publications overlap and complement each other in assisting personnel with appropriately maintaining their electrical systems.
• Learn the proper maintenance of an electrical system.
• Understand the consequences of an improperly maintained electrical system.
• Know the codes and references to use in future design.
FIGURE 1: NFPA 70B: Standard for Electrical Maintenance equipment condition assessment flow chart. Courtesy: CDM Smith
William McGugan, PE, and John Drawbaugh, PE, CDM Smith, Raleigh, North Carolina
ENGINEERING SOLUTIONS
NETA is a trade association that develops testing standards and specifications for electrical systems and ANSI may be a familiar entity in the electrical design world for the extensive material testing work they do. The ANSI/NETA MTS is a document of testing specifications developed by the two formerly mentioned institutions.
The MTS is a comprehensive specification guide designed to “assure tested electrical equipment and systems are operational, are within applicable standards and manufacturer's tolerances and are suitable for continued service” (ANSI/NETA 2023).
Electrical maintenance codes, standards and guidelines
NFPA 70B was upgraded to a standard in 2023.
As defined in NFPA 1: Fire Code, a recommended practice is “similar in content and structure to a code … but contains only nonmandatory provisions.” In comparison, a Standard, such as NFPA 70: National Electrical Code (NEC) “contains
only mandatory provisions” in the main text and is “generally suitable … for adoption into law.” A code is “a standard that is an extensive compilation of provisions covering broad subject matter or that is suitable for adoption into law independently of other codes and standards.” In layman’s terms, a recommended practice details what should be done, whereas a standard or code details what must be done.
While an NFPA publication is not legally enforceable simply because it is a standard, it must be adopted by states or other authorities to gain legal force. However, becoming a standard strengthens the relationship between NFPA 70B and associated codes such as NEC and NFPA 70E: Standard for Electrical Safety in the Workplace. Additionally, becoming a standard establishes a publication as an industry consensus, further reinforcing Occupational Health and Safety Administration (OSHA)’s ability to refer to NFPA 70B in determining where violations may have occurred. As discussed in an official OSHA interpretation, while OSHA does not enforce NFPA 70, NFPA 70E or NFPA 70B, it may use such industry consensus standards to “support citations for violations.”
A person reviewing NFPA 70B will notice significant overlap with portions of NEC and NFPA 70E, confirming the interconnected importance of proper installation, safety and maintenance procedures for designing and operating electrical systems efficiently and safely for personnel, equipment and processes.
The general requirements of NFPA 70B mandate that equipment “be maintained in accordance with the manufacturer’s instructions and applicable codes and standards.” In the absence of such instructions, equipment should “be maintained in accordance with industry consensus standards.” While NFPA 70B does not directly refer to ANSI/ NETA acceptance testing specifications (ATS) and MTS in any standard requirements, it references both as industry consensus standards in the nonproscriptive informative annexes.
Chapter 4 of NFPA 70B provides general maintenance requirements, including that an equipment owner implement and document an electrical maintenance plan (EMP). The EMP must include and document elements such as an electrical safety program (refer to NFPA 70E), electrical maintenance and testing procedures, implementation
FIGURE 2: NFPA
70B: Standard for Electrical Maintenance interval flow chart. Courtesy: CDM Smith
of corrective measures and cleaning of electrical equipment. The EMP must be audited every five years or less.
Chapter 6 of NFPA 70B requires that an electrical system’s one-line diagrams be maintained up-to-date and that system studies — including short-circuit, coordination and incident energy analyses studies — be conducted and updated as necessary to support risk assessments.
Chapters 7, 8 and 9 of NFPA 70B discuss fundamental tests, field testing and test methods and recommended maintenance intervals. Fundamental tests include testing of connections and terminations and insulation resistance testing. Testing connections and terminations via infrared thermography, contact resistance testing and/or permanent heat sensors is vital to ensure connectors are not poor, which could lead to heating, sparking or failures.
Insulation resistance testing is important to confirm that the electrical equipment’s insulation is not showing signs of breaking down, which could lead to faults and flashovers. Field testing and test methods include brief discussions of general testing categories, personnel, equipment calibration and record requirements.
Chapter 9 of NFPA 70B provides recommended intervals for electrical equipment maintenance first based upon manufacturer recommendations and afterward based on the condition assessment of the equipment. The condition assessment determines the recommended interval based on the worst of a given piece of equipment’s physical condition, criticality condition and operating environment condition.
• Physical condition 1: Equipment appears in like-new condition, is clean, free from moisture intrusion and tight, has no unaddressed notifications or active recommendations and has been maintained according to the EMP.
• Physical condition 2: Equipment is like physical condition 1, except that maintenance results might deviate from past results, there are issues requiring repair or replacement or there are active notifications or recommendations.
• Physical condition 3: Equipment has missed the last two successive cycles required by the EMP, needs repair or replacement of major components or has active notifications or actions required. Equipment may be in:
• Criticality condition 1 or 2: Failure of the equipment would not endanger personnel.
• Criticality condition 3: Failure of the equipment would endanger personnel.
• Operating environment condition 1 or 2: Rated for the environment where installed.
• Operating environment condition 3: Not rated for the environment where installed or where the environment has harsh chemicals, contaminants or extreme conditions.
Though there are variations, the recommended minimum interval for:
• Condition 1 equipment is five years.
• Condition 2 equipment is three years.
• Condition 3 equipment is one year.
Manufacturer’s recommendations supersede NFPA 70B recommendations. Intervals may be adjusted based on changing conditions and inspection results. Equipment that suffers unexpected failures might require more frequent servicing. Equipment that has completed more than two inspections without issues may have inspection intervals increased beyond Chapter 9 recommendations.
Chapters 11 through 38 provide additional details on the maintenance of specific types of electrical equipment and systems, including transformers (Chapter 11), cables and conductors (Chapter 18), motor control equipment (Chapter 28) and even electric vehicle charging systems (Chapter 33).
Standard for maintenance testing specifications
ANSI/NETA MTS is a guiding document that influences project design specifications and oper-
FIGURE 3: The NETA equipment reliability matrix found in Appendix B of ANSI/ NETA. Courtesy: CDM Smith
‘ ANSI/NETA
MTS is a guiding document that influences project design specifications and operations and maintenance manuals as well.
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ations and maintenance manuals as well. In this article, the items highlighted from ANSI/NETA 2023 focus on establishing regular maintenance intervals for electrical systems. This is a crucial step that sets up a system for long-term success.
ANSI/NETA also publishes the Standard for Acceptance Testing Specifications for Electrical Power Equipment and Systems to guide testing of equipment during the installation process. While a separate publication, ANSI/NETA ATS is similar in scope and layout to ANSI/NETA MTS and while not technically related to maintenance of equipment, there is a direct correlation between the quality of an installation and the long-term life of the equipment being installed.
As will be discussed later in this article, where data trends are important to understanding the current state of equipment, the results of testing performed during commissioning in compliance with ANSI/ NETA ATS form the baseline for later evaluations conducted in compliance with ANSI/NETA MTS.
NETA’s guidance on maintenance intervals is detailed in Appendix B and labeled “Frequency of Maintenance Tests.” A table and matrix are provided. The “Maintenance Frequency Matrix” offers multiplication factors that should be applied to the table depending on the current equipment condition and required reliability rating (see Figure 1).
Insightsu
Maintenance insights
uMaintenance of electrical systems is a requirement, not a suggestion. Here are things to watch.
u A neglected power system may function normally for many years until a catastrophic event occurs.
For example, when determining the recommended visual, mechanical and electrical maintenance test frequency for a small dry-type transformer, a base number of 36 months is gleaned from the table. If the transformer in question is determined to be in good condition but has a reliability requirement of “high” (e.g., a piece of a critical system), the matrix provides a multiplication factor of 0.75. This factor times the 36 months base number means the recommended frequency of full maintenance tests is every 27 months.
NETA/ANSI details the recommended approach to perform these maintenance tests in Sections 5 and 7. All facility technicians or maintenance teams should be aware of the ANSI/NETA specification when taking control of an electrical power system.
Results of improper maintenance
Properly installed electrical systems are reliable and can remain so with minimal hands-on maintenance for years. This reliability is a testament to the quality of name-brand products purchased under certification from a testing facility.
However, a single weak point in the system can cause catastrophic damage to itself and the surrounding environment, potentially putting human life at risk. Therefore, regular inspections are crucial and awareness of common failure points is essential.
Two commonly cited points of failure are distribution transformers and loose connections. Distribution transformers serving campuses or individual customers can quickly become overloaded in areas experiencing rapid growth. If calculations are not adjusted for additional loads on existing transformers, the only way to catch a potential catastrophic overload is through visual, physical or like electrical inspection. Maintenance inspections on a transformer involve checking the remaining insulation material. If this material breaks down before being replaced, a short circuit is highly likely, which could even cause an arc flash. Arc flashes may destroy equipment, cause fires and injure personnel or bystanders.
Loose connections are a classic wear and tear issue that develops over time. This mainly applies to branch circuits that are frequently being unplugged, replugged, moved or otherwise disturbed from a permanent connection. Copper and aluminum wires wear over time, especially if they are repeatedly manipulated.
