www.controleng.com
Now you can expect more from your HMI! MORE LOGIC • New tag combinations allow simple logic with multiple events
The C-more EA9 HMI software (just $99) now delivers more functionality, usability and value to our popular C-more touch panels. Dozen of new features and upgrades give you MORE for LESS!
• Combine up to four different tags to trigger actions based on logical results
MORE MATH • New math functions let you create custom formulas with constants or tag values • The Math Keypad provides both simple and complex operations including log, sine, and square root
MORE ACCESSIBILITY • The new ObjectLayer List Window shows all the objects on the active screen and lets you lock/unlock, hide/unhide objects or quickly select them for editing • The Object LayerList allows access to individual objects in a group; additional lists for hidden, locked or overlapping objects • Recipe database supports 99 recipe sheets, each with 1000 recipes of 256 possible tags or values; operator can now modify and save while the process is active • New menu options, customizable toolbars and updated graphics for improved ease of use
MORE ALARMING OPTIONS • Enhanced Alarm List offers more options for alarm customization • New alarm filters allow for dedicated alarm summaries
C-more EA9 Touch Panels start at
$499! C-more EA9 Software
EA9-T12CL 12” model shown priced at $1790
$99
MORE DRIVERS • C-more panelshave driversfor most major brands of PLCs. See the entire list at www.automationdirect.com/c-more-drivers LESS COST • With softwareat $99 and hardware starting at just $499, C-more gives you one of the best costs of ownership, considering initial price, features, ease of use, reliability and free award-winning technical support
EA9-PGMSW
C-more Remote HMI App For only $4.99 you can have remote access and control on the go! Available now in your Apple® or AndroidTM app store.
* EA9-PGMSW for use with EA9 series panels only; cannot be used with EA7 series panels.
Get more than you paid for . . . C-more.AutomationDirect.com 1-800-633-0405
input #1 at www.controleng.com/information
www.AutomationDirect.com
DO MORE WITH
YO UR DATA Introduce real-time industrial data to your cloud-based business systems with Kepware’s industry-leading communications platform.
Kepware Technologies provides a portfolio of software solutions that connect diverse industrial automation devices and software applications. Established in 1995 and now distributed in more than 100 countries, Kepware has helped thousands of customers improve operations and decision making. Visit us online to learn more about our communications platform that’s enabling the Internet of Things. input #2 at www.controleng.com/information
MARCH 2016
Vol. 63 Number 3
Features 26 Cover Collabora tive robots: safety, other benefits story: Collaborative robots are becoming more common on the plant floor. Deciding if they should be used requires considering safety and business goals. New guidance on safety is available.
30 Industrial Internet of Things (IIoT), Industrie 4.0: World views 30
26 COVER:Fanuc America’s CR-7iA (left),
ABB’s YuMi (top), and Universal Robots’ UR10 (right) are among collaborative robots available. Michael Smith, Control Engineering creative director, designed the composite cover using images courtesy of the companies mentioned.
The advent of Industrie 4.0 in the Czech Republic
32
Industrie 4.0 is opportunity, challenge: China
33
Data analysis: a key requirement for IIoT: Europe
34 Quantified benefits of
Industrial Internet of Things implementations
36
IoT gateways: Industrial automation’s path to Industrie 4.0
38
Use IIoT to improve operations
40 PC-based control drives
38
global adoption of Industrie 4.0,
IIoT concepts 42 Enabling
IIoT requires communication protocol translation
43 Cognitive Digitalcomputing edition exclusives delivering answers, new questions; Technology developments for IIoT, real-time data
44 High-performance HMIs for increased efficiency and overall process safety Using high performance human-machine interfaces (HMIs) is a powerful way to streamline how operators manage processes and allows them to react to process upsets as efficiently as possible.
46 Using programming standards to leverage modern HMI solutions Modern human-machine interface (HMI) solutions can benefit from automation technology (AT) and information technology (IT) convergence solutions.
48 Using connectivity softwareto integrate the IoT with existing systems Open platform communications (OPC) and data distribution service (DDS) provide two approaches to bridge the communication gap.
51 Hannover Preview Hannover Messe preview: Reasons and examples show why you should go to this show.
2
|
MARCH 2016
CONTROL ENGINEERING
46 CONTROL ENGINEERING (ISSN 0010-8049, Vol. 63, No. 3, GST #123397457) is published 12x per year, Monthly by CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523.Jim Langhenry, Group Publisher /Co-Founder; Steve Rourke CEO/COO/ Co-Founder . CONTROL ENGINEERING copyright 2016 by CFE Media, LLC. All rights reserved.
CONTROL G is registered CFE Media, LLC offices. used under license. PeriodicalsENGINEERIN postage paid at aOak Brook, ILtrademark 60523 andofadditional mailing Circulation records are maintained at CFE Media, LLC, 1111 W. 22 nd Street, Suite #250, Oak Brook, IL 60523. E-mail: customerservice@cf emedia.com. Postmaster: send address changes to CONTROL ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Publications Mail Agreement No. 40685520. Return undeliverable Canadian addresses to: 1111 W. 2 2nd Street, Suite #250, Oak Brook, IL 60523. Email: customerservice@ cfemedia.com. Rates for nonqualified subscriptions, including all issues: USA, $150/yr; Canada/Mexico, $180/yr (includes 7% GST, GST#123397457); International air delivery $325/yr. Except for special issues where price changes are indicated, single copies are available for $30.00 US and $35.00 foreign. Please address all subscription mail to CONTROL ENGINEERING, 1111 W . 22nd Street, Suite #250, Oak Brook, IL 60523. Printed in the USA. CFE Media, LLC does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the material contained herein, regardless of whether such errors result from negligence, accident or any other cause whatsoever.
www.controleng.com
input #3 at www.controleng.com/information
Re-Route Your Temperature Measurements Around Potential Roadblocks The new THZ /TDZ Dual Input Smart HART 3
3
®
temperature transmitters can help you avoid costly process interruptions and maintenance delays by ensuring your measurements always make it safely to your control system. Our Sensor Backup and Failover protection feature means you will never miss those critical readings - even if something goes wrong with one of the sensors. Plus, with Device Intelligence, a series of new and advanced features that enable smarter control and monitoring, the THZ3/TDZ3 gives you the condence that your temperature measurements will get from Point A to Point B despite any potential roadblocks.
Demand Moore Reliability
input #4 at www.controleng.com/information
To learn more about our Dual Input Temperature Transmitter, go to: www.miinet.com/THZ3TDZ3 Or call 800-999-2900
Controller outputs
MARCH 2016
Vol. 63 Number 3
100
75
e g a t n e c r e p ,l 50 a n g i s V M
25 Plot area
Inside Process Appears after page 57; If not, see the Digital Edition: www.controleng.com/DigitalEdition
0 0
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180
P1
Time, seconds
P1 Neural networks in process control: architecture, controls Neural networks have been used in process control strategies for years, but they’re still not commonly found in industry. This technology has been applied in a number of fields with great success. With proper training to lift the veil from the technology, it can be more widely applied—without mystery—to solve some of the most nagging process control problems.
P9 Filtration process improves vermouth drinks A food and beverage equipment manufacturer designs and builds rotating dynamic crossflow filter systems to replace traditional vacuum filters.
P9
Products 70 8 Think Again Disruptive opportunities
10 Apps for Engineers Control methods
12 Research Information integration
14 Control Engineering International
Robot series
designed for fast, repeatable movements; Programmable alarm trips for process, chemical applications; Particulate monitoring system with multichannel configurations
Creating a universal robot controller for Industrie 4.0
16 IT Insight Why manufacturing software should be tested before updates
18 Technology Update Understanding fiber-optic network technology for SCADA
72 Back to Basics Ladder Logic 105: PLC scanning
News 22 23 24 25
Engineer a culture of service excellence Open systems transitions; New robot sales record Plant of theYear; Motor repair help; cyber security budget Cloud-based IoT acquisition; Events; online; corrections
www.controleng.com
CONTROL ENGINEERING
MARCH 2016
|
5
More resources posted daily at:
MARCH
www.controleng.com
Trending
New Products
Control Systems
Process Manufacturing
Discrete Manufacturing
System Integration
Networking & Security
Planning algorithms for automatic contingency planning
Collaboration on time-sensitive networking testbed announced
Projects for improving manufacturing challenges receive funding
Ladder logic 104: Memory organization
Benefits of using a process historian
IoT standards group formed to unify companies, developers.
Education & Training
Industrial Internet of Things (IIoT) 2016 webcast series
There’s a lot more to read online. Go www.controleng.com/news to to read Control Engineering’s exclusive Web content.
Info Management
Control Engineering ’s webcast series on the IIoT continues in 2016. Learn more Webcasts about the upcoming webcast in the series here www.controleng.com/webcasts:
IIoT Webcast Part One: Effective change management
Thursday, March 31, at 11 a.m. PT/1 p.m. CT/2 p.m. ET
Oil & Gas Engineering February issue
Newsletter: Safety and Cyber Security Industrial cyber security: Learn from the mistakes of others
De-risk by design: Maintaining safety at heights
Protecting FPSOs from arc flash
ICS security trends.
Keep up with the latest industry news by subscribing toControl Engineering’ s 14 newsletters at www.controleng.com/newsletters
New version Global System Integrator Database CFE Media has launched the latest version of the Global System Integrator Database. Find and connect with the most suitable service provider for your unique application.
6
|
MARCH 2016
CONTROL ENGINEERING
Oil & Gas Engineering provides industryspecific solutions designed to maximize uptime and increase productivity through the use of industry best practices and new innovations, increase efficiency from the wellhead to the refinery by implementing automation and monitoring strategies, and maintain and improve safety for workers and the work environment. Read the digital edition at www.oilandgaseng.com. 1
_
_1 _
.i n
Digital Edition The tablet and digital editions of this publication have unique content for our digital subscribers. This month has digital exclusives on: Cognitive computing in a data-driven age; and technology development using the IIoT.
www. c o n t r o l e n g . c o m
www.controleng.com
11/ : :/
1
Reliable Detection For Your Application
You can’t afford not to know. See it all atthinkallied.com/sensors
1.800.433.5700
© Allied Electronics,Inc 2015. ‘Allied Electronics’ an d the Allied Electronics logo are tradem arks of Allied Electronics,Inc.
input #5 at www.controleng.com/information
An Electrocomponents Comp any.
THINK AGAIN IIoT disruption 1111 W. 22nd St. Suite 250, Oak Brook, IL 60523 630-571-4070, Fax 630-214-4504
Disruptive opportunities
Content Specialists/Editorial Content Manager Mark T. Hoske, 847-830-3215,
[email protected] Jack Smith, Content Manager 630-907-1622,
[email protected]
Industrial Internet of Things and Industrie 4.0 models bring disruptive opportunities to manufacturing and other increasingly automated industries, augmenting human productivity. Five years from now, will you be grinding in first gear while your competitors innovate in overdrive?
Director of Research Amanda Pelliccione, 631-320-0655,
[email protected] Joy Chang,Digital Project Manager 630-571-4070 x2225,
[email protected] Chris Vavra,Production Editor 630-571-4070 x2219,
[email protected]
Contributing Content Specialists Frank J. Bartos,P.E.,
[email protected] Peter Welander,
[email protected] Vance VanDoren,Ph.D., P.E.,
[email protected]
F
For years, automation
end users and system integrators have sought greater innovation through interoperability. For years, many automation vendors have hesitated, some, perhaps, fearing loss of market share. Disruption and innovation opportunities from the Industrial Internet of Things (IIoT) and Industrie 4.0 frameworks give automation and controls vendors an opportunity to encourage connections and interoperability in ways that will more quickly facilitate benefits, according to several end users and analysts at the ARC Advisory Group Industry Forum in February. Disruptive thinking, changes, and innovation are required for large leaps, noted Luke Williams, New York University (NYU) Stern
Control Engineering Europe Suzanne Gill,
Be the disrupter, Williams suggested,
[email protected] Control Engineering Russia Ekaterina Kosareva, ing that never has there been a better time to
[email protected] try new things and to re-arrange your busiControl Engineering Poland Wojciech Stasiak, ness. Moving slowly can be hazardous, he said.