Wires can come loose or come into contact with other wires, causing open and short circuits. Loose wires may expose conductors to flammable environments, which can cause fires in some scenarios. Loose connections should be inspected on every operable piece of equipment in an electrical system during a maintenance check. Properly referencing NFPA 70B and NETA/ANSI ensures this step is never missed. PE
William McGugan, PE, is an electrical engineer with CDM Smith with a focus on the design and analysis of electrical power systems.
John Drawbaugh, PE, is an electrical engineer with CDM Smith with a focus on the design of renewable and substation power systems.
FIGURE 4: An example of damaged equipment due to lack of maintenance. Courtesy: CDM Smith
Modernize, monitor and maintain to make aging switchgear safer
Breathe new life into old switchgear with modernization and see the benefits of improved reliability and safety
Reliability and safety are critical topics when it comes to optimization of switchgear asset performance and life cycle. Today’s business asset managers face economic limitations that require deeper analysis to prioritize investment needs. In many cases, traditional practices, such as reactive and even preventive maintenance, may appear to be the most cost-effective solutions; however, in practice, they may compromise performance targets for reliability and safety, leading to economic setbacks in downtime and overall operational cost.
Conversely, switchgear modernization and monitoring can support equipment maintenance practices that lead to robust performance and life-cycle extension of the equipment. Through modernization and digitalization of their equipment, asset managers can optimize their equipment maintenance plans (EMP) for a more reliable, safer and more cost-effective result.
Evolving maintenance needs
Designing and implementing effective EMPs is critical. A robust EMP requires consideration of many factors including, but not limited to:
• NFPA 70B: Standard for Electrical Equipment Maintenance and NFPA 70E: Standard for Electrical Safety in the Workplace requirements.
• Manufacturer recommendations.
• System conditions.
• Workforce availability.
• Outage restrictions.
• Budget constraints.
Maintenance plans are complex to build and require continuous improvements as the processes and methodologies are implemented. Lessons learned on a continuous basis must be implemented to ensure the maintenance plan is set up for success. All of these considerations help ensure that the safety of personnel and assets always takes top priority.
With today’s pressure-cooker economic environment, having an EMP with traditional practices is not enough, particularly with aging assets. Assessing the long-term viability of maintaining legacy switchgear involves evaluating factors such as equipment reliability, performance and operational needs against the cost of ongoing maintenance and potential risks.
Developing a strategic asset management plan that considers life cycle costs, risk mitigation strategies and technology trends is essential for informed decision-making. There are five major challenges:
Obsolescence of parts/equipment
Legacy equipment often contains parts/accessories that are no longer manufactured or available in a reasonable timeframe. Sourcing these items becomes a supply chain nightmare due to higher costs and longer lead times, potentially leading to extended downtime to maintain, if even possible. From an inventory management aspect, more parts must be stocked to reduce risks of higher lead times and limited availability, adding more costs to maintenance budgets.
Lack of technical documentation
Legacy equipment may lack comprehensive documentation, including maintenance manuals, sche-
• Explore challenges with maintaining legacy switchgear.
• Learn how equipment maintenance plans can enhance electrical safety.
• Learn the impact of modernization and digitalization to enhance optimization and effectiveness of equipment maintenance plans.
ENGINEERING SOLUTIONS
matics and operating instructions. This lack of documentation complicates troubleshooting, diagnosis and repair efforts, requiring maintenance personnel to rely on their experience and knowledge of the equipment.
Expertise gap
Maintaining legacy equipment requires specialized expertise that is scarce in the labor pool. As experienced professionals retire, their tribal knowledge also retires. This leads to gaps in the maintenance capabilities of the next generation of labor.
Reliability and safety
Aging switchgear generally undergoes a gradual decrease in reliability, causing unexpected downtime and failures. In addition, electrical safety codes and standards evolve over time. While in most cases these do not mandate replacement of legacy equipment, ensuring maximum safety of personnel and equipment becomes increasingly difficult with older switchgear that was not built to comply with today’s codes and standards.
Sustainability and environmental impact
As organizations globally focus on sustainability, much emphasis is placed on reducing carbon footprints. Legacy assets can contribute to a higher footprint due to increased maintenance requirements and waste generation among other issues.
Many older switchgear components use insulating material such as SF6 gas and oil. SF6 gas is a potent greenhouse gas. The European Union is already moving toward legislation to have electrical equipment SF6-free as early as 2026 for voltage levels to 24 kilovolts (kV), and by 2030 for up to 52 kV (some exceptions apply to installed products).
Legacy switchgear is also known to contain hazardous materials such as lead, asbestos, mercury and cadmium, posing significant risks to personnel and the environment. End-of-life services for equipment containing such materials must be carried out by licensed waste management organizations as determined by relevant regulatory authorities.
Considering the factors outlined above, an effective EMP must include consideration for a
FIGURE 1: Modernized switchgear provides numerous operational advantages.
Courtesy: ABB Inc.
mix of modernization plans to enhance the impact of maintenance toward safety and reliability. From an economic standpoint, the cost of maintaining legacy equipment can be substantial, encompassing expenses related to spare parts, repairs and downtime (see Figure 1).
Modernization strategies help achieve safety goals
Switching devices are the switchgear components most impacted by electrical and mechanical aging. Effective modernization strategies focus on techniques that enhance technology and maximize value of the maintenance and asset management process. Consider three key modernization strategies:
Hard bus retrofill
A hard bus retrofill solution involves a standard cradle/fixed part hosted inside the legacy panel. The cradle consists of a standard, fully tested compartment with all new interlocks and shutter mechanism, as per the latest applicable standards interfacing with the existing switchgear. These solutions use standard withdrawable circuit breakers, offering vacuum interrupter technology and options for spring-charged energy storage mechanism or magnetic-actuation mechanism.
Some manufacturers also offer motorized racking options with the new circuit breakers, providing enhanced arc flash safety for the operators. This technique renews main functional components of the original switchgear. The installation process requires significant modification to the panel to accommodate the new apparatus as well as new secondary wiring.
Cradle-in-cradle solution
The cradle-in-cradle solution has the new cradle/fixed part hosted inside the legacy panel. The fixed cradle is designed to connect to the fixed part of the legacy panel in the same manner as the moving part of the legacy circuit breaker — although as a fixed installation. The other fixed part uses standard components to accept a standard withdrawable breaker. The two fixed parts make one single assembly.
Like the hard bus retrofill, the cradle consists of standard compartment features such as new interlocks and shutter systems. These solutions use standard withdrawable circuit breakers as well. The installation process requires moderate modification to the panel to accommodate the new apparatus as well as new secondary wiring.
Direct replacement/roll-in-replacement
Direct replacement solutions are engineered to match the original switching apparatus. The base breaker module used is a new standard fixed breaker based on the latest technology. It mounts on a truck that matches all interfaces in the existing panel (racking positions, shutter opening interfaces, interlocks, ground connection and so forth).
This solution is the most complex to design among the modernization techniques discussed because it requires in-depth knowledge of the existing legacy equipment to develop a new direct-replacement solution matching the fit, form and function of the legacy circuit breaker (see Figure 2). This solution does not require modification to the panel, and the secondary disconnect matches that of the existing equipment, eliminating wiring changes and requiring the least downtime to install.
Condition monitoring for safety and reliability
With these modernization techniques, advanced monitoring and diagnostics (M&D) can be applied as part of a modernization strategy, adding value to the maintenance plan. M&D systems provide
‘FIGURE 2: Modernization solutions include direct replacement, hard bus retrofill or cradle-in-cradle retrofill. Courtesy: ABB Inc.
Some manufacturers also offer motorized racking options with the new circuit breakers, providing enhanced arc flash safety for the operators.
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‘ Creating an effective maintenance plan is a complex endeavor and requires thorough planning and consideration.’
detailed insights into the operation, condition and performance of the switchgear asset. These features enhance reliability, safety and efficiency by enabling condition-based proactive maintenance, early anomaly detection and faster fault resolution.
The M&D system collects condition monitoring data from various sources, including relays and sensors. It then processes this data using advanced algorithms to compute key performance indicators (KPIs), which describe the health status of monitored assets. Following are the key components of advanced M&D:
Circuit breaker diagnostics: The M&D system monitors circuit breakers by retrieving key performance data from numerical protection relays. Examples of monitored data include:
• Opening and closing times.
• Slipping and failed spring-charging attempts.
• Inactivity days.
• Remaining life estimation.
• Trip coil supervision.
The monitored parameters help detect electrical or mechanical abnormalities that can lead to a circuit breaker failure.
Partial discharge monitoring: Throughout the industry, multiple methods are used to detect partial discharge (PD). For example, in the UHF technique, antennas detect PD activity and can be localized to the specific compartment. Another method involves the use of capacitive couplers to detect PD events on the three different phases and synchronize those events with power line voltage. Early detection of PD patterns can help prevent arc flash and catastrophic equipment failures.
Temperature monitoring: In temperature monitoring, sensors detect real-time values in key locations, including bus bar joints, cables and circuit breakers. Installation of these sensors requires no modification to existing switchgear, and absolute and delta temperature readings can be used to monitor critical situations.
Temperature monitoring enables quicker detection of loose joints, insulation degradation, load unbalancing and other thermal failures than traditional meth-
ods, such as infrared (IR) thermal scanning. It also enhances safety by eliminating the need for site operators to perform IR scanning on live equipment.
Maintenance optimization to meet safety KPIs
Advanced M&D systems make it possible to access all critical KPIs remotely and send them to the control room. This enhances data visualization and asset management by providing real-time dashboards, trend analysis and status indicators. Centralized data collection enables predictive analytics for fault prediction and calculates health indices to prioritize maintenance. This results in optimized maintenance scheduling, improved resource allocation and enhanced switchgear reliability and safety. Artificial intelligence will play a larger role in the future to make algorithms smarter and more accurate, increasing the impact even more.
In a data center example, implementation of M&D systems reduced the amount of time required for routine maintenance and increased the time interval of maintenance by 30%. This was achieved by reducing maintenance tasks required for a three-year maintenance plan due to availability of real-time data replacing manual inspections, making operations leaner and eliminating safety risks during unnecessary inspections.
Repair/overhaul optimization by design
Older circuit breakers require maintenance at very short intervals due to aging to function properly and to avoid unforeseen downtime. Vacuum interrupters used in modern medium-voltage breakers require significantly less maintenance and offer clean, quiet operation compared to air magnetic breakers with arc chutes. Contacts used in the vacuum interrupters are designed to reduce arcing time and contact wear with good surface behavior. Additionally, modern circuit breakers offer a simpler operating mechanism with fewer parts requiring maintenance. Spring tension and associated operating speed is not a concern. The breakers can be equipped with a magnetic actuation mechanism for medium voltage and compact modular structures for low voltage, both of which have few moving parts, reducing maintenance needs. Operating personnel can be trained on the newer equipment, increasing maintenance capabilities and expertise.
Stock parts management
Original manufacturer replacement parts for vintage circuit breakers are scarce. The used equipment market may no longer be able to supply dependable parts due to the aging of refurbished or used components, which can compromise reliability. Even if these parts are available, the lead times and costs are high.
In contrast, modern circuit breakers are often designed with standardized components, making it easier to find compatible spare parts across different models supported by the manufacturer — with significantly lower lead times and costs.
Operational safety by design
As mentioned, legacy circuit breakers may contain hazardous materials. For example, older circuit breakers contain arc chutes with asbestos. These materials are liabilities for the environment as well as a safety threat to personnel. The arc chutes are also known to be heavy, requiring removal before a safe and thorough inspection. New breakers do not contain hazardous materials,
making operation and maintenance tasks easier, safer and more efficient.
Furthermore, changes in the power system over the years can expose equipment to higher fault levels and cause it to run closer to operational ratings, leading to equipment failure. With modernization, equipment can be upgraded to higher ratings as required by its current operational landscape.
Creating an effective maintenance plan is a complex endeavor and requires thorough planning and consideration. Modernization and upgrade of switchgear assets optimize EMPs, helping organizations achieve significant improvements in maintenance efficiency and system performance, ultimately ensuring a resilient and dependable electrical infrastructure, minimized downtime and safer operations. PE
Umer Khan, PEng, is Global Product Manager at ABB Electrification Service focusing on equipment life cycle services on medium- and low-voltage product lines, helping customers in optimizing the safety and reliability of their equipment.
Insightsu
Electrical safety insights
u
Switchgear modernization and monitoring enhance reliability, safety and cost-effectiveness by optimizing equipment maintenance plans, surpassing traditional reactive and preventive practices that can compromise performance.
uEffective maintenance plans (EMPs) should integrate NFPA standards, manufacturer recommendations and modernization strategies to address challenges like part obsolescence, expertise gaps and sustainability concerns, ensuring long-term reliability and safety.
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Scott Dowell, Wesco, Pittsburgh
Benefits of modernizing manufacturing power, electrical systems
Many organizations are looking to modernization a flexible power system and approach maintenance for their power systems to improve sustainability and efficiency.
In today’s manufacturing environment, every operator is looking to enhance overall equipment effectiveness (OEE), drive productivity and avoid downtime. As the evolution of “smart” factories gains momentum, the ability to supply power to machines and systems — some old, some new — puts a much-needed emphasis on the electrical distribution systems already in place.
Objectives Learning
• Learn about the changing dynamics and needs for electrical and power systems for manufacturers.
• Learn about the techniques companies can use to get the most out of their electrical and power systems.
• Learn where to start and how modernization can help manufacturers get the most out of their systems.
Many organizations, who also are trying to improve their sustainability efforts, are taking a fresh look at how to best create a flexible power system and approach maintenance for those systems.
Old equipment, new equipment and the smart factory
From low voltage to medium and high voltage, it’s fair to say many legacy power and electrical systems are nearing the end of life. This wasn’t much of a problem because these systems were one-dimensional machines that ran until they could not perform any longer. Then they were replaced.
Operators no longer have that luxury. As budgets have shrunk, businesses can’t afford to replace new equipment — they need to prolong the operating lifecycle for as long as possible. The downtime caused by a failure in the power system can
have serious business ramifications. And as power systems have become “smart”, interconnected and microchip driven, waiting for failure is not an option. Instead organizations need to anticipate and address problems before they become an issue so they can improve the efficiency of power systems.
Getting the most out of electrical, power systems while minimizing downtime
Consider it this way: Companies no longer have the luxury of fixing the plane while it’s in the hangar. Now they have to fix it while it’s in the air. This is a challenge because there are many moving parts, each piece dependent on the other and any one failure can be catastrophic. Even if systems and machines operate properly, companies still need to ensure constant, reliable access to power.
For plant managers, staying on top of these nuances can be complex and overwhelming. Individual components do more than ever, which requires plant employees to make sure they are on top of the ins and outs and working as intended. It used to be if a component overheated and something tripped, it might take time to identify where and what went wrong. Now, several technologies can help plant managers stay on top of these challenges and address them before they impact operations.
• Predictive maintenance: By leveraging sensors, internet of things (IoT) devices and advanced analytics, plant engineers can get deep insights into how different machines or components are operating. These technologies can flag potential indicators that a machine may need service or maintenance, allowing workers to address issues before they become larger problems. For example,
‘ In 2023, NFPA 70B was moved from a recommended practice to a standard. Standards are recognized, mandatory rules of technology that strive to provide safety for all involved. ’
vibration sensors can send alerts when a machine is beginning to operate outside normal parameters. Engineers can then replace or fix any components before a catastrophic failure occurs.
• Smart metering: Smart metering is another example of a proactive shift in managing electrical power and distribution systems. Smart meters can show energy usage is near real time, allowing plant engineers can identify how and when power is being consumed. Manufacturers can in turn leverage power consumption outside of peak times to create a much more sustainable flow of power. They also can detect power outages quicker — and automatically alert utility providers when they occur. This is critical, because when the power goes out, minutes matter. Every minute of production lost due to a power outage can cost tens — if not hundreds — of thousands of dollars.
• Renewables and microgrids: Aging grid infrastructure and a rise in catastrophic storms have made these an attractive solution for companies that need guaranteed, uninterruptible power. Battery storage systems, solar panels and other renewables can not only help with sustainability goals, it also can ensure businesses still have access to power if the grid fails. As an added bonus, businesses can save money by generating their own power and selling it back to the utility.
Factoring in safety, standards considerations
It’s important not to forget about safety when thinking about maintenance for power and electrical systems. According to the Electrical Safety Foundation (ESF), contact with or exposure to electricity is one of the leading causes of workplace injuries and fatalities in the U.S. While many newer
machines and power systems have enhanced safety capabilities, it’s also vital to have safety standards in place, especially when it comes to maintaining electrical equipment or components.
In 2023, NFPA 70B, which addresses electrical equipment maintenance, was moved from a recommended practice to a standard. Standards are recognized, mandatory rules of technology that strive to provide safety for all involved. At a high level, NFPA 70B sets maintenance guidelines and schedules for electrical equipment based on the type of equipment, its age and/or condition and how critical that equipment is for operations. While more rules can be frustrating, the pros outweigh any cons. A properly maintained piece of equipment is safer, less likely to fail and more likely to operate effectively.
These rules can provide benefits across the entire manufacturing process but perhaps most critically create an environment of trust. Trust the right processes, procedures and tools are being deployed across the plant floor.
Starting with switchgear modernization
While an organization’s need often vary, many often start with their switchgear, as these systems are vital to safety and operational success. Many switchgear systems are designed to last for decades, but as they age, they become more vulnerable to failure. Completely replacing switchgear generally requires a significant capital investment, which is where modernization and life-extension solutions come in.
FIGURE 1: By leveraging sensors, IoT devices and advanced analytics, plant engineers can get deep insights into how different machines or components are operating. Courtesy: Wesco
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At a high level, this process converts a legacy system to a more modern platform without needing to replace it. Switchgear modernization can be a cost-effective way to extend the useful life of the facility's electrical equipment. The original infrastructure can often be kept in place — including the existing conduit and cabling.
This solution improves OEE and overall safety while requiring less downtime than a complete equipment replacement.
Filling in the gaps with modernization
When it comes to modernization, industrial facility managers need to keep up with best practices to ensure OEE and compliance with the latest regulations. From electrical safety programs to low-voltage communications to cutting-edge industrial IoT (IIoT) applications, the nuances of electrical power systems are vast.