[email protected] , Control Engineering Czech Republic Lukáš Smelík Ask Nokia, Motorola, and Blackberry about
[email protected] smartphones. Ask Blockbuster about streamAileen Jin,Control Engineering China
[email protected] ing video. Ask a taxi driver about Uber. Publication Services “Traditional suppliers have to be nontradiCo-Founder/Publisher, CFE Media Jim Langhenry, tional, or there are others who will help,” said 630-571-4070, x2203;
[email protected] Andy Chatha, ARC president. “We critically Co-Founder, CFE Media Steve Rourke, 630-571-4070, x2204,
[email protected] need innovation. If the automation industry Executive Assistant, Kelly, doesn’t provide it, others will.” Chatha said that Trudy 630-571-4070, x2205,
[email protected] one-third of the ARC Forum audience was Marketing Manager Elena Moeller-Younger , 773-815-3795,
[email protected] there for the first time; many are trying to be the disruptors in industry, where the money is. Kristen Nimmo,Marketing Manager 630-571-4070, x2215,
[email protected] Don Bartusiak, ExxonMobil Research and Brian Gross,Marketing Consultant, Global SI Database Engineering, chief engineer process control, 630-571-4070, x2217,
[email protected]
Creative Director Michael Smith, School of Business, clinical associate profes- said ExxonMobil is working with Lockheed 630-779-8910,
[email protected] sor of marketing, and executive director at the Martin and others to define amore open conPaul Brouch,Director of Operations W.R. Berkley Innovation Lab. Williams, speak- trol system, with a plan to deploy in 2019. This 630-571-4070, x2208,
[email protected] ing at the A3 Business Forum, in February in isn’t a custom effort and should benefit all. Print Production Manager Michael Rotz, 717-766-0211 x4207, Fax: 717-506-7238 Orlando, said to think disruptively: 1) Craft Sandy Vasser,ExxonMobil Development,
[email protected] a disruptive hypothesis; 2) define a disrup- ities I&E manager added, “We have to make Account Director Maria Bartell, Infogroup Targeting Solutions tive market opportunity; 3) generate disrup- big changes; wehave no choice.” W orking with 847-378-2275,
[email protected] tive ideas; 4) shape a disruptive solution; and suppliers may bring about disruptive, benefiRick Ellis,Audience Management Director 5) make a disruptive pitch. cial changes more quickly. 303-246-1250,
[email protected] : Please e-mail us your opinions to Letters to the editor Michael Carroll, Georgia Pacific,
[email protected] or fax us at 630-214-4504. Models for disruption ident innovation and operational excellence, Letters should include name, company, and address, and may be edited for space and clarity. See views on IIoT and Industrie 4.0 in this noted the need to not let prior knowledge be issue representing disruptive opportunities the enemy of what may be next. He said there’s Information:For a Media Kit or Editorial Calendar, email Trudy Kelly at
[email protected]. for greater investment in automation where more at risk for those who choose not to parReprints it makes sense, in more connectivity and real- ticipate than those who do. For custom reprints or electronic usage, contact: Brett Petillo, Wright’s Media time analytics to get useful information where Technology spending for IIoT and Indust281-419-5725,
[email protected] needed for smarter decisions, and in digital rie 4.0 are being accepted to a greater degree, Publication Sales manufacturing for greater simulation, collab- Bartusiak observed; it’s increasingly underPatrick Lynch, ContentStream, Director of Content Marketing Solutions 630-571-4070 x2210
[email protected] oration, efficiencies,and optimization. How? stood that related investments will pay off. AR, IL, IN, IA, KS, KY, LA, MN, MO, MS, NE, ND, OK, OH, SD, TX, WI, Bailey Rice, Most innovation of the next 10 years, WilCentral Canada MORE liams said, won’t be driven by what drove the 630-571-4070 x2206
[email protected] Iris Seibert, AK, AZ, CA, CO, HI, ID, MT, NV, NM, OR, UT, WA, WY, last 80 years. Think again if you believe old ADVICE Western Canada methods can suffice. 858-270-3753
[email protected] In this issue, see IIoT articles and the Digital Edition ce
article on computer cognitive learning. Online seeadditional article links: Automation vendors: Connect and interoperate, or someone else will Engineers:Be disruptive in thinking, innovation 8
|
MARCH 2016
CONTROL ENGINEERING
Julie Timbol, CT, DE, MD, ME, MA, NC, NH, NY, NJ, PA, RI, SC, VA, VT, WV, DC, Eastern Canada
978-929-9495
[email protected]
Maggie Hatcher, AL, FL, GA, MI, TN, classified, product mart, media showcase
Mark T. Hoske,Content Manager
630-571-4070, x2221
[email protected]
International Stuart Smith, Tel. +44 208 464 5577
[email protected] [email protected]
www.controleng.com
BOA Spot TM
NEW
Low Cost Integrated Vision Sensor BOA Vision System Performance at Vision Sensor Affordability • Integrated light, lens and processing
• Built-in factory communications
• Easy-to-use application interface
• 100% automatic inspection
• Embedded vision tools for matching, counting, feature
• Low cost of ownership
finding and measuring
View the BOA Spot Features Guide: http://goo.gl/effIC9 input #6 at www.controleng.com/information
APPS FOR ENGINEERS
data collection www.controleng.com/appsforengineers
Mobile apps for monitoring, control
Stop traveling on site for support! Let’s stay Cosy!
Control and monitoring mobile applications have potential to help engineers do their jobs better. CFE Media’s Apps for Engineers is an interactive directory of engineering-related apps for Apple iOS and Android operating systems from various companies. Apps are organized by category, company, and type. These are listed in the app as of February 2016.
BOGE iOS 4.2 +, Android 4.0+ Cost: Free Company:Cybob Communication GmbH Website:www.cybob.com The BOGE app allows the user to check the status on BOGE compressors and compressed air stations at any time. This app is designed to provide information on the component’s runtime, status, maintenance level, and other important technical values.
CTC qMon iOS 5.1+ Cost: Free Company:Control Technology Corp. Website:http://controltechnologycorp.com The CTC qMon app is a tool allowing the user to gain access to your automation systems, locally and remotely. With the app the user can monitor and configure CTC controllers and connect wirelessly to any CTC automation controller. The app can also write values to the controller and from there you can set outputs, numeric registers, and flags.
Data Dashboard for LabVIEW iOS 8.0+, Android 5.0+ Cost: Free Company:National Instruments Website:www.ni.com/mobile
Secure VPN Remote Access
The Data Dashboard lets the user fabricate a custom rendition of NI LabVIEW applications by showing values of network published shared variables and web services on charts, gauges, text indicators, and LEDs.
for machine builders • Firewall friendly solution • 3 Million VPN Connections
Energi Savr iOS 6.0+
• Free VPN service
Cost: Free Company:Lutron Electronics Inc. Website:www.lutron.com Energi Savr allows the user to adjust the programming and configuration of a Lutron Energi Savr Node (ESN) system over a Wi-Fi network with an i Phone or iPod Touch.
www.ewon.us Pittsburgh, PA|412 586 5901 input #7 at www.controleng.com/information
10
|
MARCH 2016
CONTROL ENGINEERING
www.controleng.com
OPEN THE DOOR TO ASIA INTERESTED? Visit G2A.CCLinkAmerica.org CLPA-Americas:
[email protected]
You’ve implemented the local open network technologies in your products. But now it’s time to look further afield. Chances are these technologies leave a large part of the Asian market inaccessible. So how can you also capture that? CC-Link is a market leading technology for open automation networking in Asia. Adding this connectivity can lead to a significant business increase in critical markets such as China. Our Gateway to Asia (G2A) program offers a comprehensive package of development and marketing benefits to capture this additional market share.
TM
input #8 at www.controleng.com/information
Control system cyber security threat levels High Severe 9%
25%
18%
research
48%
2015 IIoT, INDUSTRIE 4.0, INFORMATION INTEGRATION STUDY: Low
Six key findings on integrating operations
R
Respondents
to the Control Engineering 2015 Industrial Internet of Things (IIoT), Industrie 4.0, Information Integration Study identified six high-level findings impacting control systems today: 1. Integrated levels: Seventeen percent of organizations’ manufacturing floors (Level 1) and advanced manufacturing control (Level 2) are highly integrated. Another 9% report Level 2 and enterprise (Level 3) to be highly integrated, and 8% cite the same level of integration between Levels 1 and 3. 2. Lack of integration: The most
4. Challenges: One in four respondents have found a lack of budget to be the top challenge when integrating operations, followed closely by confusion over project scope and/or benefits. 5. Information sharing: Internal networks and weekly reports are popular methods for which corporate management receives information from the manufacturing and enterprise levels of organizations. 6. Integration tools: To establish and sustain integration, respondents take advantage of system integrators
popular reasons for low levels of integration at respondents’ facilities are an unwillingness to assign resources/benefits are not recognized and the difficulty and cost of implementation. 3. Benefits: Some benefits from recent integration projects include better support for decision making (47%), faster decision making (39%), and better control of resources (39%).
(42%), customized software (42%), and browser-based interfaces (34%), among other methods. ce
View more information at www.controleng.com/2015InfoStudy. Amanda Pelliccione is research director at CFE Media,
[email protected].
Status of information integration over the next few years Information integration will slowly increase
44%
Information integration should be improved, but it’s a low priority
Moderate
Nearly half of control systems are considered moderately at risk to a cyber security breach. Source: Control Engineering 2015 Cyber Security Study
49%
of engineers admit that they or their peers lack communication/presentation skills necessary for advancing in their career. Source:Control Engineering 2015 Career Study
15:
Average number of system integration projects worked on or outsourced per year; 57% work on/outsource 10 projects or fewer annually. Source:Control Engineering 2015 System Integration Study
3 in 10
engineers report a lack of integration between the manufacturing floor and enterprise due to an executive decision to restrict information access. Source:Control Engineering 2015 IIoT, Industrie 4.0, Information Integration Study
25%
More research Improvements are currently underway No change expected
24%
15%
Forty-four percentof survey respondents believe that information integration within their facilities will increase at a slow pace, while 24% are currently undergoing improvements. Courtesy: Control Engineering
Control Engineeringsurveys its audience on several topics each year, including cyber security; career survey; system integration, and IIoT, Industrie 4.0, information integration. All reports are available at www.controleng.com/ce-research.
www.controleng.com/ce-researchFOR MORE RESEARCH INFORMATION
12
|
MARCH 2016
CONTROL ENGINEERING
www.controleng.com
D!
CFE Media’s
E T A Global System
D U P Integrator Database CFE Media’s Global System Integrator Database is an interactive community of global end-users and system integrators hosted by Control Engineering, Plant Engineering, and our global partners in Asia and Europe. e newest version of the online database is even easier to use. Features and updates:
• More search results can now be seen on the screen • Relevancy score indicates how closely an integrator’s qualications match a user’s search criteria • Users can now preview the most pertinent data of an SI before clicking to view the full corporate prole • New feature allows an from end-user to requestsite a quote for a project directly the database • Te most relevant data about an integrator’s engineering services appear on one page on their corporate prole – other details are organized by tabs.
Find and connect with the most suitable service provider for your unique application.
Start searching the Global System Integrator Database now!
www.cfemedia.com/global-si-database
ROBOT CONTROL Control Engineering International
Creating a universal robot controller for Industrie 4.0 A controller designed for independent robot developers aims to help the Chinese robot market to continue to grow rapidly. See other robotic and Industrie 4.0 coverage in this issue.
C MORE
ADVICE GO ONLINE
www.controleng.com/international www.cechina.cn
has to gone through a major period of industry growth thanks the China’s robotics approval and implementation of policies such as “Intelligent manufacturing” and “Made in China 2025.” In 2014, the Chinese industrial robot market became the largest in the world with more than 56,000 robots sold and industry growth of 54%. Robots continue to become more sophisticated as intelligent controls develop. The accuracy and stability of the robot’s controller are key factors in influencing the robot’s performance. Li Guozhong (Vincent Li), the business development director for Advantech (China), discussed with Control Engineering Chinahow the company is developing a robot controller designed to operate like an industrial PC (IPC). “Some users who used the low-cost controller at the very start would find the accuracy and stabil-
This to extensible make the hardware layerItfunction is andesigned open and architecture. can control industrial robots such as Delta, selective compliance assembly robot arms (SCARA), and 6-axis robots. The open hardware architecture and plug-and-play rapid development are designed to improve the working efficiency of users who need secondary development platforms and special flexible customizing functions. Li said that when control functions are designed for a 6-axis robot, an IPC with the robot controller will suffice. Data collection or machine vision cards can be added, if needed. The media board processor can control vision without consuming CPU capacity. Li said that control system efficiency is improved with a strong hardware design.
ity of such controller can’t meet the requirements half a year later,” Li said. Currently, robot controllers are mainly manufactured by non-Chinese manufacturers, however, the “four biggest manufacturers” who dominate about half of the world sell high-quality controllers with their robot systems. More enterprises are manufacturing robots and must rely on others due to the lack of a universal controller. Aimed at the demands of independent development of users, a robot controller is being designed for independent developers. It integrates a traditional robot controller into one PCI control card, which can be inserted into any IPC with a PCI interface; development runs in Microsoft Windows.
Things (IoT) and Industrie 4.0 helps in designing a robot controller, Li said. Advantech acquired LNC in 2013, gaining expertise in control technology and precision machining. Applying that knowledge to robot control may make it easier for Advantech to integrate robots into factories. “When robots appear in factories or the production line, it will not become an isolated island. We can integrate robots with the Internet of Things and Industrie 4.0 with a more complete plan from the very start,” Li said. Advantech’s IoT plans are reflected in controller integration and in vertical industries such as metalworking. Advantech also has entered into Industrie 4.0 memorandum of cooperation with Goodway Machine Corp., the largest machine tool plant in Taiwan. By preassembling new equipment or adding modules or software in the old equipment, Advantech upgraded Goodway equipment for end users to an Industrie 4.0 or Industrial Internet of Things (IIoT) architecture, including uniform management and system monitoring. The Goodway experience is helping Advantech launch an Industrie 4.0 solution to meet the needs of metalworking end users.
Independent developerswill benefit from Advantech’s RC200 0 Robot Controller, according to Vincent Li, business development director for machine automation at Advantech (China). The
RC2000 integrates the traditional robot controller into one PCI control card, which could be inserted into any industrial PC (IPC) that has a PCI interface and could run all development procedures in Microsoft Windows. Li said Advantech has a competitive advantage in the field of robot controllers: “The integration of the Internet of Things and Industrie 4.0 is the core advantage of Advantech.” Courtesy: Control Engineering China, Advantech (China) 14
|
MARCH 2016
CONTROL ENGINEERING
Help with integration Knowledge about integration of the Internet of
ce
Aileen Jin is editor-in-chief,Control Engineering
China. Edited by Chris Vavra, production editor, Control Engineering,
[email protected]. www.controleng.com
Learn about the latest engineering trends and technologies. Check out our Control Engineering webcasts on topics like: • Ethernet (with 2015 research) • lloT • HMI • Cyber security for industrial automation • System Integration case studies • lloT, Industry 4.0 • and more Professional Development Hours are available!
www.controleng.com/webcasts
INSIGHT IT & engineering
Why manufacturing software should be tested before updates The way Microsoft is updating its Microsoft Windows 10 operating system, the ball is out of the user’s court. Instead, Microsoft has installed an automated ball machine that fires when it wants, even if the user isn’t ready. This new update scheme may wreak havoc for many mission-critical systems.
It is vitally important to test any updates or changes before committing them to production use, and there can be consequences for not completely testing. There have been so many reports of an untested update crashing a critical system that it is common sense to test before committing an update. The typical manufacturing application relies on tens to hundreds of underlying libraries, processes, services, and operating system elements.