While the number of potential solutions are vast, navigating them and understanding which ones are right isn’t always easy. That’s why it’s important to
have trusted partners in place. With the right partner, manufacturers can take a fresh look at the systems, machines and processes they have, identify potential maintenance gaps and ensure that their power delivery systems operate effectively. If new solutions are needed, the right partner can help companies identify what would best fit their specific business needs. They also can address concerns to ensure worker safety and maintain a competitive edge. PE
Scott Dowell, senior vice president and general manager, U.S. Industrial and CIG, Wesco.
Insightsu
Electrical and power insights
u In modern manufacturing, predictive maintenance and smart metering are essential for minimizing downtime and improving equipment effectiveness, ensuring reliable power supply and operational continuity.
uSwitchgear modernization extends the lifespan of electrical systems, balancing safety, costeffectiveness and compliance with evolving regulations, crucial for sustaining efficient manufacturing processes.
FIGURE 2: Keeping up with best practices and understanding the potential impact of cutting-edge technology is key to successfully modernizing electrical power systems. Courtesy: Wesco
How Close is Close Enough: Pneumatic and Electric Actuation to Accomplish Positioning Accuracy
Jerry Scherzinger | IMI
“How Close is Close Enough: Pneumatic and Electric Actuation to Accomplish Positioning Accuracy” explores various actuation technologies to achieve precise positioning in industrial applications. It compares pneumatic and electric actuation systems, highlighting their respective advantages and limitations. Pneumatic systems, particularly multi-position cylinders, offer cost-effective solutions with high repeatability due to hard-stop mechanisms, but lack flexibility.
Electro-pneumatic systems enhance this by incorporating electronic controls for greater adaptability, though they may compromise on precision. On the other hand, electric actuators, especially those with stepper and servo motors, provide superior precision, flexibility, and reliability, making them ideal for applications requiring high accuracy and dynamic load handling. Stepper motors offer precision through digital pulse control, while servo motors provide enhanced feedback and adaptability to changing loads.
The paper emphasizes the importance of selecting the right system based on specific application needs, considering factors such as accuracy, repeatability, cost, and operational flexibility. It also underscores the role of reputable manufactures in recommending suitable technologies to meet diverse positioning requirements.
Optimizing Facility Management with High-Performance Coatings
Paul Pineda | Market Segment Manager, Semiconductor and Aviation/Aerospace Facilities, Sherwin-Williams Protective & Marine
Mike Durbin | Market Segment Manager, Pharmaceutical and Data Centers, Sherwin-Williams Protective & Marine
This paper explores the key role of advanced protective coatings in supporting facility managers in manufacturing and processing industries. These coatings can enhance durability, safety and regulatory compliance, while also potentially extending infrastructure lifespan, reducing maintenance costs and creating more resilient, efficient operations.
Applying high-performance coatings to floors, walls, and steel surfaces can help facility managers more effectively protect their assets and improve operational efficiency.
Tailored coatings can be critical for maintaining safety, cleanliness and compliance, especially in facility areas with specific needs, including wet and dry processing zones, chemical storage areas and R&D laboratories.
This paper also highlights the importance of protective coatings for building exteriors and water treatment systems, which face environmental challenges and corrosion risks. By partnering with coatings experts, facility managers can take a proactive approach to maintenance, which can promote long-term stability and operational success across industrial environments.
Download the paper at: https://tinyurl.com/2hk6s3sb
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UMass Amherst designs a multirobot team that shares situational awareness.
A new kind of collaboration
in the warehouse
BY STEPHANIE NEIL • EXECUTIVE EDITOR
The capabilities of collaborative robots, commonly referred to as “cobots,” could soon expand beyond direct human-robot interaction to include heterogeneous robots intelligently coordinating and interacting with each other.
New research from the University of Massachusetts Amherst is proving robots can be programmed to create their own teams and voluntarily wait for their teammates to execute a set of dependent tasks. This new multi-team robot collaboration has the potential to improve manufacturing and warehouse productivity.
The research, funded by the U.S. Defense Advanced Research Projects
Agency (DARPA) Director’s Fellowship and a U.S. National Science Foundation Career Award, is led by Hao Zhang, associate professor in the UMass Amherst Manning College of Information and Computer Sciences and director of the Human-Centered Robotics Lab. Zhang’s research on “autonomous group introspective learning and coopetition for cross-capability multi-robot adaptation,” uses lessons from the social psychology of humans to help teams of robots with different capabilities work together and adapt to complex situations.
When Zhang was awarded the DARPA prize last year to improve robot teamwork, he was already focusing on
two main areas – group introspection and cooperative competition, dubbed “coopetition.”
Group introspection would allow robots in a team to be aware of all their other team members, so they have a shared situational awareness of the overall team’s capabilities. To accomplish that, Zhang is modeling robots in a team as a graph to enable group awareness, and using conditional models that identify backup robots with similar capabilities to replace failed teammates. They are solving the competition aspect by simultaneously modeling cooperation at the team level and competition at the individual level. Cooperation tackles tasks that are
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AUTOMATED WAREHOUSE
infeasible for individual robots to solve, while competition encourages each robot to perform better and adapt faster.
Multi-robot mix and match
In a warehouse setting there may be many different types of robots and payload capacities: fixed in place robotic arms, mobile automated guided vehicles (AGVs), heavy-lifting palletizers, etc. The challenge, however, is coordinating a diverse set of robots for a common purpose.
“There’s a long history of debate on whether we want to build a single, powerful humanoid robot that can do all the jobs, or we have a team of robots that can collaborate,” stated Zhang. “Robots have big tasks, just like humans. For example, [if] they have a large box that cannot be carried by a single robot, the scenario will need multiple robots to collaboratively work on that.”
The other behavior is voluntary waiting. “We want the robot to be able to actively wait because, if they just choose a greedy solution to always perform smaller tasks that are immediately available, sometimes the bigger task will never be executed,” Zhang explains.
As a solution, Zhang created a learning-based approach for scheduling robots called learning for voluntary waiting and subteaming (LVWS) coupled
“There’s a long history of debate on whether we want to build a single, powerful humanoid robot that can do all the jobs, or we have a team of robots that can collaborate”
with a graph attention transformer network (GATN) that computes rewards for scheduling tasks to robots. LVWS includes nodes (robots) and edges (communication, relationships, or spatial positions).
According to the multi-robot research, collaborative scheduling is formulated as a bipartite matching problem where robots are assigned to tasks. These tasks are put into a GATN that integrates graph attention networks to encode the local graph structure and transformers to encode contextual information.
The resulting outputs are embeddings for each node, as well as global embedding for each graph which are used to compute a reward matrix used to perform bipartite matching.
To test their LVWS approach, the research team gave six robots 18 tasks in a computer simulation and compared
Group introspection and cooperative competition enables multi-robot teams to collaborate. | UMass Amherst
their LVWS approach to four other methods. In this computer model, there is a known, perfect solution for completing the scenario in the fastest amount of time. The researchers ran the different models through the simulation and calculated how much worse each method was compared to this perfect solution, a measure known as suboptimality.
The comparison methods ranged from 11.8% to 23% suboptimal. The new LVWS method was 0.8% suboptimal.
“So, the solution is close to the best possible or theoretical solution,” said Williard Jose, an author on the paper and a doctoral student in computer science at the Human-Centered Robotics Lab, in a statement.
The team has also demonstrated this method running on real-world robots.
Worth the wait
A common question the research team has received is, “How does making a robot wait make the whole team faster?”
Jose responds by describing this scenario: There are three robots — two that can lift four pounds each and one that can lift 10 pounds. One of the small robots is busy with a different task and there is a seven-pound box that needs to be moved.
“Instead of that big robot performing that task, it would be more beneficial for the small robot to wait for the other small robot and then they do that big task together because that bigger robot’s resource is better suited to do a different large task,” Jose explained.
Zhang hopes this work will aid the progress of developing teams of heterogeneous robots, particularly as it relates to the scalability of large industry environments that require specialized tasks. AW
Scan the QR code to watch a demonstration of the LVWS method in a manufacturing assembly case study run in a Gazebo simulation or visit: www.youtube.com/watch?v=zslbOXQXtSI
Hao Zhang
Williard Jose
in the automated warehouse in cybersecurity Mitigate risk
BY STEPHANIE NEIL • EXECUTIVE EDITOR
How to recognize threats, track critical data, and train employees.
Thewarehouse is integral to the manufacturing supply chain. As such, with cybersecurity threats on the rise, there’s an urgent need to adopt best practices that will ensure that the warehouse doesn’t become the weakest link in the supply chain.
As more automation makes its way into warehouses and more assets are integrated, there is a pressing need to safeguard the digital and physical infrastructure. This is especially urgent since cybercriminals are crafty and could use an opening in a warehouse as a backdoor into a partner’s network.
For example, in February 2023, Applied Materials, a semiconductor technology supplier, was reportedly the victim of a cybersecurity incident that originated from a ransomware attack on one of its suppliers. That incident cost Applied Materials $250 million in its second quarter that year.
No warehouse or fulfillment center wants to be a catalyst for cyber catastrophe. Yet, staying safe is not easy, as malicious actors are finding new ways to infiltrate organizations.
McKinsey has identified three cybersecurity trends that represent the biggest threat now and in the future:
• On-demand access to ubiquitous data and information platforms. Recent shifts toward mobile platforms and remote work require high-speed access to ubiquitous, large data sets. This dependency exacerbates the threat of a breach. And since organizations collect more data about their customers, such a breach could be costly.
• Hackers are increasingly using artificial intelligence to launch sophisticated attacks. Attackers using advanced tools such as AI, automation, and machine learning could cut the end-toend life cycle of an attack from weeks to days or even hours.
• The growing regulatory landscape and continued gaps in resources, knowledge, and talent. Many organizations don’t have enough cybersecurity expertise. The shortfall is growing as regulators increase their monitoring of cybersecurity in corporations.
With these trends in mind, it’s important to understand how to mitigate risks.
To get a better understanding of the actions needed to protect the automated warehouse, Locus Robotics outlined some best practices. The company makes autonomous mobile robots (AMR) for fulfillment. In June, it received the 2024 Fortress Cybersecurity Award in the Compliance category from the Business Intelligence Group.
Locus specified three areas of importance: understanding the threats, capturing the data, and training the workforce.
Bad actors vs. bad decisions
Cybercrime is growing and is descending upon unsuspecting businesses from all directions. There are nation-state adversaries that pose a national security risk in the form of advanced persistent threat activity (APT) aimed at targeted and prolonged network intrusion. There is malware, phishing, and ransomware, which are
the most common forms of attacks on business, and, as seen in the Applied Materials example, can be costly.
And then there are the employees who make mistakes – such as plugging a virus-infected USB drive into a system. Or simply taking a call from the wrong person. The data breach at MGM Resorts in September 2023 that shut down electronic payments and casino machines was initiated by a hacker group impersonating the IT staff, gaining access to systems via a call to an employee.
Fouad Khalil, senior director for enterprise security, risk, and compliance at Locus Robotics, is a member of a group called InfraGard, a national nonprofit organization that has formed a partnership between the Federal Bureau of Investigation and the private sector to educate and share information on security threats and risks. As an InfraGard member, he has access to timely insight on threats to critical infrastructure, providing the knowledge and resources to not only protect Locus Robotics, but also its customers.
However, other threats are already penetrating the plant and warehouse.
“Artificial intelligence, I think, is a big security risk,” Khalil said.
The cybersecurity risks associated with generative artificial intelligence (GenAI) in warehouses can be broadly categorized into data breaches, system vulnerabilities, and compliance challenges.
While GenAI may boost productivity and enhance decisionmaking, its integration into robotics and other systems exposes new potential attack vectors for cybercriminals.
“The data that powers GenAI — often sensitive and proprietary — can become a target,” said Khalil. “Moreover, the interconnected nature of modern warehouses means a breach in one area can have cascading effects throughout the entire operation.”
To that end, the cybersecurity risks associated with this technology should be considered and steps taken to mitigate risk. (see sidebar).
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While GenAI uses data, robots generate it. To secure that data throughout the warehouse, it has to be tracked.
“When you follow the data, you understand where it is stored, how it is transmitted, how it is processed, and you have sufficient controls over those data elements to make sure that it’s protected,” Khalil said. “And if it’s not protected, then [you have to figure out] what action you can take to mitigate the risk.”
One way to mitigate the risk is to create a barrier, which is what Locus Robotics does with its secure tunnel of encrypted data used to share information. But constant infrastructure changes in a warehouse can affect the environment. Adding a network node or allowing an OEM access into the network, for example, could open the door to unauthorized network access.
“It sounds simple, but it's a lot of complexity that comes into play,” said Khalil.
While Locus Robotics builds AMRs, they are just one piece of the solution. According to the Wilmington, Mass.-based company, it has designed its navigation software with measures to protect customers’ proprietary data.
“It's a one-stop shop/blackbox secure solution that gets deployed to a warehouse that offers the cloud reporting, the onpremises reporting, the robotics, services, operational efficiencies, connectivity for the network, and everything else that comes into play to make it effective and more productive,” Khalil explained. “That black-box approach is what we deliver, and security comes through that entire lifecycle, from start to end.”
Awareness must be raised for security
Khalil emphasized that security is everyone’s responsibility – from the robot provider to the management team to the engineers and the operators in the warehouse. With all these different people in the mix, education is imperative.
“The first challenge that you find in our industry is awareness and acceptance that there is a risk,” he said, noting the shared responsibility model is important to understand.
“Every time we deploy our solution to a warehouse, we are accepting the risks that they're experiencing.”
Shared responsibility should be reflected throughout the ranks of an organization, as well. Security
awareness training is a critical part of keeping the warehouse safe from cyber threats. “Especially given the fact that employees are your front line of defense, they must be always kept up to date on all things security,” Khalil said.
And it's not just about training your employees to be cybersecurityaware, but also training everyone in the partner ecosystem. To ensure a safe environment in the warehouse and beyond, the entire supply chain needs to embrace cybersecurity best practices. AW
Locus Robotics locusrobotics.com
Mitigate Your Cybersecurity Risks
According to Locus Robotics’ Fouad Khalil, the cybersecurity challenges of integrating GenAI into warehouse operations are significant, but not insurmountable. Here are some ways to safeguard warehouse operations:
• Conduct a comprehensive risk assessment: Begin with a thorough assessment of the cybersecurity risks associated with implementing generative AI. Understand where vulnerabilities may exist and how they can be exploited.
• Use robust data-protection measures: Implement state-of-the-art encryption, access controls, and data anonymization techniques to protect sensitive information from unauthorized access.
• Regularly update systems and manage patches: Keep all systems, including AI algorithms and connected devices, updated with the latest security patches to close any vulnerabilities that could be exploited by attackers.
• Train employees: Educate your workforce about the potential cybersecurity risks and best practices for preventing breaches. A wellinformed team is your first line of defense against cyber threats.
• Have an incident-response plan: Develop a comprehensive incident response plan that outlines steps to be taken in the event of a cybersecurity breach. This should include procedures for containing the breach, assessing the damage, and communicating with stakeholders.
• Collaborate with AI vendors: Work closely with your GenAI vendors to ensure they adhere to rigorous cybersecurity standards. Understand their data handling and storage practices, and ensure they align with your security requirements.
AUTOMATED WAREHOUSE
Preparing the plan warehouse automation
BY CHRIS VAVRA • SENIOR EDITOR
Consider this five-step strategy for a successful move away from manual processes.
The warehouse industry has transformed from its dire state 20 years ago, to an exciting era driven by Industry 4.0. Automation, fueled by efficiency, drives global growth, especially in the United States. However, newcomers to robotics need a solid warehouse automation plan, according to Movu Robotics, a maker of shuttle systems and autonomous mobile robots (AMRs).
Five current trends, including e-commerce growth and workforce challenges, are driving warehouse adoption of automation. Upcoming trends like actionable data and robotics-as-a-service (RaaS) also
promise significant benefits, reflecting continuous industry evolution.
Christoph Buchmann, sales director at Movu Robotics, outlined a five-step process for successful automation adoption. The steps include change management, a robust process review, software design emphasizing IT integration, hardware considerations, and meticulous implementation with worker training for long-term success.
The warehouse industry was in a terrible state 20 years ago, according to Buchmann. Today, he said, it’s a very exciting time, thanks to the rise of Industry 4.0 and other concepts,
which are fueling the growing trend toward automation and data exchange in technology and processes.
Automation offers great potential for manufacturers, Buchmann said during his presentation, “Mastering the Path to Automation: A Roadmap for Successful Implementation” at Modex in Atlanta earlier this year. “If you’re not thinking about automation now, you should start,” he said.
Five trends to consider in a warehouse automation plan Buchmann said five things are driving the acceleration of warehouse automation:
THE 5 PHASES OF TRANSITION
Movu Robotics presented steps to a successful warehouse automation plan. | Chris Vavra, WTWH Media
“The one thing you can expect is the unexpected”
1. Greater efficiency and profitability. It’s more costeffective than ever to implement automation.
2. Workforce development changes. The worker shortage remains a major challenge for employers.
3. Rising cost of real estate. Rather than build new facilities, companies are trying to make more of what they have.
4. E-commerce growth. The COVID-19 pandemic was among the factors forcing changes in consumer behavior and expectations for faster order fulfillment.
5. Food supply. The food and beverage industry has been using automation even more to match consumer demand and keep costs down.
While these trends are fueling automation’s growth now, Buchmann said five more trends are coming that will have just as big an impact:
1. Actionable data. There is more data than ever, and the technology has evolved to where companies can take advantage.
2. Accelerating technology. Advances in machinery, software, and now artificial intelligence are continuing.
3. Entry-level automation. Buchmann said automation was big and complex 20 years ago. That has changed. Now, robots are more scalable, more affordable, and less complicated.
4. RaaS. Robotic fleets have grown in manufacturing facilities and small-to-midsize enterprises (SMEs) are turning to the service
model to use robotics for their short-term needs rather than making the long-term investment right now.
5. Safety and sustainability. Keeping workers and facilities safer has always been a priority, but now companies are trying to reduce energy costs.
Five steps to moving from a manual to an automated process
Buchmann said there are many benefits automation can bring, such as better efficiency and throughput, higher profitability, better safety, and improved accuracy. However, he acknowledged that it isn’t as easy as pushing a button.
Buchmann described a fivestep process to transition from a manual process to an automated one. The entire transition requires a culture change, he said, and taking ownership and trusting in your partners and employees is key.
Management might approve, but the workers are the ones who will make a deployment happen, Buchmann added. It’s critical that the plan be flexible throughout the entire process.