I
Expensive lessons learned
The typical manufacturing facility uses about 50 to 100 applications, ranging from simple spreadsheets to a multimillion-dollar distributed control system (DCS) and manufacturing execution system (MES). Each application relies on tens to hundreds
input #9 at www.controleng.com/information
of underlying elements. Clearly, there is a lot to test in an update. The problem came from failing to test the small applications, especially those that are not mission critical per se, but are ones that are important and were always assumed to work. The problem occurred on the Microsoft Windows 10 Version 1511 update. With Microsoft Windows 7 and 8.1 it was easy to setup a system so it wouldn’t automatically update. Microsoft Windows 10 changed the pattern and not for the better. Microsoft considers Windows 10 a service, so they will decide when to update, not the user. The concept of “patch Tuesday,” when all patches were released on the second Tuesday of the month, is also gone. Patches can be pushed out at any time. The Microsoft Windows 10 Version 1511 update was massive at 3 GB and seemed to touch almost every part of the system. Some Microsoft Windows 10 editions will allow updates to be deferred for several months, but security updates will still install. No one in the user community discovered that “stop updating” solutions provide a long-term answer, which is bad news 16
|
MARCH 2016
CONTROL ENGINEERING
1-888-576-9668
Buy.Advantech.com
We Manufacture it > You Click it > We Ship it
1-888-576-9668 1-888-576-9668
Buy.Advantech.com Buy.Advantech.com
We WeManufacture Manufactureitit>>You YouClick Clickitit>>We WeShip Shipitit
for mission-critical manufacturing systems. associations, removed shortcuts, removed However, even security updates, which applications from the start menu, changed can’t be easily stopped, can cause problems. the printer options, even crashed MicroOn Dec. 30, 2015, Microsoft pushed soft Windows Explorer on one machine, out a security patch that disabled Skype, and caused a set of problems that collecHP scanner software, and various other tively took days to resolve. Fortunately, systems, and in June 2015 a security patch the systems it affected were not missiondisabled some graphic card drivers and critical, just annoyingly hard to fix. multi-monitor support. Microsoft Windows 10 is used for Expensive lessons learned office applications, document manageThe lesson learned is if you are using ment, projecttest management, program development, machines, and other applications. The systems are set up to delay installing the updates. We carefully tested the 1511 update on a few systems with quick “confidence” tests. These were faster and less comprehensive than the full set of tests used when Microsoft Windows 10 was first installed. After the test systems passed the confidence tests, we allowed the other machines to be updated. Then we discovered that the confidence tests didn’t cover the “small” applications and all of the supporting services. The update changed file
Microsoft Windows 10 a manufacturing environment for inmission-critical, or even mission-important, systems, then you have to disable automatic updates. This requires using group policies and Windows Server Update Services (WSUS). WSUS allows full control over the internal distribution of updates using existing management solutions such as System Center Configuration Manager. The most important point, however, is to ensure that the operations group controls the updates for the mission-critical, and mission-important systems. These systems should never be updated using the same rules as the business systems.
Dennis Brandlis
president of BR&L Consulting in Cary, N.C. His firm focuses on manufacturing IT. Contact him at
[email protected]. Edited by Mark T. Hoske, content manager, Control Engineering,
[email protected]. MORE
ADVICE KEY CONCEPTS Microsoft Windows 10 updates can be deferred, but not security patches. Watch for unintended consequences to mission-critical systems. Disableautomatic updates to allow testing. GO ONLINE The posted version contains “Patch management advice” and other information. At www.controleng.com, search Brandl for more on related topics. See other articles for 2016 at www.controleng.com/archives. CONSIDER THIS Operating system updates are becoming more cumbersome and, in some cases, are being forced upon the user. How will you ensure mission-critical systems are not compromised?
Industrial Internet of Things, Industry 4.0, Information Integration Turning research into insights makes for better business decisions The 2015 Industrial Internet of Things, Industry 4.0, Information Integration study was conducted by Control Engineering to better understand how companies have undertaken projects to integrate multiple levels within their organization. The top three technologies/trends that respondents believe will change how they work over the next few years are 3-D printing/additive manufacturing (43%), the Industrial Internet of Things (41%), and Big Data (39%). Access the full Control Engineering 2015 Industrial Internet of Things, Industry 4.0, Information Integration report with additional fndings and insights. www.controleng.com/2015InfoStudy
TECHNOLOGYUPDATE serial-to-Ethernet for IoT
Understanding fiber-optic network technology for SCADA Supervisory control and data acquisition (SCADA) networks have undergone significant changes, and the technological developments have made fiber-optic technology a viable solution for users looking to build a network or transition from serial to Ethernet.
S
Supervisory control and
data acquisi- works could support thousands of sensors to monition (SCADA) networks have undergone significant tor processes and equipment and report to a central changes since the start of the decade as companies console over the network. IoT driving more bandmodernize systems, improve security, and reduce width and consolidation of OT and IT systems to networking costs. As networks need more band- better process valuable production data and enable width to support security, Internet of Things (IoT) faster decision making with the information. sensor data, and other application data traffic, many organizations are considering moving to fiber-opticMoving to fiber optics networks for next-generation SCADA networks. Even though fiber-optic networks provide bandOne of the biggest changes in SCADA network- width, transmission distance, security, and elecing has been the evolution from serial networking tromagnetic interference (EMI) advantages, it is protocols to the Internet protocol (IP), the widely important to choose the right network technology. used network technology for enterprise networks. Network technology decisions can provide Adopting IP for SCADA networks means equip- added reliability, manageability, and redundancy. ment costs can decrease, and bandwidth can scale Each network implementation will have costsrelatup to 10 Gbps for end stations and up to 100 Gbps ed to total capital costs to build the network and for backbone networks. The move to IP can provideongoing operating expenses.Networks can be built a way to better integrate SCADA-based operation- in a variety of topologies. Two main topologies for a
MORE
ADVICE KEY CONCEPTS: Fiber-opticnetworks are a good choice for SCADA networks and remote communications with the demand for more bandwidth and speed. One of the biggest changes in SCADA networking has been the evolution from serial networking protocols to Internet protocol (IP). There are three main network technologies to consider in building a fiber-optic SCADA network: Coarse wave division multiplexing, Multiprotocol label switching, and Ethernet backbone networking.
GO ONLINE See related stories about the IoT and SCADA networks with this article online at www.controleng.com. CONSIDER THIS What other networks could be used in building a fiber-optic SCADA network? 18
|
MARCH 2016
al technology (OT) systems withinformation tech- fiber-optic SCADA network are: nology (IT) systems to set the stage for Internet of Ring: A ring topology is a network in which Things (IoT), facilitate better and lower-cost track- each network node (remote facility) is connected to ing of network conditions, and provide access to its adjacent nodes in a logical ring fashion so data better data analysistools for operations. travels around the ring until reaching its destinaNot every organization has moved to IP. Some tion. Ring networks are the easiest to build and to still are cautious about the ability of a packet-orient-scale (a new node must connect to its peers in any ed technology like Ethernet to replace deterministic part of the ring) as long as the distance that packets serial networks based on time-division multiplex- travel around the circumference of the ring is withor (TDM) technology with guaranteed data deliv- in the latency requirements of the network protocol. ery. Most SCADA applications have real-time data Cable redundancy must be built into a ring network needs that require 99.999% network reliability and to protect against node failures or cable breaks. low end-to-end delay. With the recent introduction Mesh: In a fully connected mesh network, each of ITU G.8032 (an International Telecom Union node is directly connected to everyother node, and standard) Ethernet has a 50 ms failover that deliversdata can be routed to any network node with very levels of reliability to match serial protocols. Many low delay. Mesh networks are complex and costly to industrial network managers are just becoming scale though, because each new node added to the network requires a quadratic increase in conneccomfortable with this technology. SCADA backbone networks are needed to sup- tions for every node in the network. port data flows from substation equipment. Substa- Consider three main network technologies in a tions increasingly require better physical security, fiber-optic SCADA network design. often with increased video surveillance–leveraging the SCADA backbone network to backhaul the 1. Coarse wave division multiplexing With coarse wave division multiplexing video data to a central location for monitoring. In the near future, these networks will require (CWDM), up to 16 wavelengths of light are transgreater capacity to support sensors that monitor mitted in a pair of fiber cables; each wavelength is a wide range of industrial processes as part of the an independent data channel for a separate data flow emerging IoT applications. Some predict that net- up to 10 Gbps. CWDM networks use ring topology.
CONTROL ENGINEERING
www.controleng.com
Example of substation data connectivity. Courtesy: Transition Networks
Connected from concept to completion. Smart HMIs plus expansive I/O designed to work for your application. End-to-end solutions you can trust.
PROUDLY MADE IN THE USA
input #10 at www.controleng.com/information
TECHNOLOGYUPDATE serial-to-Ethernet for IoT
INCREDIBLY DETAILED! The USB 3 uEye CP with 18 Megapixel ON Semiconductor AR1820HS color sensor
ON SEMICONDUCTOR
AR1820HS
USB 3.0
WITH 90 FPS
½"
4K
PLUG & PLAY
OPTICAL CLASS
WITH 38 FPS
TRIGGER & FLASH
29x29x29 mm
1 SOFTWARE FOR ALL
Learn more about the high resolution USB 3 uEye CP: www.ids-imaging.com/usb3
CWDM is a passive technology that can support transport of any protocol over the link, as long as it is at a specific wavelength (serial bit streams over fiber at 1,570 nm, alongside 10 Gbps Ethernet at 1,590 nm). This allows network managers to build a backbone that can be upgraded as the network evolves. If a new network type is supported, 10 Gb Ethernet for example, then any open channel can be configured for this data. This is because the multi-
networking equipment is considered carrier grade for telecommunications networks: high reliability, and more expensive to build and operate.
3. Ethernet backbone A third option is to create a routed Ethernet backbone network. Advantages of Ethernet include flexibility, versatility, and a very wide bandwidth range with standards from 10 Mbps to 100 Gbps. Ethernet
plexor simply refracts at anyused. network can or fiber-optic media, in a speed, regardless of thelight protocol meshuse or copper ring topology, and many Ethernet CWDM networks, like any circuit-ori- products have been hardened to provide ented technology, ties up backbone chan- the ruggedness and wide operating temnels, meaning that if they are not being perature range (-40 to 75 C/-40 to 167 F) used, bandwidth is unavailable for other for remote locations or outdoor use. networks to use. Packet-switched networks Most data protocols can be packetized to not guarantee channels, but the full for an Ethernet network; with support for bandwidth of the link isavailable. 50 ms Ethernet failover capabilities and quality of service functionality, Ethernet 2. Multiprotocol label switching brings high-quality wide area network feaMultiprotocol label switching (MPLS) tures to local area network technology. encapsulates data into packets with a Ethernet packets can be routed, based “label” to switch the packet to its destina- on IP addresses (layer 3 address), key to a tion. MPLS is an open standard via the well-controlled SCADA network. IP protoInternet Engineering Task Force (IETF).It cols broadcast data packets to all stations in has been rapidly adopted by almost every a broadcast domain. Each network device major telecommunications service provid- must examine that data packet and discard er as a platform for supporting thousands or accept it as appropriate. In larger broadof customers over a common infrastruc- cast domains each device has to process ture. It is heavily used in service provider more packets. Creating a reasonable layer and enterprise networks and is a compel- 3 broadcast domain can help limit network ling choice for SCADA networks. flooding and boost capacity. In MPLS, when the packet enters anetThe Power over Ethernet (PoE) stanwork, it is assigned a route called a for- dard allows power delivery over the same warding equivalence class (FEC). Each Cat 5 or Cat 6 copper cable that transmits router knows that packet’s FEC thanks to Ethernet data. Devices such as IP cameras, its label—a bit sequence that identifies the gas analyzers, and embedded computers FEC. The FEC indicate the path through can operate without addional power. the network and tells the router how to IEEE 802.3af PoE delivers up to 15.4 handle the data flow. The FEC appended to W (good for a VoIP phone or WiFi access video data packets, for example, will map point); IEEE 802.3at Power over Ethernet that data flow to a low-latency path. Plus (PoE +) standard delivers up to 25.5 Because of its design, MPLS can trans- W and is backward compatible. port many payload types. In a SCADA Any SCADA network that deploys Ethapplication, this could include serial bit ernet as an access network can benefit from streams, IP packets, video data streams, PoE or PoE+ even if another type of backand others. This flexibility makes MPLS a bone network technology is selected.With viable option for a modern network design the steady demand for increased bandthat also supports legacy data formats. width and speeds, fiber-optic networks MPLS is a mature and reliable tech- are a clear choice for SCADA network and nology, proven in large-scale networks. It remote communications needs. offers a flexible network architecture that supports the connection of remote substa- Tony LeFebvre is director, product managetions either in redundant network rings or ment, Transition Networks. Edited by Chris in a linear structure where data flows in a Vavra, production editor,Control Engiline between each substation. Most MPLS neering,
[email protected]. ce
®
www.ids-imaging.com input #11 at www.controleng.com/information
20
|
MARCH 2016 CONTROL ENGINEERING
www.controleng.com
Need a System Integrator? Outbound Technologies, Inc.
EXCEEDING E XPECTATIONS
ese are just two of many service providers in the Global System Integrator Database. Find a System Integrator for your project today!
To search the Global System Integrator Database, or to create your own System Integrator Corporate Profile visit www.controleng.com/global-si-database
Outbound Technologies is a full-service Systems Integrator specializing in electrical controls, software and networking. Our diverse customer base includes Automotive, Food & BeverChris Tury Jr., age, Consumer Products, General Manager Medical Device and many New Hudson, MI other industries. We deliver Telephone: (248) 735-500 0 fixed price (design, build Fax: (248) 735-5001 and commission) projects, Email:
[email protected] turn-key special equipment, Website: www.outboundtech.com equipment validation and hourly engineering services Primary Industries to leading manufacturers Automotive throughout the world. Over Food & Beverage 150,000 engineering hours Consumer Products per year allows Outbound to meet the high demands of the manufacturing environment. Since 1994 our goal has always been to develop long-term business relationships based on trust and respect by delivering designs and services that exceed customer specifications and expectations.