“The one thing you can expect is the unexpected,” he said.
1. Change management
Putting people, particularly those who will be most affected, in a leadership role is critical. Buchmann said people are naturally reluctant to change, and they need to be persuaded. He said doing this with a heavy hand and making people feel bad about what they’re doing wrong right off the bat will shut down the conversation before it even begins.
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Five current and future trends are driving automation growth in warehouse facilities.
| Chris Vavra, WTWH Media
He said the trick is to encourage them by highlighting what they’re doing well and lowering their emotional barriers to new ideas.
“You’ll be surprised how quickly they’ll buy in,” Buchmann said. “Workers want to shine.”
By building on those small wins and having them own the new processes and technology, it’ll be easy to get buy-in on the ground floor, which is where change management starts.
2. Process review and design
Buchmann said developing a strong plan is critical because it needs to improve upon what is already being implemented. Having the right data is critical to success, and any potential solution is only as good as the data that goes into the design. Developing an automation plan on bad data or a bad process is only going to lead to a bad automated process, he said.
Gathering the right data requires an in-depth data analysis of the information most important to the operation and creating models that illustrate a full view of the four walls within an operation. It can also help uncover the nuances that make each corporation unique and provide a foundation to build success, said Buchmann.
He recommended that companies follow these three steps during the process review and design:
Assess current operations. Conduct a thorough analysis of warehouse processes, workflows, and technologies and consider future needs.
Set clear objectives. Define specific goals for warehouse automation and establish key performance indicators (KPIs) and targets to measure the implementation’s success.
Educate yourself. Buchmann said people involved in the project should engage with vendors and technology experts as well as evaluate the latest automation technologies to find successful examples.
It’s important to answer key questions such as “What is the automation
transition designed to achieve?” he said. It’s also worth looking at an alternative analysis and determining what is the cost or risk of not automating.
From there, the plan can move forward with a business case that provides a thorough and detailed roadmap for success.
3. Software design
Buchmann said companies should not underestimate the importance of IT integration because the most common reason for failed automation implementations is lack of it.
It’s a little more complicated because warehouse software can have overlapping functions and no fixed function divisions. That means each IT landscape of a warehouse is different. Companies need to find the right set of functions to successfully fulfill operational needs.
Getting the automated interface right and using a digital twin, which is an emulation and virtual replica of a real-life system, also can help as a tool to drive improvements in warehouse productivity and efficiency.
4. Hardware design
There are many types of automation equipment used in warehouse facilities. The four most common are:
1. Mobile robots
2. Automated storage and retrieval systems (ASRS)
3. Conveyor and sortation systems
4. Stationary and collaborative robots.
Buchmann explained that there are many operational needs and priorities to consider, such as whether the facility should be semiautomated or fully “lights out.” It’s also worth asking about operational redundancy, adaptability, and scalability during the process.
Whatever the case, a thorough analysis is a must because mismatched technologies lead to inefficiencies.
5. Implementation and support
Now the real physical work starts, said Buchmann. The good news is everything is all set because KPIs were already established.
The commissioning and implementation process should cover the fundamentals, such as testing everything at all levels and doing performance tests beforehand. Worker training is also critical for a warehouse automation plan to be successfully executed.
It won’t be a perfect process and it shouldn’t be, but the issues will be minor, Buchmann said, as long as people know how to react. “Minor problems can cause downtime if you’re not trained for them,” he said.
People are at the heart of the process, and companies that realize and value their workers’ potential and take the time to develop a strong process will come out ahead in the automation race. It’s one they can’t afford to lose as it becomes more than a “nice to have,” like it was 20 years ago. Now, a warehouse automation plan is a necessity. AW
Christoph Buchmann, sales director at Movu Robotics, discussed how to adopt warehouse automation in Atlanta. |
Chris Vavra, WTWH Media
Unleashing Efficiency: The Dynamic Duo of Conveyors and Robotics in Modern Warehousing
In the dynamic landscape of modern warehousing, the integration of conveyors and robotics has emerged as a game-changer, revolutionizing how facilities meet goals of throughput and accuracy. This combination enhances operational efficiency and catapults warehouses into a new era of productivity.
Elevating Throughput with Robotic Precision:
Robotics, equipped with advanced vision systems and machine learning, are transforming the movement of goods within warehouses. Automated guided vehicles (AGVs) and robotic arms seamlessly collaborate, ensuring a continuous flow of items from receiving to shipping. Conveyors act as the arteries, efficiently transporting products between robotic workstations and amplifying throughput rates.
Dorner conveyors specifically act as the Autonomous mobile robots (AMRs) and robotic arms have redefined order picking. Conveyors play a pivotal role in integrating these robotic picking systems, allowing for a smooth transition of items from storage to packing stations. This dynamic interaction ensures that orders are fulfilled rapidly, meeting the demands of today’s fast-paced supply chains.
Dorner’s 2700 Medium Duty series conveyors are designed for AGV/ AMR compatibility, allowing for quick and easy integration of the technology
into existing conveyor systems. With a robust design, increased weight rating, extended widths, and a low-profile aluminum frame, the 2700 series is ideal for applications that require both speed and precision.
Precision at Scale: Conveyors and Robotics Driving Accuracy:
Automated Quality Control: Robotics with computer vision capabilities ensure unparalleled quality control process accuracy. Conveyors serve as a conduit for products to undergo automated inspections by robotic systems, guaranteeing that only defectfree items proceed through the supply chain. This not only reduces errors but also maintains high product quality.
Error-Free Order Fulfillment:
Integrated with robotic order fulfillment systems, Conveyors contribute to flawless picking and packing processes. Robots navigate the warehouse, guided by conveyors, ensuring the correct items are selected and efficiently transported to packing stations. This collaborative approach significantly reduces order errors and enhances overall accuracy.
Real-time Inventory Accuracy: In conjunction with conveyors, robots are transforming inventory management. Drones and robotic platforms equipped with RFID technology conduct real-
time inventory checks. Conveyors efficiently transport these robotic platforms, enabling swift and accurate updates to inventory levels. This synergy ensures that warehouses maintain optimal stock levels, reducing the risk of stockouts or excess inventory.
Looking Forward: The Future of Warehousing Efficiency:
As modern warehousing continues to evolve, the integration of conveyors and robotics is a testament to technological innovation. This dynamic duo not only meets the demands of today’s throughput and accuracy goals but also positions warehouses for a future of continuous improvement and adaptability. By embracing this integrated approach, warehouses are not merely keeping pace with the times but defining the future of efficient, accurate, and responsive supply chain management.
The Data Driven Warehouse
How real-time data collected at every touch point smooths out operations
Emerging technologies are revolutionizing supply planning, enhancing supply chain efficiency, agility, and resiliency. Real-time data and advanced analytics driven by connected assets and systems help identify potential disruptions, mitigate risks and make informed decisions. We will discuss key insights into today's supply chain challenges.
What are today’s supply chain challenges?
The constantly evolving global supply chain landscape poses a range of challenges for businesses today that can impact their operational efficiency and effectiveness. Here are the biggest challenges:
• Business disruptions and market volatility: Over the past five years, supply chain operations in various industries faced unexpected events, which resulted in reactive responses. This can impede the ability to meet demand, leading to lost revenue, increased costs, and a decline in overall profit margins.
• Demand predictability: Social media, COVID driven direct-to-consumer (DTC) models, market volatility, and now inflation have made traditional demand forecasting insufficient. Operations are leaning on outdated forecast approaches that also lag and fail to respond adequately to current market dynamics.
• Holistic inventory visibility and optimization: Inventory management is complex and dynamic. The end of 2022-2023 saw excess inventory across many organizations due to COVIDrelated supply chain constraints. This led to higher costs, lower margins, and waste. The long term impact will lead to lost sales, and loss of differentiation, loyalty, and market positioning. Adopting an integrated approach and leveraging advanced technology and best practices, businesses can overcome these challenges - improving supply chain efficiency and resilience.
What is lacking in today’s supply chain strategies?
Supply planning today involves technology, data analysis and stakeholder collaboration. While technical and data analytic advancements have been made, there are still several areas that need improvements in the industry:
• Accurate transparency of data
• Dynamic supply planning and execution based on integrated intelligence and automated decision-making
• Convergence of network modeling, scenario and traditional planning and planning
Businesses want to improve supply chain visibility, predict, and mitigate risks, and optimize performance. Incorporating advanced concepts can enhance agility and resilience, meet customers’ evolving needs, and optimize performance. Below are a few advanced technologies and characteristics that must be included in an organization’s growth plans for supply chain optimization.
• Artificial intelligence and machine learning: Artificial Intelligence (AI) and Machine Learning (ML) can help businesses analyze data, find patterns, and make proactive decisions to mitigate risk. Many planning solutions have already integrated AI/ML into their core plans, but further integration of this can enhance algorithms. This could include detecting shifts and anomalies -- optimizing execution, automating operations such as key planning processes and real time decisions, and more.
• Digital twins and advanced simulation: Digital twins and simulation create virtual versions of physical assets, processes, and systems. These outputs can be used to evaluate scenarios and risk, identify key constraints, optimize, and evaluate alternative configurations.
With data and AI/ML, digital twins can continuously evaluate supply chains and networks, informing businesses in an unprecedented way.