Integro Technologies
WE SEE WHAT OTHERS CAN’T! Integro Technologies is a turnkey, machine vision company with offices and dedicated resources in NC, SC, VA, MD, TN, AL, and IN. At Integro, we design and develop custom solutions utilizing a range of machine vision systems, robotics, system integration, and 3D vision system applications. Shawn Campion, President Email: sales@integro- tech.com Telephone: (704) 636-966 6 Website: www.integro-tech .com
Primary Industries Primary Industries Pharmaceuticals Plastics Household, Personal Care Products Packaging Rubber, Tires
Since its founding in 2001, Integro Technologies has cultivated strategic partnerships with recognized machine vision suppliers, and we continuously provide superior solutions for the most challenging applications. We are an Advanced Imaging Association (AIA) Certified Integrator, 1 of only 8 internationally. We are a Cognex PSI that is fully-trained and authorized on Cognex’s entire product line, and we have been recognized as the TOP Cognex PSI in North America. We are certified vision integrators for Keyence, Omron, Universal Robotics (3D systems) and Microscan as well. Our other partnerships include,and Moritex, KukaRobotics. Robotics, Universal Robotics, Yamaha
Other office locations Franklin, TN Salisbury, NC (headquarters) Spartanburg, SC Pendleton, IN Charlottesville, VA Birmingham, AL Hagerstown, MD Full Profile at
Our staff is well-trained, leveragingcombined a 450+ years of hands-on industrial vision experience. Our clients, including numerous Fortune 500 companies, rely on our expertise to solve their most demanding vision applications on-time and within budget. We also offer several training opportunities at our headquarters throughout the year including Cognex In-Sight Spreadsheets training and Maintenance and Troubleshooting training.
www.cfemedia.com/global-si-database/IntegroTechnologies
INDUSTRY NEWS
and events
When engineering a culture of service excellence, demonstrate the message Engineering firms need to instill service excellence in existing and prospective team members by living important values, according to Dennis Snow, consultant and 20-year employee of Walt Disney Co. at the A3 Business Forum. Snow
thing like: “I don’t know what you’re talking about. That’s just what we do.” What do you want customers to say about their experience with your com-
said that demonstrating company’s vision, engaging the minds the of team members through involvement, and making everyone accountable for expectations are ways to create and expand a culture of service excellence at engineering-related companies. Snow admitted to making up words to emphasize the point, explaining the need to “inculturate” service excellence into their organizations by demonstrating important values. It doesn’t matter how much anyone tells a candidate how much people matter in the organization, Snow said, if that candidate doesn’t feel welcomed, interested, and positively challenged during the interview process. A3, the Association for Advancing Automation, is the umbrella organization
pany? For key Disney, said, three pointsSnow are, “It was magical, the attention to every detail, and they made us feel special.” Disney knows if they do that, people will return and tell others about the positive experience. The average guest at Disney will carry a piece of Company cultureis in the center of vision, involvetrash 27 ft before dropping ment, and accountability, demonstrated daily. Don’t it. The average distance miss a teaching moment. Courtesy: Mark T. Hoske, between trashcans is 26 ft, Control Engineering, CFE Media and everyone, top to bottom, picks up trash (Snow showed a photo mortgage on his house to finish his first of Walt Disney doing so). film, Snow White and the Seven Dwarfs. To keep and retain the best talent, 2. Understands the true product ensure that the talent isn’t ignored when offered. Disney creates happiness. Prod-
for the AIA, Advancing Vision, Imaging, Motion Control and Motor Association (MCMA), and the Robotic Industries Association (RIA). A3 holds an annual meeting Feb. 3-5, this year, in Orlando, Fla. Here are other “Lessons from the Mouse” from Snow, of Snow and Associates Inc.
Dennis Snow,consultant at Snow and Associates Inc. and 20-year employee of Walt Disney Co., spoke at the A3 Business Forum, offering “Lessons from the Mouse” about improving company culture by living the message. Courtesy: Mark T. Hoske, Control Engineering, CFE Media
uct is not the hamburger; it’s the happiness the hamburger creates. 3. Understands what’s expected. When employees see others doing what is needed, that’s worth much more than manuals or training. The vision should always be there, alive. He also suggested having a quarterly meeting to air out the barriers to excellence and then doing something about overcoming them.
Hold people accountable Accountability is often the reason Live the message hiring. Most people interviewing focus on things don’t happen. I didn’t say this and Whether it’s the 3 p.m. parade in a Dis- skills and knowledge and don’t observe tal- couldn’t find out who did, but it’s true: ney theme park or your next big engi- ent (the hardest thing to teach) during the Intolerable service exists because intolerneering project, the magic that goes into interview. If a position requires someone to able service is tolerated. Never let a coachany experience is because of the employ- be friendly, for instance, don’t hire some- ing moment go, but coach in private. ees involved. How can 60,000 people get one who’s grumpy during the interview. Ensure people know why they’re appreciit right most of the time? To “inculturate” Study your best people. Who would ated and recognized. service excellence means living the impor- you like to clone? Learn what makes them Snow quoted Tom Peters while showtant values of the company, every minute of tick and look for those attributes to be ing a photo of Walt Disney picking up every day, from the top down in the orga- demonstrated during interviews. Training trash: “The problem isn’t that your peonization in everything team members do, and positive communication need to hap- ple don’t know what you’re doing. It’s that as second nature. pen throughout a career. Ensure the team they do know what you’re doing.” You know behaviors are ingrained and member is: working when you ask an employee: “How 1. Proud of the organization. I didn’t Mark T. Hoske, content manager,Control does that happen?” and the reply is some- know Walt Disney had to take a second Engineering,
[email protected]. 22
|
MARCH 2016
CONTROL ENGINEERING
www.controleng.com
Reading the digital edition? Click on headlines for more details. See news daily at www.controleng.com/news
Your Global Automation Partner
‘Industry in transition’ transformed by open systems
A
manufacturing plant that is open and connected is at the core of what ARC Advisory Group president and CEO Andy Chatha sees as an industry that is in transition overall. Chatha addressed about 700 attendees at the 20th annual ARC Industry Forum in Orlando on Feb. 9. If an open, connected plant seems to run contrary to the way plants operate today, that was one of Chatha’s main points: Industrial plant operations are adapting to new rules and new technology. “We see the world changing,” Chatha said. “Theaerospace industry is being transformed, the automotive industry is being turned upside down. And we know what fracking companies have done to the oil and gas industry. Industry after industry is being transformed by companies from outside theindustry.” To accomplish this, Chatha saidmanufacturers have to adopt new, open architecture control and operation systems to augment or replace the proprietary systems of today. “We believe process plants are ripefor next generation digitaltransformation,” Chatha said. “Most plants are aging, and most of the plant assets are 30 years old. If you want to see the most highly automated plants, go to China. Old plants are prone to failure and are very difficult to operate. Because plants are so expensive and so complex to upgrade, many companies don’t upgrade; they just keep existing plants up as long as they can. We believe today’s proprietary systems don’t provide a good foundation for future plants.” The new model points to the use of connected assets: a connected supply chain, connected workers, connected machines, and connected finished products. “You need some sort of an open system to do that,” he said. The open architecture and smart machines provide a framework to allow a full, interactive manufacturing process. “It has to be an end-toend process, from the time you design the product to the time you decommission the line.” Information technology (IT) and operational technology (OT) are converging. “We believe you need to have your experts working together,” Chatha said. “I know many companies are integrating IT and OT and others are trying to get there. That’s a very important thing our industry has to do.”ONLINE see: five traits of innovation-driven companies.
WARNING Not suitable for repairing flimsy connectors (or your reputation).
Rugged, reliable industrial automation products from Turck are
built to perform in the
Bob Vavra
toughest conditions, and our engineered solutions
is content manager,Plant Engineering, CFE Media,
[email protected].
are customized to meet
Robot sales in North America set record for 2015
your application challenges. Cheap knock-offs can’t
Robot orders and shipments in North were coating and dispensing (49%), mateAmerica set records in 2015, according to rial handling (24%), and spot welding Robotic Industries Association (RIA), the (22%), according to Alex Shikany, RIA industry’s trade group. A total of 31,464 director of market analysis. Recent record robots valued at $1.8 billion were ordered performance by the robotics market in from North American companies in 2015, North America is concurrent with falling an increase of 14% in units and 11% in dol- unemployment. Last month, the Bureau lars over 2014. Robot shipments set new of Labor Statistics announced that the U.S. records, with 28,049 robots valued at $1.6 unemployment rate reached 4.9%, its lowbillion shipped to North American custom- est level since February 2008. ers in 2015. Shipments grew 10% in units “Today there are more opportunities and 9% in dollars over the 2014 records. than ever before in the robotics industry,” The automotive industry was the pri- said Jeff Burnstein, RIA president. “The mary driver of growth in 2015, with robot continuing growth in robotics is opening orders increasing 19% year over year. Non- many new job opportunities for people automotive robotorders grew five percent who can program, install, run, and mainover 2014. The leading nonautomotive tain robots....automation is helping to save industry in 2015 in terms of order growth and create jobs. A lot of companies tell us was semiconductors and electronics at 35%. they wouldn’t be in business without robotThe fastest growing applications for ics and related automation.” robot orders in North America in 2015 Edited from an RIA press release. www.controleng.com
CONTROL ENGINEERING
MARCH 2016
|
23
compare. Turck works!
Overmolded Deutsch Connectors Designed for longevity in demanding environments where shock, vibration, cold, moisture and oils can affect performance.
Call 1-800-544-7769 or visit info.turck.us/connectivity
input #12 at www.controleng.com/information
INDUSTRY NEWS and events
Nominees being accepted for Plant of the Year award The FieldComm Group is seeking qual- not on the size or location of the installaified nominees for the 14thannual Plant of tion. We are seeking a plant that has taken the Year Award. End users and manufac- the capabilities of Foundation Fieldbus, turers from all world areas are encouraged HART-, or WirelessHART-enabled instruto enter their plant or customer’s plant. The ments beyond configuration and calibraFieldComm Group Plant of the Year is pre- tion,” said Ted Masters, FieldComm Group sented to end user companies in the pro- President and CEO. “Or, the plant that is cess automation recognize the exceptional and industry valuabletoapplication of Foundation Fieldbus and/or HART Communication technologies. Nominations will be accepted until May ...recognizing 16, 2016. capabilities of “Selection of the Plant Foundation Fieldbus, of the Year HART-, or WirelessHART- is based on a plant’s use of enabled instruments our field combeyond configuration munication and integration technologies— and calibration.
‘
’
using real-time device diagnostics and process information integrated with control, information, asset management, safety systems, or any other system to lower operating costs, reduces unplanned downtime and improves operations.” This award has been expanded to include all communication and integration technologies supported by the FieldComm Group. Previous recipients include Nucor Steel, Dow Chemical, Monsanto, Shell, Mitsubishi Chemical, Statoil, Sasol, and DuPont. Edited from a FieldComm Group press release by CFE Media.
Motor repair standards for increased efficiency and reliability updated
A
n updated edition of the repair of motors and generators—ANSI/EASA AR100-2015: Recommended Practice for the Repair of Rotating Electrical Apparatus—was recently published for use by the repair industry and its customers. The standard describes industry best practices for the repair, rewinding, and testing of electrical apparatus in order to maintain or enhance the energy efficiency and reliability of both ac and dc motors and generators. The revision introduced new requirements, added or tightened performance tolerances in several critical areas, and expanded testing procedures. The standard now includes requirements relating to the machining of commutators and slip rings and establishes temperature limits for the process of removing motor windings. Additional performance tolerances were added for balancing motors rated above 2,500 rpm. Finally, testing procedures were established or clarified relating to bearing insulation, winding surge comparison and resistance, no-load performance, and vibration. Edited from an EASA press release by CFE Media.
TMPS series for energy efficiency in low power mode. AC/DC power modules 3 to 5 Watt for PCB mount.
Administration asks for more for cyber security
Reliable. Available. Now.
tracopower.com
input #13 at www.controleng.com/information
The White House allocated more than $19 billion in the proposed 2017 budget for cyber security, more than 35% above the 2016 enacted level. Resources are designed to enable agencies to augment cyber security, improve private-sector protection, disrupt and deter adversary activity, and incident response. The Obama Administration is implementing a Cybersecurity National Action Plan (CNAP) to help with long-term strategies to enhance cyber and digital security awareness, protections, and public safety. Department of Homeland Security is collaborating with industry to develop a cybersecurity assurance program to test and certify networked devices for Internet of Things (IoT). Edited from a White House press release fby CFE Media. 24
|
MARCH 2016
CONTROL ENGINEERING
Reading the digital edition? Click on headlines for more details. See news daily at www.controleng.com/news
Your Global Automation Partner
More headlines online Industry events At www.controleng.com , on the right side, click on the events box and scroll by month to see related industry events including:
MODEX 2016, Atlanta, April 4-6 www.modexshow.com
PMI steadies itself in January reading The Institute for Supply Management’s (ISM) Purchasing Managers’ Index (PMI) rose for the first time in six months to 48.2% in January to start 2016 on a somewhat positive note.
4th USA Science & Engineering Festival, Washington, DC, April 15-17 www.usasciencefestival.org
Process mapping with a purpose Process maps are lean tools to be used for a purpose. Use the lean tool to help you solve
CSIA Executive Conference, Puerto Rico, April 19-22 www.csiaexecutiveconference.org
Hannover Messe 2016, Hannover, Germany, April 25-29 www.hannovermesse.de
The AIA Vision Show, Boston, May 3-5 www.visiononline.org/mvo-content-adv. cfm?id=247
problems. Remote support update advice and best practices When a controls programmer has make a live update to an already running process, it is best to follow strict procedures and best practices to mitigate risks and ensure success when making these changes.
Falling oil prices’ impact on pump and compressor suppliers While they face many tough challenges, Offshore Technology Conference and Exhibition, innovation and intelligent manufacturing Houston, Tex., May 2-5 http://2016.otcnet.org initiatives are still driving forces in these markets; IHS believes they will greatly reduce Rockwell Automation TechED, the full impact of the ongoing oil price crisis. Orlando, Fla., June 12-17 www.rockwellautomation.com/global/events
Top 5Control Engineering articles Feb. 8-14: The most visited articles included the 2016 Engineers’ Choice Awards winners, Microsoft Windows XP Embedded, Learning from past cyber security mistakes, Wireless for closed-loop applications, Process models and feedback control.
WARNING Not suitable for repairing crummy sensors (or your reputation).
Rugged, reliable industrial automation
Added protection through virtualization Network virtualization is the process of combining hardware and software network resources and network functionality into a single, software-based administrative entity,
built to perform in the
and it is essential that preventive measures be taken to protect the network from potential breaches.
toughest conditions, and our engineered solutions
products from Turck are
are customized to meet your application challenges.