• Automation and autonomous systems: The targeted deployment of automated storage retrieval systems (ASRS), autonomous mobile robots (AMR) and other assets with IoT connectivity, RFID asset tracking and machine vision can mitigate risks ranging from labor shortages to inventory loss. Working in tandem with digital twin and AI/ML, these assets comprise self-optimizing systems that drive higher output and efficiency by learning from both physical and simulated scenarios in the connected warehouse.
The future of supply chain planning requires digitization, automation, connectivity, and data-driven decision-making. Organizations that embrace these technologies create agile, transparent and efficient supply chains that are resilient to market changes and disruptions.
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sustainable package designing the perfect
sustainable package designing the perfect the
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Consumer
packaged goods (CPG) companies are under pressure to create more sustainable packaging. Now, faced with the inevitable move to environmentally friendly products, manufacturers are reassessing the materials, the packaging machines, and the recycling responsibility. All of which starts with the packaging design.
Dassault Systèmes provides software that can optimize the design process. Design World asked Raymond Wodar, the company’s global director business consulting for the CPG and retail industry, how the initial design impacts the entire product lifecycle — and how to start the process.
Who in a CPG organization is responsible for sustainable design?
Wodar: In a consumer packaged goods organization, sustainable design is typically a cross-functional effort that involves several departments and roles. The brand marketing function will likely define the parameters for the project and the packaging design and development teams are responsible for incorporating sustainable materials into the design. The teams need to work with internal sustainability or environmental affairs groups that will provide the goals
Stephanie Neil Executive Editor
and standards needed to achieve sustainability targets. Supply chain and procurement teams will also be involved for sourcing sustainable materials and managing the logistics packaging requirements. Other functions may involve advanced R&D topics like materials research and help from outside agencies to determine latest trends and consumer requirements.
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Beyond materials, what needs to be considered when creating a sustainable package design?
Wodar: When creating a sustainable package design, several factors beyond just the choice of materials need to be considered to minimize environmental impact and enhance overall sustainability. The design should be optimized to minimize the size and weight of the package to decrease material usage and excess packaging while still effectively protecting the product. A lighter product will also reduce transportation emissions in the supply chain. A thorough evaluation of the entire supply chain will help us understand the environmental impact from production through transportation and distribution. This includes considering how far materials and finished products need to travel and the associated carbon footprint of that journey.
Considerations for end-of-product-life are critical as well. This involves designing for disassembly (if applicable), providing clear recycling or disposal instructions, and considering the lifecycle impact of the packaging once it has been discarded. Using materials that are widely accepted by recycling systems or that can biodegrade in industrial composting facilities is critical.
For a brand manufacturer, the cost profile of the package will be very important so that tradeoffs between material cost, weight, and quality can be properly balanced to provide the consumer a great value while managing internal product margins.
What are the regulatory pressures associated with sustainable packaging?
Wodar: Regulatory pressures related to sustainable packaging are increasingly influencing how companies design, produce, and manage packaging. These pressures come from various levels of government and regulatory bodies and can vary by region. Many regions are implementing extended producer responsibility (EPR) programs that require producers to take responsibility for the Dassault Systèmes
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entire lifecycle of their packaging, including end-of-life disposal and recycling. Companies may need to manage or contribute to the costs of collection, recycling, or disposal. Several countries and states have introduced bans or restrictions on single-use plastics and certain types of packaging. Regulations might limit or prohibit the use of plastic bags, straws, or other singleuse plastic items, pushing companies to seek alternative materials or packaging solutions. Governments are starting to set targets for waste reduction, recycling rates, or the reduction of packaging waste. Companies are often required to meet these targets or face penalties. For companies operating globally, international regulations and agreements, such as the European Union’s Packaging and Packaging Waste Directive, can affect packaging design and sustainability practices.
How can 3D modeling software help?
Wodar: 3D modeling software enhances the design process by providing a detailed, interactive platform to explore and optimize sustainable packaging solutions, leading to more effective and efficient design outcomes. 3D modeling software allows designers to create detailed visual representations of packaging designs. This helps in visualizing how sustainable materials and design choices will look and function in the real world before physical prototypes are made. Before creating physical prototypes, 3D models can be used to simulate how the packaging will behave under various conditions. This includes testing durability, functionality, and fit, which helps in optimizing the design for better performance with sustainable materials. More advanced 3D modeling tools can also integrate with lifecycle assessment (LCA) software to evaluate the environmental impact of packaging designs. This helps in understanding the potential environmental footprint of different design choices and materials.
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What does a virtual twin do?
Wodar: A virtual twin is not only a digital replica of a physical object, system, or process, but it integrates real time data, simulations, and analytics to provide a comprehensive and dynamic model that mirrors the real-world counterpart. The most powerful part of virtual twins is the ability to perform ‘what-if’ scenario analysis. This allows for simulation of various scenarios and testing of different conditions without impacting the physical entity. Imagine testing how a package will behave when dropped, or when stacked in a pallet, or when going through temperature extremes, without needing to use a physical prototype. This is useful for assessing the impact of design changes, operational adjustments, or environmental factors. More advanced virtual twins can predict future performance or potential issues based on historical data and simulation results.
Can creating a virtual twin using 3D modeling software accelerate the time-to-market for a sustainable package design?
Wodar: Yes, using a virtual twin created with 3D modeling software streamlines and accelerates the entire process of sustainable package design. By enabling rapid design iterations, accurate simulations, and efficient collaboration, it reduces the time required to bring a new sustainable packaging solution to market. Designers can simulate how different design changes impact the packaging functionality, sustainability, and consumer appeal without the need for physical prototypes. This includes testing how the packaging performs in various conditions. This highly compresses the time needed to validate the design. Virtual twins also enable the testing of different sustainable materials to evaluate their performance, recyclability, and environmental impact, leading to
better material selection and design optimization.
What are the other benefits of using a virtual twin in sustainable design?
Wodar: Virtual twins offer a wide range of benefits in sustainable design, from cost savings and quality improvements to enhanced collaboration and environmental impact reduction. By leveraging these advantages, organizations can drive innovation, optimize design processes, and achieve their sustainability objectives more effectively. Using virtual twins minimizes the need for physical prototypes, saving costs associated with materials, manufacturing, and testing. By optimizing designs and processes virtually, companies can reduce material waste and energy consumption, leading to lower production costs and a smaller environmental footprint. Virtual twins enable designers to fine-tune every aspect of the design for optimal
Christoph Burgstedt | Adobe Stock | Generated with AI
IE5+ Technology
Intelligently controlled, high efficiency solutions for conveyor applications
Reduced Total Cost of Ownership and fast Return on Investment
Reduction of variants through constant torque over a wide speed range
Ventilated synchronous motors for quiet, cool operation
packaging oem
performance, durability, and sustainability. This leads to higher-quality products that meet or exceed performance expectations.
What is the Dassault Systèmes product that CPGs would use to accomplish this?
Wodar: It is called the Perfect Package industry solution experience. The comprehensive solution helps CPG companies design and optimize packaging in record time. Capabilities include structural design, modeling and simulation (MODSIM), project management, specifications management, lifecycle analysis, and more.
Is understanding the production of the sustainable package part of the process?
Wodar: Yes, understanding the production of a sustainable package is integral to ensuring that the packaging is truly sustainable. It helps in making informed decisions about materials, manufacturing processes, and cost implications, ultimately leading to a more effective and environmentally responsible packaging solution. Different materials may require specific manufacturing processes. Understanding these processes helps ensure that the packaging can be produced efficiently and sustainably. For instance, some materials may need specialized machinery or processes that could impact production costs and the environmental profile. Also, assessing the energy consumption, water use, and waste generated during production is vital for understanding the overall environmental impact. Sustainable production practices aim to minimize these factors.
What is the responsibility of the machine builder in this sustainability journey?
Wodar: The machine builder's role is integral to the sustainable packaging journey. Their involvement in designing, producing, and supporting efficient and adaptable machinery helps ensure that packaging manufacturers can meet
their sustainability goals effectively. By collaborating with other stakeholders and focusing on energy efficiency, material compatibility, and innovation, machine builders contribute significantly to the advance of sustainable packaging solutions. Builders must ensure that their machinery can handle and process sustainable materials, such as biodegradable films, recycled paper, or alternative substrates, without compromising performance or quality.
In a circular economy, does recycling of the package come into the design process?
Wodar: Yes, in a circular economy, the design process is significantly influenced by how the package will be recycled. The principles of a circular economy aim to minimize waste and make the most of resources. This requires considering the entire lifecycle of a product, including its end-of-life stage. Key considerations in the design process for packaging in a circular economy include choosing materials that are recyclable and can be separated easily from other components. Biodegradable or compostable materials might also be considered. OEM
Find more packaging news, trends, and research on WTWH Media’s Packaging OEM by visiting packagingoem.com or scanning the QR code
Raymond Wodar Dassault Systèmes
Door Mounted Motor Disconnect Switch
• Dual AC/DC rated; see below specifications
• Integrated door or side panel mounting
• Rear facing terminals for easy installation
• Loadsafe RT Series
• Switch make/break operation is semi- independent from operator’s actuation speed
• Silver contacts ensures safe and durable operation
• UL 60947-4-1
scan the qr code to learn more
35 Royal Road Flemington, NJ 08822
908-806-9400 908-806-9490 (FAX) info@altechcorp.com
www.altechcorp.com/HTML/MDS-A.html
KHK USA offers the broadest selection of stock metric gearing in North America. Designed for use in industrial automation applications, conveyor systems, packaging equipment, robotics, and general machinery applications, KHK’s selection of spur gears, helical gears, internal ring gears, gear racks, bevel gears, screw gears, worms & wormwheels, ratchets & pawls, gear couplings, right-angle gearboxes, and gear lubrication systems are available in various materials and sizes. KHK’s website offers free 3D CAD models for all gear products, complete product specifications, and 24/7 shopping. With KHK USA, stock gears are delivered from stock, with no minimum order or credit card surcharges.
khk usa inc.