Cloud-based IoT company to be acquired
Cheap knock-offs can’t
C
compare. Turck works!
isco announced its intentto acquire Jasper Technologies Inc., a privately held company based in Santa Clara, Calif., that delivers a cloud-based Internet of Things (IoT) service platform designed to help enterprises and service providers launch, manage, and monetize IoT services. Under the terms of the agreement, Cisco will pay $1.4 billion in cash and assumed equity awards, plus retention-based incentives. The proposed acquisition intends to allow Cisco to offer an IoT solution that is interoperable across devices and works with IoT service providers, application developers, and an ecosystem of partners. Cisco will build on the Jasper IoT service platform and add services such as enterprise Wi-Fi, security for connected devices, and advanced analytics for better device usage management. Jasper develops and provides a software as a service (SaaS) platform with an IoT business that manages and drives a wide range of connected devices and services for more than 3,500 enterprises worldwide, working with 27 service provider groups. The acquisition is expected to close in the third quarter of fiscal year 2016, subject to customary closing conditions. Edited from a Cisco press release by CFE Media.
QR24 Rotary Inductive Sensors An expanded line of noncontact inductive rotary position sensors with optional stainless steel housing. Wide variety of outputs includes HTL Incremental, SSI, CANopen and analog in voltage and current.
CORRECTION “IEC 61131-3: What’s the acceptance rate of this control programming standard?” (posted online at www.controleng. com on Feb. 16) is a revised online version of the Control Engineering, January 2016, print and digital edition cover story: “More intelligent and efficient PLC programming.” The online version clarifies previously approved edits. See the corrected article under January 2016 at www.controleng.com/archives.
www.controleng.com
CONTROL ENGINEERING
MARCH 2016
|
25
Call 1-800-544-7769 or visit info.turck.us/sensors
input #14 at www.controleng.com/information
COVER STORY collabo rative robots
Tips for improving safety, ROI for collaborative robots Collaborative robots are becoming more commonon the plant floor. Deciding if they should be used requires considering safety and business goalsand return on investment (ROI). See new safety guidance in a technical specification, ISO/TS 15066:2016 Robots and robotic devices – collaborative robots. MORE
C
GO ONLINE See morelinked with this article at www.controleng.com. Watch the“Changing ROI for Industrial Robotics” webcast on-demand at
ollaborative robots have gone through major developments over the last few years as the myth of robots and humans working together in a defined workspace have now become a reality. As the technology continues to evolve, this will become standard on many plant floors for a variety of applications in manufacturing and automation. Jeff Fryman and Rick VandenBoom examined the attributes of collaborative robots and what they mean for a company’s process and automation development in the Dec. 17, 2015, Webcast “Changing ROI for Industrial Robotics.” Robotic safety for collaborative robots and return on
www.controleng.com/webcasts CONSIDER THIS What applications and industries would benefit the most from collaborative robots?
investment (ROI) for robotics were among topics covered. A collaborative robot technical specification released in February offers more details. Fryman, a principal consultant for JDF Consulting Enterprises and a retired director with
ADVICE KEY CONCEPTS A collaborative robot is an operation between a person and a robot sharing a common workspace. With collaborative roboit’s ts, important to determine if it is profitable to change the process for a robot. Understand what kind of automation a company needs.
the Robotic Industries Association (RIA), defines a collaborative robot as “A special kind of operation between a person and a robot sharing a common workspace.” Safety, collaborative robots Furthermore, collaborative operations need to follow specific criteria:
They can only be used for pre-determined tasks.
They’re only possible when all required protective measures are active.
They’re only for robots with features specifically designed for collaborative operation complying with ISO 10218 Part 1.
The primary feature is safety-rated soft axis/ space limiting, which consists of software that provides defined limits to robot motion. The software uses space limiting that is used to define any geometric shapes that define where the robot may do the work. Fryman said that this feature is only available for new robots, and the customer must ask when purchasing the robot for this feature. It is not a standard feature. Other features mentioned include optional safety-rated speed controls that meet ISO standard 13849-1. Fryman explained that the speed of the tool center point (TCP) does not exceed the limit set for reduced speed and that a protective stop is immediately issued when a fault occurs. Collaborative robotscan
be designed with human-like dimensions and movements to improve safe interactions with humans, and some are fitted with lightweight elements wrapped in soft padding to absorb potential impacts for increased safety, like this ABB YuMi robot, which also has integrated machine vision. Courtesy: ABB 26
|
MARCH 2016
CONTROL ENGINEERING
www.controleng.com
Packaging,consumer electronics, and small parts assembly are some of the applications that benefit from collaborative robots. ABB’s YuMi is shown. Courtesy: ABB
Risk assessment, said Fryman, is a key element of robot safety because each robot system is unique. There are special considerations to make, especially for power- and force-limited robots, and the assessment, as such, must be comprehensive. Fryman said there are many important things to consider, such as the plant floor and workspace layout design, limits of the robot system, hazard and task identification, and risk reduction. Fryman stressed that workspace requirements need to be clearly defined so the operator knows where he can directly interact with the robot. “It may be good to paint the floor, but it’s not said in the standard,” he said. The workspace design needs to be flexible so the operator can easily perform all tasks while maintaining a clearance of 500 mm from any trapping or pinch point, which is unique to collaborative robots. When it comes to collaborative operation, one or more of the safety features shall be appropriately selected to ensure a safe work environment for all personnel exposed to potential hazards. Any detected failure of the selected safety features shall result in a protective stop. “These safeguards are directed toward the integrator and toward how the collaborative application is designed,” Fryman said. This is especially true, Fryman said, when trying to discern the direction of the robot’s movement against the human and its possible movement. “It is unsafe if the robot is able to strike the human above the neck,” he said. “Anything below that has a number to it, but anything above the neck must be corrected.” www.controleng.com
Some collaborative robots are designed to help manufacturers solve ergonomic challenges that are physically demanding for humans. Fanuc America’s CR-35iA can lift 35 kg (77.2 lb). Courtesy: Fanuc America
CONTROL ENGINEERING
MARCH 2016
|
27
COVER STORY coll aborative
robot s
The challenge with power and force limitations for collaborative robots is that they aren’t well understood. It is a relative issue compared to speed controls, which can be easily measured and defined. The ISO/TS 15066:2016 (TS stands for technical specification) Robots and robotic devices – collaborative robots, was published in February 2016 and provides additional information and guidance on collaborative robots. Understanding automation, process strategies Rick VandenBoom, automated system group manager for Applied Manufacturing Technologies (AMT), said any particular company needs to deterimine if collaborative robots are useful. He said that it’s important to determine whether or not it is profitable to change the process are designed to work Collaborative robots alongside operators in small spaces without the need for safety fences in applications such as small part sorting and assembly, inspection, machine tending, and part delivery. This Fanuc America CR7iA collaborative robot is based on Fanuc’s popular LR Mate 200iD series of mini material handling robots. Courtesy: Fanuc America
to accommodate a robot and what needs to be considered in return on investment (ROI) calculations. Automation, VandenBoom said, is valuable because it can:
Improve throughput
Reduce direct labor costs
Improve product quality
Improve worker safety
Reduce overall footprint.
While there are many good reasons to use automation, VandenBoom warned against getting caught up in automation just because the competition is doing it or because collaborative robots are the hot new trend at the trade show, and you have money to spend. “You should clearly understand which of these factors are driving your decision process and what their relative importance is,” VandenBoom said. “When you automate for the wrong reasons, you end up with failed automation.” VandenBoom also said companies should identify the business requirements of a proj-
has installed three collaborative UR robots to tend Injection molder Dynamic Group two injection-molding machines and a kitting application. The collaborative robot enabled the Minnesota-based contract manufacturer to quadruple production in those applications resulting in a two-month payback for the robot investment. Courtesy: Universal Robots
28
|
MARCH 2016
CONTROL ENGINEERING
www.controleng.com
ect, understand the process needed, and determine the appropriate level of automation when deciding on whether or not to incorporate collaborative robots. With business requirements, VandenBoom said that it’s important to meet the production milestones and part volumes. And that means being realistic. Every company, he said, wants the shortest schedule, highest quality, and lowest cost. “You can be fast, good, or cheap. Sometimes
crucial. What applies to one company doesn’t necessarily apply to another, and each challenge is unique. VandenBoom argues that if a company wants to improve its automation through robotics it should find an expert with a breadth of experience across many industries and applications and mine their knowledge. “Leverage the experts in these situations,” he said. “Don’t try to re-invent the wheel.” Regardless of what the company ends up deciding, VandenBoom said that the options that
you do two, but never Pickrealistic two and aim can for that as your goal,” all he three. said. “Be within your own team and your suppliers.” Determining the appropriate level of automation changes demands a strong understanding of the current process being employed on the plant floor. Knowing where you can improve and where you’re already efficient goes a long way. Among the things to consider with a process are the number of processes, the number of operators, types of equipment being used, current cycle time, and current footprint. “The better you understand the current process the better you can achieve your goals, mitigate risks, and make intelligent trade-offs and achieve synergistic results,” VandenBoom said. Understanding what kind of automation and how much is needed on the plant floor is also
are being considered should be the of a structured empirical approach that hasresult removed the guesswork out of the potential choices. “It begins with gathering the right data, following a structured analysis, and presenting multiple fact-based solutions,” he said.
‘appropriate level
ce
Chris Vavrais production editor,
Control Engineering, CFE Media,
[email protected].
Determine the
of automation
when deciding on whether or not to incorporate collaborative robots.
’
Cage-free safety,different than collaborative robotics, is accomplished with an area sensor and the robots built-in safety. This allows operators to quickly and easily interact with the robot without entering cages. Courtesy: Mitsubishi Electric
In trying to meet demand on laborintensive, high finish loudspeakers, Paradigm Electronics in Toronto has now implemented a UR10 robot from Universal Robots in polishing applications. The collaborative robot delivered significant increased production output, eliminating bottle necks while improving the work environment. Courtesy: Universal Robots
www.controleng.com
CONTROL ENGINEERING
MARCH 2016
|
29
INDUSTRIE 4.0 Underway in the Czech Republic
The advent of Industrie 4.0 in the Czech Republic The core topic and trend in the Czech industrial market is Industrie 4.0. Many recent investments in computer systems are evolving manufacturing in that direction, and more specific instructions are yet to come. There is risk in moving too slowly, explainsControl Engineering Czech Republic.
I
f you were looking for one core topic and trend in the Czech industrial market [and perhaps the world], it’s Industrie 4.0. Each conference of experts, press release, or technical article suddenly looks much better if it includes the all-encompassing subject of new industrial revolution. Should these changes really be called a revolution? And at what progress is the heart of Europe making? Like a Shakespearean play, many say that Industrie 4.0 is “much ado about nothing.” In the Czech Republic (and in Slovakia) Industrie 4.0 is more like the mythical Mrs. Columbo from the old detective television show:
in September 2015 summarizing the issue. Luckily, it was compiled under expert group supervision, so it covers much more than just a fancy Czech mascot “Lion 4.0.” The question that remains is: When and in what form we will see the announced “Industrie 4.0 implementation action plan?” Changes underway now Industrie 4.0 already is gradually changing the manufacturing industry. There is a huge risk that we will respond too slowly and lose the valuable competitive edge, because decisions about where to manufacture tomorrow are being taken today. This is confirmed by the recent survey conducted among more than 270
o
Logo is shownfor the “Prumysl 4.0,” a national initiative defined first by Jan Mládek, Czech Minister of Industry and Trade, who also introduced the white paper in September 2015 summarizing the issue. Courtesy: Control Engineering Czech Republic
MORE
ADVICE Key concepts Industrie 4.0 implementations are happening now, even if they’re not ideal. Those using Industrie 4.0 concepts are adding value now, helping with the skills gap, even if people aren’t necessarily calling it Industrie 4.0.
GO ONLINE See related IIoT and Industrie 4.0 coverage in this issue and linked to this article at www.controleng.com. CONSIDER THIS Industrial connectivity can offer benefits no matter what you call it. 30
|
MARCH 2016
someone everybody talks about, but never sees in person.
Many names, one flavor There is a general consensus that Industrie 4.0 is primarily an effective marketing name that works very well to promote changes in the name of technical progress. Although industry decision makers often hesitate to implement something called Industrie 4.0, under closer examination of the technical side they discover that many recent investments, mainly to computer systems, have launched this process already. Conversely, no one would likely believe the assertion: “From now on we will manufacture in line with the Industrie 4.0 trends.” How could anyone say that, when nobody knows exactly what such a perfect manufacturing model should be? This is the moment when the higher authority should chime in. Good news is that the first step to define Industrie 4.0 implementation was taken by the Czech Republic too, although a little bit late. The “Průmysl 4.0” national initiative was defined for the first time by Jan Mládek, Czech Minister of Industry and Trade, who als o introduced the white paper
CONTROL ENGINEERING
companies in Czech. Results indicate that online interconnections of value-adding processes are a decisive or very important factor for more than half of companies. Large players are realizing this rapid development more than small- and medium-sized companies do. Commenting on the current situation, three quarters of respondents described the digitization in their companies as fully (10%), well (39%), or sufficiently (28%) implemented. The survey results may lead to a conclusion that Czech companies perceive Industrie 4.0 efforts positively. Based on discussions with market players, the reality isn’t as bright. Vendors are prepared, for the most part. Their solutions are capable of integrating the Industry 4.0 concept into the Czech plant environments; however, they are not that much interested in doing so yet. Unfortunately, there are still a number of cases (typical in the Czech way of thinking) of unwillingness to make any change. Where does the hesitation srcinate? As with many prior developments, misunderstanding is the culprit. Revolution vs. evolution A frequent and philosophical question remains: Is this a revolution? Technologically www.controleng.com
‘technology
speaking, these changes are generally considered resulting from industrial systems evolution in recent years. This school of thought tends to promote the term evolution rather than revolution. However, the pace of such changes (if Moore’s Law is to blame) really intensifies. Mobile technology development and the ability of machines to talk to each other, combined with the advent of the Industrial Internet of Things (IIoT) or Internet of Services (IoS), are changing the face of manufacturing. Moreover, competitive globalization forces profit-hungry companies to take the advantage of all the benefits coming from deployment of automated and robotic workplaces. This vision won’t fully materialize anytime soon. Despite the wishes of many, just having technologies readily available will not be reflected in the massive influx of investments. Remember, the first industrial revolution was not achieved in one day either. Future generations will likely claim the revolution status as they implement 4.0 factories. And this might be the core issue. Why do these changes occur? Whether deemed a cause or effect, the underlying factors are human behavioral changes. Industrie 4.0 relates to advances in technology, but humans still must have a place in the factory of the future.
Mobile
development and the ability of machines to talk to each other, combined with the advent of the Industrial Internet of Things (IIoT) or Internet of Services (IoS), are changing the face of manufacturing.
Lukáš Smelíkis
’
managing director of Control
Engineering Czech Republic. Courtesy: Control Engineering Czech Republic
How much for machines?
It’s a justified claim that machines should take on work that is difficult, repetitive, and can be harmful to health, the workers of the future are expected to handle mentally more demanding tasks. Although advances in construction and control of machines will play a role (mostly in simplification and to accommodate habits of the future generations of workers), the changes must begin now. Actually, the Czech Republic already faces a lack of experienced workers (not to be discussed publicly due to the rate of unemployment). Generation X is to be replaced with Generation Y, and it appears there is a serious lack of them. Without some n-th revolution, mainly in education, and if we fail to get the future generation excited about technical matters, it might be inevitable for machines to substitute humans’ abilities and handle it all by themselves. And then, what purpose will be left for us humans?
Boleslav can spot the technology elements of the smart factory: automated warehouses, robots cooperating with humans, and digitization of the manufacturing process, along with elements of the Internet of Things concept. The same applies for the Bosch Diesel plant in Jihlava, where an Industrie 4.0 project aims to monitor vibrations in machine tools and report deviations that can indicate upcoming faults. However, all of this can be found in other plants, without necessarily being named Industrie 4.0. This doesn’t necessarily mean that the fourth industrial revolution isn’t in progress, although, as a matter of semantics, we should rather call it the industrial evolution. Thus, Industrie 4.0 is not like Mrs. Columbo who everyone talks about but no one ever sees. More likely, we’ve met her already. Maybe we even know her well. We just have not been introduced to her real name.
Digital plant progress
Lukáš Smelíkis managing director of Control Engineering Czech Republic . Edited by Mark T. Hoske, content manager, Control Engineering ,
Czech Republic enterprises owned by German companies are deploying Industrie 4.0 the most. Any visitor of the Škoda plant in Mladá www.controleng.com
ce
CFE Media,
[email protected]. CONTROL ENGINEERING
MARCH 2016
|
31
INDUSTRIE 4.0 94 projects in China
Industrie 4.0 is opportunity, challenge
Aileen Jin
Editor-in-chief, Control Engineering China
China is pushing ahead with Industrie 4.0 with 94 intelligent manufacturing efforts in China Manufacturing 2025; challenges remain.
I
ndustrie 4.0 is the fourth industrial revolution, a long-term process to implement. At earlier stagthe general orientation, transformation, and es, no effects may be obvious after great amounts of upgrade of the manufacturing industry, and an spending and effort. In moving from Industry 2.0 unprecedented opportunity for development in and Industry 3.0 to Industrie 4.0, there will be huge the industrial automation industry. Whether challenges. large-scale application of robots or wise use of facIndustrie 4.0 needs powerful hardware support tory Internet, it will bring huge changes to the glob-to complete the functions such as data collection al manufacturing industry. and acquisition, network connections, computa2015 is the first year for Industrie 4.0 in China. tional analysis, visualization, and more, while the On May 8, 2015, the State Council released the hardware investment cost is rather high. strategic planning of China Manufacturing 2025, To obtain more information about machine which symbolizes the formal implementation of efficiency and health, more sensors will need the Chinese blueprint for Industrie 4.0. After that, to be installed. After a data connection is estabthe Ministry of Industry and Information Tech- lished, massive amounts of data will come out of nology introduced 94 special projects of intelli- the machine in real time, although data transmisgent manufacturing, initiated more than 30 pilot sion speed and transmission quality are affected by intelligent manufacturing demonstration projects, hardware quality. The analysis, cleansing, andstor-
MORE
ADVICE KEY CONCEPTS Industrie 4.0is being demonstrated in 94 projects in China. Investmentsand efforts may produce few recognizable benefits initially. Securityof off-site data analysis is a concern. GO ONLINE www.controleng.com/international www.controleng.com/webcasts www.controleng.com/ce-research
ce
CONSIDER THIS When will yoube implementing the best practices from Industrie 4.0? 32
|
MARCH 2016
and released a package of policies to promote and age of big data also need support from high perforimplement the China Manufacturing 2025 strategy.mance computers and mass storage memory media. For a while, publicity about Industrie 4.0 and At present, many factories have no such hardware intelligent factory demonstration projects was over-or data connections, and a digitalized analysis platwhelming, boiling the manufacturing industry of form will require additional investments. China overnight. After more than a half year, people tend to have calmer thinking about Industrie Safety,security 4.0 after following it blindly at the start and finding Another challenge comes from safety and secufew shortcuts on the road of transformation leadingrity. Industrial data often contains many trade to intelligent manufacturing. Instead, it calls for a secrets. Risk of divulging secrets increases with data transmission and analysis. With industrial big data more down-to-earth craftsman spirit. analysis, a factory may cooperate with a third-party data analysis company, which separates the analysis Transformation, upgrades Developed countries are speeding up the imple- algorithm or software of intelligent data from a facmentation of reindustrialization, and developing tory’s internal data environment. Safely securing a countries are also speeding up the industrialization connection between data in a factory and an analyprocess. China is confronting dual challenges from sis platform outside the factory becomes difficult. the advanced technologies of developed countries Industrie 4.0 needs to be implemented. Future and low-cost competition of developing countries, engineers will no longer focus on just one field. so it is extremely urgent to accelerate industrial Instead, they need to grasp multidisciplinary transformation and upgrade. knowledge. At present, lack of comprehensive tal“Different from developed countries stepping ents in the industrial circles and the gap in human into Industrie 4.0 based on Industry 3.0, China not resources are challenges in the realization of only needs to keep up with Industrie 4.0, but also Industrie 4.0. needs to make up missed lessons in Industry 2.0 and Industry 3.0,” said Li Keqiang, premier of the Aileen Jin is editor-in-chief ofControl Engineering State Council. China; Edited by Mark T. Hoske, content manager, In spite of very bright prospects, Indus trie 4.0, is Control Engineering,
[email protected].
CONTROL ENGINEERING
www.controleng.com
GLOBAL IIOT improving data analytics
IIoT requires data analysis Data analysis can help industry benefit from the Industrial Internet of Things (IIoT), said Suzanne Gill, editor-in-chief for Control Engineering Europe, from the 27th Honeywell User Group EMEA event.
he dramatic change in fortunes of the the IIoT will allow for
Vimal Kapur,president of Honey-
T
well Process Solutions (HPS), at the oil sector in the past fewacross years greater efficiencies hasand hadgas a wide-ranging impact increased uptime. and It annual Honeywell User Group (HUG), many industry sectors, resulting in an offers nothing new, just a in Madrid in November 2015, increasing requirement for engineers to way of doing things difexplained the importance of data show a good return on any technology investment. ferently,” he said. analysis to improve process This has led many to consider doing things differKapur said Honeyently, with automated solutions becoming more rel- well is enabling cussafety, reliability, security, evant and easier to justify. At the annual Honeywell tomers to leverage the and sustainability. Courtesy: User Group (HUG) in Madrid in November 2015, benefits of cloud-based Control Engineering Honeywell emphasized data analysissolutions. applications and this, Europe “Our customers run some of the most complex he says, is helping to industrial operations in the world, and they require lower engineering costs better knowledge to improve process safety, reliabil-and optimize schedulity, security, and sustainability,” said Vimal Kapur,ing during the front-end president of Honeywell Process Solutions (HPS). engineering design (FEED) stage, where time savHe said new engineers replacing those now reach- ings of up to four months have been achieved along ing retirement age do not have the same wealth of with up to 30% reductions in engineering costs. experience relating to the often aging control tech- “We have seen an increase in projects executed in nology in use at many process plants; more intuitivethe cloud environment–almost 2,000 projects since
control solutions are required to help inform deci- April 2015.” sions on process efficiency improvements. Bruce Calder, chief technology officer for Honeywell Process solutions, said the process industry More rapid updates are needed has “been doing [IIoT] for decades....We already “The pace of technology change is much fast- have the capacity to make use of this information er today,” said Kapur. “Systems traditionally wouldto benefit plant performance....the next big change have become obsolete every 5 to 10 years. However,will be how this data is managed.” the underlying operating system technology used One-third of process and manufacturing industoday is changing much more rapidly so there is a try executives from around the world surveyed by need to update systems more regularly.” Honeywell said that they already are using data anaThere is also increasing interest in cyber securitylytics to improve business performance. Two-thirds MORE issues and the IIoT. “At this point the IIoT is throw-said that they are using data analytics capability to ADVICE ing up more questions than answers,” said Kapur. monitor assets to drive a proactive maintenance KEY CONCEPTS “Customers will not be throwing away their exist- program. Two-thirds also said they were invest- Data analysis was widely discussed ing systems to implement IIoT, so we need to help ing heavily in IT infrastructure to collect more data at the Honeywell User Group. them unleash the power that they already have. I from their facilities or remote assets. Cloud-basedapplications can save believe that control systems will become the heart of “There is a huge interest in data,” said Calder. up to four months in engineering design and lower engineering costs the IIoT, which will rely on process data for opera- “Data aggragation solutions can be used to up to 30%. tion, maintenance, and optimization—and that datamonitor applications and identify potential safeData analysis helps monitor applicacomes from the control system.” ty and performance issues. ” tions and identify potential safety and Kapur said the IIoT will give engineers the To securely enable an increasingly connectperformance issues. ability to host applications in a more centralized ed world, accurate instrumentation is needed, GO ONLINE environment. With different source applications from field devices to gas measurement control, ” Read morein this article online and becoming centralized in the cloud, it will no lon- Calder said. at www.controleng.com/international ger be necessary to maintain the same applicaCONSIDER THIS tion multiple times, and upgrades will be much Suzanne Gillis editor-in-chief of Control Engineerwith data Are you keeping up easier to achieve. It will also allow less skilled ing Europe. Edited by Joy Chang, digital project man- analytic opportunities to improve processes? engineers to manage applications. “I believe that ager,Control Engineering,
[email protected]. ce
www.controleng.com
CONTROL ENGINEERING
MARCH 2016
|
33
IIoT implementation savings
Quantified benefits of Industrial Internet of Things Automation experts already have been implementing Industrial Internet of Things (IIoT) architectures for years, prior to calling it IIoT; benefits of digital manufacturing including less downtime, fewer defects, and more new product introductions, as explained by Douglas Bellin, Cisco Systems Inc., at the A3 Business Forum, the day after Cisco spent $1.4 billion for a cloud-based service company, Jasper Technologies Inc.
I Douglas Bellin,
senior manager, industry lead, Cisco Systems Inc., presented at the A3 Business Forum Feb. 4 in Orlando. All images courtesy: Mark T. Hoske, Control Engineering, CFE Media
34
|
MARCH 2016
mplementations of Industrial Internet of Things (IIoT) architectures and the benefits of digital manufacturing deliver real benefits, including 48% less downtime, 49% fewer defects, and 23% increase in new product introductions, according to Douglas Bellin, senior manager, industry lead, Cisco Systems Inc. Bellin made the com ments at the A3 Business Forum Feb. 4 in Orlando, the day after Cisco spent $1.4 billion for a cloud-based service company, Jasper Technologies Inc. A3, the Association for Advancing Automatio n,
not the norm, Bellin said, citing that 86% of 64 million U.S. machines are completely unconnected. Some say 40% of businesses won’t be the same or exist as we move forward if they don’t do IoT.
is the umbrella organization for the AIA, Advancing Vision+Imaging, Motion Control and Motor Association (MCMA), and the Robotic Industries Association (RIA). A3 helds its annual meeting Feb. 3 to 5, this year, in Orlando, Fla.
Consortium (IIC) are advocating IoT
Realities of IoT, less pain Bellin offered other pieces of advice about the IIoT and what it means for engineers. In a poll of the room, just a few admitted to liking the information technology (IT) department, yet operational technology (OT) and IT personnel will need to work together more closely, Bellin said. “We’ve been doing IoT (Internet of Things) for years,” Bellin said, pointing to machine-tomachine (M2M) communications and other information integration efforts. The IIoT resolves pain points that we all have suffered with for years, such as rising energy costs, aging and remotely located workers, globally distributed operations, customer support across time zones, world competition, product proliferation, asset optimization, and others. The Internet of Everything (IoE) brings people, processes, data, and things together to make better business decisions. While almost every machine has a controller with a lot of data available, data driven manufacturing is
CONTROL ENGINEERING
Disruptive trends Disruptions changing manufacturing include:
IT and OT are converging
Industrie 4.0 and Industrial Internet
Original equipment manufacturers (OEMs) have an increased focus on services, such as offering machines as a service, similar to software as a service (SaaS)
An increase in data-driven manufacturing
There are more secure operations and machines.
Implementations of digital manufacturing have delivered benefits including: 48% 49% 23% 16% 35% 18%
less downtime fewer defects increase in newproduct introductions gain in overall equipment effectiveness improved inventory less energy use.
“Cisco Systems offers networking tools, so we, like many others advocate that networking is an important part of the answer,” Bellin said. Challenges are many, he acknowledged, including the skills gap, but supply chain visibility is the largest challenge, according to research. www.controleng.com
Mazak, a machine tool manufacturer, tested a data-collection box retrofitted outside its machines, which connects to algorithms that allow predictive maintenance. Cisco, Fanuc, and Rockwell Automation are working together in the robot space capturing stranded data and pushing it into the cloud (remote servers) in a capable form, he said. This provides predictive maintenance with a twoweek lead-time on failures. Bearings resulting unplanned downtime andfailures related and costs and fines are falling dramatically as a result. The goal is to have 3 to 5 weeks of failure prediction. Sub-Zero and Wolf Appliances, based in Madison, Wis., opened an Arizona factory. After an engineer often flew back and forth, an interface offering online video eliminated most troubleshooting, unnecessary trips for the engineer. The interface allows collaboration among the designer, factory worker, and supplier to resolve issues and get back up and running, reducing downtime. Applied to oil rigs, such technologies could save millions of dollars in a short time by getting things fixed without loss of translation issues. “See what you’re saying to
are connectivity foundation, business, The five waves of connectivity people, things, and convergence. They are designed to be the framework of the IIoT, according to Bellin.