259 Elm Place, Mineola NY 11501 516-248-3850
www.khkgears.us
PBC Linear is here to provide innovative solutions through the development and manufacturing of linear motion components, mechanical subassemblies, and customized systems to meet customers’ specific application needs.
Headquartered in a 200,000 square-foot facility in Roscoe, Illinois, USA, where production is streamlined and maximized to produce unmatched quality and designed specifically for the most complex and meticulous applications, resulting in ready to install linear solutions.
PBC Linear has the ability to provide smooth and reliable linear motion solutions for a wide array of applications ranging from very small pick-and-place assemblies and scanners used in lab automation to heavy-duty lift systems in industrial manufacturing.
Other applications utilizing our components and/or systems are kiosks, unattended retail systems, scanners, printers, and etchers.
Robotics Weeks
AUTOMATED WAREHOUSE
From mobile robots and automated storage to picking, palletizing, and sortation systems, warehouse operators have a wide range of options to choose from. To get started or scale up with automation, end users need to evaluate their own processes and environments, find the best fit for their applications, and deploy and manage multiple systems.
6402 E. Rockton Road Roscoe, Illinois 61073 USA
+1.815.389.5600
Pbclinear.com pbc linear
Automated Warehouse Week will provide guidance, with expert insights into the evolving technologies, use cases, and business best practices.
ROBOTICS ENGINEERING
Robotics Engineering Week features keynotes and panels, delivered by the leading minds in robotics and automation, addressing the most critical issues facing the commercial robotics developers of today.
Combating the Changes of Evolving Automation Technology with Conveyance
In the ever-evolving packaging landscape, OEMs constantly seek ways to enhance efficiency, flexibility, and reliability in their packaging lines. At the forefront of this technological evolution is Dorner Conveyors, a leading innovator in conveyor solutions. With a commitment to integrating cutting-edge technologies and adapting to the latest industry trends, Dorner is well-prepared to continue as the preferred choice for OEMs looking to build or upgrade their packaging lines.
Pioneering Integration with Robotics
One of the most significant advancements in packaging technology is the integration of robotics. Dorner Conveyors excels in facilitating seamless interactions between conveyor systems and robotic components. Dorner's conveyor solutions are meticulously engineered to interface with a wide range of robotic arms and automation systems, enabling precise and efficient product handling, sorting, and packaging.
This compatibility ensures smooth operation across various stages of the packaging process, minimizing manual intervention and optimizing workflow efficiency. Dorner's conveyors are designed with built-in features that support automation, such as smooth transfer points, adjustable speeds, and the ability for real-time data communication.
Dorner's precision is the catalyst for this integration. Dorner's fabric belted conveyors utilize a v-guided underside of the belt, which tracks in the conveyor's frame to ensure that the belt is centered, ensuring that the product is as precise as possible to interact with the robot on the packaging line.
This integration allows for enhanced precision in packaging applications, contributing to higher productivity and reduced operational costs. Whether for a high-speed production line or intricate packaging tasks, Dorner's conveyors ensure that robotic systems perform at their best, providing OEMs with a robust solution for modern packaging demands.
Adaptability to New Technologies
As technology advances, the packaging industry faces increasing demands for flexibility and adaptability. Dorner's
conveyor systems are built with these evolving needs in mind. The modular design of our entire breadth of conveyors allows for easy customization and reconfiguration, accommodating emerging technologies such as IoT-enabled systems, advanced sensors, and machine learning applications.
This adaptability ensures that Dorner's conveyors can integrate with the latest technological innovations, making them a future-proof choice for OEMs. By leveraging Dorner's adaptable solutions, OEMs can stay ahead of technological trends and incorporate new features into their packaging lines without overhauling existing infrastructure. This forward-thinking approach enhances operational efficiency and supports long-term growth and scalability.
Superior Performance and Reliability
When it comes to performance and reliability, Dorner Conveyors sets the benchmark. Their extensive range of conveyor systems includes low-profile, sanitary, and heavy-duty models, each designed to meet specific operational requirements. With a focus on high-quality materials and robust construction, Dorner's conveyors are engineered to withstand the demands of high-speed and heavy-duty applications. Dorner's advanced controls and monitoring systems also provide realtime performance data, enabling proactive maintenance and minimizing downtime. This ensures that packaging lines operate smoothly and efficiently, contributing to consistent product quality and overall operational success.
Tailored Solutions for Diverse Needs
Understanding that every packaging line has unique requirements, Dorner offers customized solutions to meet specific needs. Our Engineered Solutions team collaborates closely with OEMs to design conveyor systems that seamlessly integrate with existing equipment and workflows. Whether you need conveyors for complex packaging tasks or highvolume production, Dorner provides tailored solutions that enhance operational efficiency and can help achieve your goals. Working with Dorner gives OEMs access
to expertise and a wide range of options for optimizing their packaging lines. This personalized approach ensures that each conveyor system is designed to address the unique challenges and objectives of the application, delivering optimal performance and value.
Commitment to Continuous Innovation
Dorner's commitment to innovation drives its continuous development of advanced conveyor technologies. Their investment in research and development ensures that their products incorporate the latest advancements, positioning them as a leading choice for OEMs seeking to stay ahead in the packaging industry. By partnering with Dorner, OEMs benefit from a conveyor solutions provider dedicated to pushing the boundaries of technology and performance. This commitment to innovation enables OEMs to build packaging lines that are not only efficient and reliable but also equipped to handle future challenges and opportunities.
In summary, Dorner Conveyors is a leader in providing advanced, adaptable, high-performance conveyor solutions for packaging lines. With their expertise in integrating robotics and new technologies and their focus on reliability and customization, Dorner is the ideal partner for OEMs looking to enhance their packaging operations and achieve long-term success. Trust Dorner to deliver innovative solutions that drive efficiency, flexibility, and excellence in your packaging line projects. OEM
For more information
on Dorner’s Packaging Conveyors visit our website dornerconveyors.com or visit booth N-5623 at Pack Expo International in Chicago.
NORD LogiDrive Complete Drive Solution
with New IE5+ Motor Technology
LogiDrive® is a complete decentralized drive package that greatly reduces engineering and commissioning efforts. With this modular system, the number of variants can be minimized, making maintenance easier and reducing Total Cost of Ownership (TCO) for the operator. The LogiDrive interface is intuitive and allows for easy control and monitoring of all units within the system. When paired with the NORDCON APP with NORDAC
ACCESS BT Bluetooth stick, LogiDrive systems can provide real or nearreal time drive status to proactively predict maintenance issues and keep systems running smoothly. LogiDrive systems can be configured with IE3, IE4, and latest IE5+ permanent magnet synchronous motors that maintain extremely high efficiency, even at partial loads.
Energy Efficient
• Compliance with the most stringent efficiency regulations
• Considerable reduction of Total Cost of Ownership (TCO)
• High efficiency, even in partial load ranges and at low speeds
• Permanent Magnet Synchronous Motor (PMSM) technology
Variant Reduction
• Standardization of gear motor versions designed for intralogistics and airport technology
• Simplified engineering and selection
• Constant torque over a wide speed range through variable frequency drive technology
Service and Maintenance Friendly
• Considerable reduction of spare parts inventory
• Plug-and-Play technology
• Compact, space-saving design
• 25% weight reduction with lightweight aluminum housing
• Replacement of individual components possible
NORD offers unmatched product versatility, fast, reliable sales and support, and direct access to our engineering team. We also offer online tools for easy configuration and ordering of gear motors and spare parts, as well as 24/7/365 emergency breakdown service. OEM
1. Publication Title: PLANT ENGINEERING
2. Publication Number: 790-920
3. Filing Date: 9/13/24
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Statement of Ownership, Management and Circulation
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9. Publisher: Patrick Lynch, WTWH MEDIA, 1111 Superior Ave #2600, Cleveland, OH 44114
Editor: Amara Rozgus, WTWH MEDIA, 1111 Superior Ave #2600, Cleveland, OH 44114
Managing Editor: Anna Steingruber, WTWH MEDIA, 1111 Superior Ave #2600, Cleveland, OH 44114
10. Owner: WTWH MEDIA, 1111 Superior Ave #2600, Cleveland, OH 44114 Scott McCafferty, Mike Emich, Marshall Matheson, 1111 Superior Ave #2600, Cleveland, OH 44114
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The new Orival Model ORZ selfcleaning screen filter requires only about 1/3 as much water for the screen cleaning process as conventional filters. Models are available with 2-24 inch connections and greatly increased screen areas. Screen elements come in either single layer woven or multi-layer 316LSS construction. Filtration degrees go from 5 to 3000 microns.
ORIVAL INC. (201) 568-3311 • www.Orival.com
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