Digital manufacturingdrives business outcomes with benefits such as 48% less downtime, 49% fewer defects, and 23% increase in new product introductions.
better understand,” Bellin said. Where’s the IoT going? The connected journey means rapid commissioning of machines, greater security, The connected journeyfor the IIoT starts with start-up templates, a machine proprietary serial islands and expands to connected integration platform, OEE machines, machine integration, machine as a sermonitoring, data offload via vice, and advanced machine automation. MTC and OPC interfaces, scaled factory data acquisition, and advanced ysis, inline quality inspections, and instant rework. security. This accelerated the journey to value-added Then IIoT will enable machines as a service, a services. If softer U.S. economy results in 2019, MORE security framework, machine-to-cloud communi- as some economists predict, offering services will ADVICE cations, secure bi-directional communications, andkeep machine builders ahead of the curve. KEY CONCEPTS remote access. Finally, IIoT will deliver advanced “Manufacturing is moving from product-cenImplementations of IIoT architecmachine automation, time-sensitive networks tric to services-centric, led by a digital transfortures and digital manufacturing deliver (TSN), high-speed standards, advanced controls, mation where services and the digital journey less downtime, fewer defects, and more new product introductions. and human-machine interface (HMI) integration converge. This delivers deeper insights into prodDisruptive trends in manufacturing with analytics. Digitization creates foundation of newuct and customer needs,” Bellin said. change how companies capture value. applications and outcomes. Fanuc has found tremen- To capture value, digital manufactureGO ONLINE dous savings with problem prediction, he said. ring builds a hyper-aware organization, makes Read more advice with this article informed decisions, executes quickly, and outpaconline, linking to an article about a Real-time analytics es the competition. Adding artificial intelligence recent Cisco transaction with Jasper In another example, a high pressure casting algorithms can improve decisions and prevent Technologies. machine offers real-time analytics, performance failures. IoT breaks down IT/OT silos. CONSIDER THIS projections, real-time data collection, with all senWhat future developmenwill ts sors connected. A 5% revenue increase resulted Mark T. Hoske, content manager,Control Engiinvolve digital manufacturing and the IIoT and how might they benefit? with continuous real-time measurements and anal- neering, CFE Media,
[email protected]. ce
www.controleng.com
CONTROL ENGINEERING
MARCH 2016
|
35
IIOT gateway connections
IoT gateways: Industrial automation’s path to Industrie 4.0 Industrial Internet of Things (IIoT) and Industrie 4.0 connect industrial automation devices and equipment, or “things,” with cloud-based systems to harvest information faster and to drive business value by providing new services to customers. MORE
T
he ever-expanding Industrial Internet of Things (IIoT), sometimes referred to as IoT for applications Key concepts beyond industrial automation, brings Industrial Internet of Things a vast communications infrastructure (IIoT) improves connectedness to the process, factory, and building automafor processes, factories, tion industries; one that is far beyond anything and building automation. these industries have typically used. With cloud IoT gateways connect to cloud-based computing and communications services available from severanalysis. al companies spread across the planet—includInformationshould connect to ing Microsoft, Amazon, and others—it has never existing systems for the best been easier or more cost-effective to connect value. even the smallest and least expensive devices to GO ONLINE a network—and not just to a local network, but
industries. This processing power, which can also be found in the cloud, is scalable from one central processing unit (CPU) with limited memory and disk space to a large array of CPUs or servers. If used effectively, this processing power can be applied to monitor and analyze data, to report events and results, and to solve problems that could never have been solved before.
to one that spans the globe. IoT carries vast amounts of processing power to the process, factory, and building automation
more. Because of the openness and standardization in emerging communications protocols, many of these applications are serviceable with
ADVICE
Link torelated production information with this article online, under March at www.controleng.com/archives.
Scalable software Many organizations embarking on their IoT initiative seek “off-the-shelf,” scalable software applications to enable monitoring, visualization of data, real-time analytics, and much
CONSIDER THIS Does yourhuman-machine interface (HMI) software promote easier mobile connectivity?
Create, save, and load
self-service dashboards via MobileHMI for use with Iconics Genesis64 HMI/SCADA software on any smartphone, tablet, web browser, or webenabled device by using KPIWorx from Iconics. Users can drag and drop data, configure widgets, and split screens to add new widgets with several preconfigured gauges, process points, trends, alarms, and grids in KPIWorX. Courtesy: Iconics 36
|
MARCH 2016
CONTROL ENGINEERING
www.controleng.com
minimal configuration and with little or no middleware. Achieving these benefits requires the availability of low-cost bridging devices called “IoT gateways.” IoT gateways communicate to the exiting sensors and automation controllers called “edge devices” and provide the bridge between an on-premise communications network and cloud-based computing power and visualization. IoT gateways must have
in the form of cost reduction, new revenue streams, or an improved customer experience. ce
Oliver Gruneris
the director of cloud business development at Iconics. Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media,
[email protected].
‘from behind firewalls and Connect edge devices
securely publish data to
cloud-based applications for better analytics.
the ability to interface with industry standard protocols such as OPC Unified Architecture (UA), BACnet, Modbus, Simple Network Management Protocol (SNMP), or web services, but can sometimes use proprietary communications protocols as well.
’
IoT gateway Connectivity is key. Without being able to connect edge devices from behind firewalls and securely publish data to cloud-based applications, organizations will not be able to achieve the promises of advanced analytics through computing power in the cloud. A premium IoT gateway, for instance, should be able to communicate with Microsoft Azure or third-party appli-
cations using the most popular transport protocols. After the IoT gateway is online, it can register with the Microsoft IoT Hub in the Azure cloud through a secure Advanced Message Queuing Protocol (AMQP) so that it can authenticate, send, and receive data. Acting as a secure message broker, the hub can allow for remote device management, provisioning, and configuration. The IoT gateway should be able to work with enterprise resource planning (ERP), manufacturing execution systems (MES), and other enterprise applications running in private or public clouds other than Azure using Representational State Transfer (REST) and Message Queuing Telemetry Transport (MQTT) as established IoT transport protocols. IIoT and Industrie 4.0 represent the advent of connecting industrial automation devices and equipment, or “things,” with cloud-based systems to harvest hidden information faster than ever and to drive business value by providing new services to customers. The benefits to organizations, line of business applications, and customers may be attained
Advance to the IIoT. Connect devices and ignite productivity. Give your existing infrastructure a brighter future. Red Lion has been connecting devices and igniting productivity for years. From plug-andplay Ethernet switches to HMIs and visual management systems with built-in protocol conversion, our industrial automation and networking solutions will enable you to connect, monitor and control virtually anything, anywhere at any time to meet today’s Industrial Internet of Things (IIoT) requirements. Visit www.redlion.net/IIoT and discover how to extend equipment lifespan, improve process visibility and push control to the edge.
input #15 at www.controleng.com/information
+1 (717) 767-6511I
[email protected] www.redlion.net CONTROL ENGINEERING
MARCH 2016
|
37
© 2016 Red Lion Controls, Inc. All Rights Reserved.
IIOT data analytics
Use IIoT to improve operations More data is just more data: data analysis software is the key to extracting insights and creating value from the Industrial Internet of Things (IIoT) opportunities in production facilities. See an implementation example. Online, see another example and the four needs of data analytics.
T
hanks to a new generation of wired and and ears of engineers being transitioned to centralwireless sensors, data can now be eco- ized remote monitoring centers or integrated opernomically generated and gathered in ations facilities. Greenfield scenarios are plants or quantities never previously available facilities just coming online with IIoT projects. This and then sent to process control and is the most common scenario for smart city or pubmonitoring systems via plant networks or through lic sector projects, and it’s where the association of the Internet. Data can then be used to improve IIoT with cloud-based monitoring systems srciautomated real-time control and to help plant engi-nates because the project isn’t designed around an neers and operators make better decisions regard- on-premise control and monitoring system. Greening operation and maintenance. It also is available field deployments may lack a control system infrato data analysis software, which can be used by structure. Examples include monitoring remote plant personnel to increase efficiency, diagnose tank farms, pump stations, and vehicles as a comequipment problems, andimprove safety. plementary system for anexisting facility. As a result of this opportunity for new insights, terms such as the Internet of Things (IoT), the Cash in on services
Figure 1:Getting the most from available information requires collecting data, transmitting it via wired or wireless methods, analyzing it with software, and making it available to engineers via smartphones, tablets, and computers. Courtesy: Seeq Corp.
38
|
MARCH 2016
Industrial Internet of Things (IIoT), big data, and Finally, “servicization” is one of several moniIndustrie 4.0 are now common. Recent advances kers describing the inclusion of a remote moniin sensors, connectivity, and data analysis software toring capability for an asset. Vendors of pumps, combine to make it easier and less expensive to valves, and many other asset types are introducacquire, send, store, and analyze information. The ing subscription services for monitoring equipment objective is to get better insights faster. installed on customer promises. The business benIIoT, to choose one of the terms, can improve efit is asset reliability and uptime, but the real driver plants in brownfield, greenfield, and service-related is the opportunity for the vendor to provide experapplications. All three can be described indepen- tise in asset performance and management. dently, and can co-exist within the same plant. Each model follows a common architecture Brownfield refers to existing plants and oper- of sensor, communications network, and analyations where new sensors are added to existing sis that is very familiar to the process industry control or plant networks. Common brownfield and noted by many prominent industry speakers. scenarios include adding a wireless system and sen- There are new opportunities for improved plant sors to expand operator visibility and asset monitor-performance enabled by these new technologies ing capabilities or adding sensors to replace the eyesand at drastically lower price points. The key question for manufacturers with existing plants then becomes: “How do we bring our facilities forward into a smarter state?” The answer should always be framed in the context of the end benefit: better insights faster. Sensors are the starting point in the data collection process. They monitor operation of the “things” in the IIoT: pumps, valves, and other assets. Their cost of implementation and use is dropping rapidly, making it cheaper to acquire more data. Plant personnel were once limited to 4 to 20 mA, HART, or various fieldbus protocols to connect
CONTROL ENGINEERING
www.controleng.com
Figure 2:Wireless transmitters eliminate the need for cables, conduit, power supplies, and safety devices. This makes it easier and less expensive to acquire data from pumping systems and other process equipment. Courtesy: Emerson Process Management
Figure 3:A scatter chart can be quickly and easily created by process plant personnel for data analysis. S eeq data analysis s oftware can give process experts first hand insights to data, enabling them to customize analysis and improve production outcomes. Courtesy: Seeq Corp.
these sensors to control and monitoring systems one 250,000 bpd refinery, pump monitoring sysand software. But today, they can use many types oftems were installed on 80 pumps throughout the wired and wireless data connection methods, often complex. The annual savings was over $1.2 milemploying multiple networks simultaneously in onelion after implementation, resulting in a payback plant (see Figure 1). period of less than six months. Sensors and connections enable new data from Similar results have been accomplished across a new sources to be accumulated quickly and inex- range of asset types: valves, steam traps, and others. pensively, and there’s a wide range of modern net-Cost/benefit ratios continue to improve because of working options for deployment. Battery-powered ongoing downward cost pressure on components. transmitters require no signal or power wiring infrastructure, so they can be installed in locations IIoT last mile: data analysis far away from a process unit’s wired signal termina- Delivering better insight faster is a good goal, tion points. They also can operate safely for years inbut the last mile of IIoT unlocks value. To deal with hazardous and other areas. the challenges of data from IIoT deployments, speWireless instrumentation enables monitoring of cialized data analysis software is required to handle a wide variety of equipment and systems previouslythe high data volumes and provide the integration too difficult or expensive to reach with wires. platform for data from disparate sources. Data analysis software should enable rapid Brownfield IIoT: using pump data insights for employees who know the process, Retrofitting a pump with sensors, a network, assets, and operations (see Figure 3). The software and pump analysis software makes it possible for must also be easy to use so as not to require the process plants to monitor pumps and detect prob- intermediate and time consuming step of programlems long before a pump fails and shuts down, and ming by developers or translation by data scientists. it is an example of a brownfield IIoT solution. The value of insight degrades quickly if develA few years ago, high cost of installing a dedi- opers and data scientists need to become involved cated online monitoring system limited use to the as they introduce time lags to the data analysis most critical pumps. With the relative ease of add- process. If changes can’t be found and implementing pump condition monitoring using wireless sen-ed in time to impact production outcomes, they sor technology, online monitoring can be done on have little value. all important pumps (see Figure 2). For example, if a pump monitoring system A pump monitoring system gathers data on sends data to software designed to analyze probtemperature, pressure, level, and other variables lems inherent to pumps, maintenance engineers can in real time and transmits via a wireless mesh use the information to understand exactly what the network to a gateway, which sends it to the con- software is telling them. trol room via a hardwired link, usually Ethernetbased. There, pump monitoring software analyzes Michael Risse is a vice president at Seeq Corp. Editdata from dozens or hundreds of pumps and alerts ed by Mark T. Hoske, content manager, Control operators when it finds potential problems. At Engineering, CFE Media,
[email protected]. ce
www.controleng.com
MORE
ADVICE KEY CONCEPTS IIoT in action: Data acquisition is easier than ever, with many wired and wireless networks available. Important assets, such as pumps in a refinery as well as valves, steam traps can be monitored for maintenance prior to failure. Ingredient tracking improves product quality. GO ONLINE Longer online version has more advice, including 4 needs of data analytics. Search on the headline at www.controleng.com.
CONSIDER THIS Information integration works best when information is put to use within an appropriate period of time.
CONTROL ENGINEERING
MARCH 2016
|
39
IIoT automation, information technologies
PC- based control drives global adoption of Industrie 4.0, IIoT concepts PC-based control systems are at the front lines of automation technology and information technology convergence (AT/IT) as businesses find ways to funnel data into a useful, actionable form designed to empower decision makers as they look to stay competitive.
E
MORE
ADVICE
KEY CONCEPTS PC-basedcontrol systems are at the
front lines of automation technology and information technology convergence (AT/IT). PC-basedcontrol systems and IIoT software can establish a seamless connection between the Internet of Things (IoT) devices. PC-basedcontrol is becoming the de facto system for companies seeking to benefit from the rising tide of the Smart Factory. CONSIDER THIS What elsecan PC-based control do
for Industrie 4.0 and the IIoT? GO ONLINE See additional stories about the
IIoT, Industry 4.0, and Big Data at Control Engineering’sNetworking and Security channel. 40
|
MARCH 2016
veryone has been talking about the Industrial Internet of Things (IIoT) and Industrie 4.0 for quite some time, but there are very good reasons it has stayed on our collective radar. The key themes behind the smart factory concept revolve around establishing high connectivity and managing the critical mass of data generated every day in manufacturing facilities around the world to gain valuable insight to optimize businesses and processes. Regardless of methodology, the business
In addition, PC-based control systems are at the front lines of automation technology and information technology convergence (AT/IT). This convergence is occurring almost everywhere in the world of automation and controls, but it has been developing far longer, with the greatest level of integration in PC-based control. Cloud-connected industrial databases, objectoriented manufacturing processes, and control system notifications pushed to mobile devices are just a few of the exciting things on the horizon for forward thinking companies.
needs that motivate companies to embrace big data and cloud-connected communication continue to grow unabated. This will be a subject of discussion for a long time to come. This is because there is a business case at the center of the constructive conversations about these subjects. Manufacturing operations produce vast amounts of data, and finding ways to funnel that data into a useful, actionable form becomes paramount to empower company decision makers with the information they need to stay competitive and innovative. However, storing and conveying this data is just the tip of the digital iceberg. Heightened levels of integration with plant operations minutiae enable companies to achieve a superior degree of operational knowledge as well as facilitate cuttingedge methods to streamline and optimize processes. Concepts such as predictive maintenance, machine downtime reductions, and control solution optimization—minimizing cycle times or energy peaks—offer companies previously unseen clarity towards increased manufacturing efficiency and driving down production costs. Though implementation of these concepts can be achieved in many ways, PC-based control systems provide an efficient means to build this type of functionality by relying heavily on standards.
Connectivity and big data IIoT and Industrie 4.0 have a strong hand in connectivity, but the data derived through that connectivity are the valuables being mined. Seamless, cycle-synchronous data acquisition and storage are prerequisites for effective production/throughput analysis and correction of processing errors in machines. To this end, Internet of Things (IoT) software includes the ability to store all process-relevant data in a cycle-synchronous manner and in a standardized data format. This data can be stored either locally in the controller, in a cloudbased solution on a server in the company network, or in a public cloud, depending on the needs of the company. The platform provides a complete temporal image of the manufacturing process and the production data, offering an ideal information baseline to assist in the event of an error, to enable comprehensive condition analysis of the machine, and other valuable functions. The recorded process and production data can be analyzed online or offline, and machine cycles can be examined for minimum, maximum, and average values of the cycle times. Features such as online and offline condition
CONTROL ENGINEERING
www.controleng.com
Integration withplant operations via the Industrial Internet of Things (IIoT) enables companies to achieve a superior degree of operational knowledge and facilitates cutting-edge methods to streamline and optimize processes. Courtesy: Beckhoff Automation
analysis, predictive maintenance, pattern recognition, machine optimization, and long-term data archival are designed to help companies that seek complete business intelligence covering the finest details of their operation. Another new feature deals with moving vital data from point to point, ensuring that authorized personnel can access this data, regardless of time or their location in the world. This feature supports standardized protocols for cloud communication such as MQTT, AMQP, and OPC-UA for smart device integration. The extension of conventional control tasks through applications such as big data, pattern recognition, or condition and power monitoring in the cloud, can result in major improvements to production throughput, equipment efficiency, and time-to-market with new products precisely tailored to rapidly changing demand. Through the use of a PC-based control system and IIoT software, establishing a seamless connection between the IoT devices and the Internet of Services becomes a simple matter of configuration via the software graphical user interface (GUI). Corresponding services can be affordably hosted in public cloud systems or within private, local networks. Using these platforms and services in combination with advanced PC-based control systems, which support native connections to these services, offers a www.controleng.com
‘
Seamless, cycle-synchronous data acquisition and storage are prerequisites for effective production/throughput analysis and correction of processing errors in machines.
’
solution that is quickly configured; process data can start being captured and analyzed. The value of data in any manufacturing operation cannot be oversold, and the ability to mold that data into the means to streamline plant operations, reduce operational downtime, and cut costs has become today’s gold standard for the modern enterprise. This is really what Industry 4.0 and the IIoT discussions should be about. PC-based control is becoming the de facto system for companies seeking to create measurable and compelling business results off the rising tide of the smart factory. ce
Daymon Thompson is automation product specialist, Beckhoff Automation. Edited by Chris Vavra, production editor, Control Engineering ,
[email protected]. CONTROL ENGINEERING
MARCH 2016
|
41
IIOT, INDUSTRIE 4.0 implementations begin
Enabling IIoT requires protocol translatio n As implementations of Industrial Internet of Things (IIoT) and Industrie 4.0 frameworks begin, Hilscher is providing network gateways and other communications from the plant floor to the enterprise and cloud for manufacturing data analysis, company executives toldControl Engineering,recently.
I MORE
ADVICE
KEY CONCEPTS Hilscheris helping enable
connectivity the IIoT requires. connect to the Plant floor can enterprise and cloud for analytics. test cases and IIoT and Industrie 4.0 demonstrations are underway. GO ONLINE with this article See more details
online at www.controleng.com. CONSIDER THIS and derive value IIoT can connect
from islands of automation.
mplementations of Industrial Internet of Things Marshall said. “You don’t have to retrofit the con(IIoT) and Industrie 4.0 frameworks are pro- trol system to get data to the cloud,” for existing and gressing, and translations of major industrial net-future PLCs, without touching or adding communiwork communication protocols enable the flow cations responsibilities to PLCs. of data that becomes actionable information with Pühringer said customers can useexisting analysis. Hilscher is among companies providing infrastructure in plants; deploy reference architecnetwork gateways and other communications from tures from Industrial Internet Consortium (IIC) the plant floor to the enterprise and cloud for manu-and Industrie 4.0, vetted for all implementations; facturing data analysis. use cyber-physical systems as a virtual twin; and Hilscher representatives said the company leverage standards and start again, in a cycle of devices aim to make it easier for end users, device continuous improvement. manufacturers, and machine builders to access the The IIC Reference Architecture includes an benefits of Industrial Internet-connected manufac- edge tier with devices, such as actuators, scanner, turing. Enabling technologies extract data in paral- sensors, motors, controls; a platform tier;and conlel with current control networks and deliver it to nections to the enterprise and cloud. Fieldincludes cloud-based analytical services without compromis-existing real-time infrastructure, Pühringer said, ing existing systems or services. and the edge bridges information technology (IT) Armin Pühringer, Hilscher business develop- and operational technology (OT), then connects to ment manager, said products are designed to help make industrial cloud benefits a reality today. Hilscher North America CEO, Phil Marshall, also addressed the benefits of connectivity, providing communications for fieldbuses and industrial Ethernet protocols, he said. The goal is to get machine builders, system integrators, and end users “out of the network wars, and allow them to connect easily to as much as they need,” Marshall said. “Devices help IIoT get data off the wire. Products are vendor independent and legacy proof,”
A Hilscher demonstrationshowed
vibration monitoring for drives, with strain gauges, and transfer of data from the edge into the cloud and analytic services. Hilscher plans to be the enabler of field data in Industrial Internet-based architectures. Courtesy: Mark T. Hoske,Control Engineering, CFE Media 42
|
MARCH 2016
CONTROL ENGINEERING
higher level systems. This is valid model, laidout in great detail for all testbeds, Pühringer said. Industrie 4.0 uses a three-dimensional RAMI 4.0 model; functional layers are in line with plant floor people, and physical objects enable IIoT functions. Installations: Flatter, faster Pilot installations underway are moving to dissolve hierarchical control architectures, Pühringer said, flattening structures and connecting the plant to enterprise resource planning (ERP)systems. A cyber-physical system holds the model to simulate process behavior. Models can be put on existing wire in the plant without disturbing the PLC, using presently available protocols and time sensitive network (TSN), an emerging Ethernet standard designed to bring one real-time Ethernet structure to the many-flavored protocol soup of today. Pühringer said companies are moving beyond prior concerns about safety, security, and privacy risks. For a major IBM pilot installation, expected to be announced at Hannover Messe, Hilscher is supplying network protocol translators. A bottle-filling application was shown at SPS Drives in Nurnberg, Germany, fall 2015. ce
Mark T. Hoske, content manager,Control Engi-
neering, CFE Media,
[email protected]. www.controleng.com
More resources posted daily at:
www.controleng.com
digital edition Exclusives, Online Extras:Benefits of the Control Engineering Digital Edition include
tablet-friendly viewing (HTML5), exclusive content in every issue; headlines link to the longer version posted online; links are live where a URL is provided; and an email link arrives when ready. In addition, link to additional “Online Extra” articles. DIGITAL EDITION EXCLUSIVES
DE1 Technology developments using IIoT,
real-time data to help workers in the field Automation and controls designed to benefit manufacturers in the field were among topics discussed at the 20th Annual ARC Industry Forum.
DE5 Cognitive computing delivers answers, asks new questions In a data-driven age, taking advantage of collective knowledge can be done with very little jeopardy. Just ask Watson. Humans in many industries are taking advantage of cognitive learning and massive data analysis, including 10% savings in aerospace industrial maintenance.
ONLINE EXTRAS
(Click on the headlines or search www.controleng.com. )
Projects for improving manufacturing challenges receive funding The Energy Department announced $3 million for 10 new projects for the High-Performance Computing for Manufacturing (HPC4Mfg) Program, which is designed to enable private-sector to use highperformance computing resources at the department’s national laboratories to tacklecompanies major manufacturing challenges.
Planning algorithms for automatic contingenc y planning Researchers at MIT and the Australian National University (ANU) have developed a planning algorithm that also generates contingency plans for logistics and control applications that can help guide autonomous robots and determine control policies for the power grid.
Changing the narrative Rethinking ways to attract and retain African-American women in academic engineering—while understanding the intersection of race and gender—has never been more important. These women are showing the way.
Following selective coordination best practices Design engineers must coordinate electrical systems so that the protective device closest to the fault opens first, and quickly enough, to prevent the upstream devices from tripping.
Augmented reality is essential for the next generation of skilled workers Newport News Shipbuilding is constantly seeking new technology and innovative ways to improve safety, quality, cost, and schedules. Since 2007, they have explored augmented reality as a means to shift away from paper-based documentation in the work environment.
Six trends for the field service industry in 2016 As manufacturing shifts to a service-based economy, many businesses are beefing up their product support departments in order to stay competitive. Six trends and technology developments will impact the field service industry in 2016.
www.controleng.com
CONTROL ENGINEERING
MARCH 2016
|
43
DIGITAL EDITION exclusive
Technology developments using IIoT, real-time data to help workers in the field At the 20th Annual ARC Industry Forum, industry professionals and experts discussed and provided demonstrations on the latest manufacturing trends and ideas designed to benefit manufacturers in the field. See related articles in this issue, pages 30 to 42.
MORE
ADVICE KEY CONCEPTS Companiesare looking to leverage the Industrial Internet of Things (IIoT) to improve worker efficiency. Balancingconnections among things, services, and people will add value beyond the IoT to other industries. Some of the developments include enhancements to real-time data processing, asset performance monitoring, and improvements for mobile applications. CONSIDER THIS What other IIoT benefits do you see that weren’t mentioned here? (See related articles in this issue.)
t the 20th Annual ARC Industry Forum, from Feb. 8-11 in Orlando, industry professionals and experts discussed the latest manufacturing trends. They touched on many subjects including the Industrial Internet of Things (IIoT), Industrie 4.0, increased plant efficiency, synergy, and delivering real-time data. Click on the headlines for each section to learn more about the latest developments as well as additional images from each press conference.
A
connects any manufacturing asset to any enterprise system, vertically and horizontally, without programming. deviceWise is designed for manufacturing verticals such as automotive, pharmaceuticals, machinery, oil and gas, electrical power generation, water, and other industries. “Companies recognize the value of the Industrial IoT, sometimes referred to as Industrie 4.0,” Yentz said. “The challenge has been securely connecting high-value production equipment to enterprise systems as well as to the information consumer outside of the enterprise.”
Connecting manufacturing assets to enterprise systems Fred Yentz, president and CEO of Telit IoT Platforms, talked about the Industrial Internet of Things (IIoT) and the formation of Telit’s IoT Factory Solutions business unit as well as how its working on helping customers to take advantage of the IIoT. The business unit’s goal involves multiple paths to deployment from one sca lable platform designed to provide secure, robust shop floor access to the top floor and a connected ecosystem of srcinal equipment manufacturers (OEMs), suppliers, and customers. Yentz said Telit is working to simplify connections with deviceWise, an industrial automation platform that seamlessly
This focus is a key component part of Telit’s vision of connected factories, connected machines, and connected consumers and ties directly into its core IoT business.
Peter Terwi esch,president, ABB
Process Automation, discussed how the Internet of Things, services, and people (IoTSP) is delivering tangible results in a number of industries at the 20th Annual ARC Industry Forum in Orlando, Feb. 8-11. All images courtesy: Mark T. Hoske, Control Engineering. DE1
|
MARCH 2016
CONTROL ENGINEERING
Increased efficiency and productivity through the IoTSP The Internet of Things, services, and people (IoTSP) is bringing tangible benefits in multiple industries, explained Greg Scheu, president, ABB Americas, and Peter Terwiesch, president, ABB Process Automation, at the 20th Annual ARC Industry Forum on Feb. 8 in Orlando. Scheu opened the presentation with a brief company overview since its inception in 1883 and some of the products the company has provided, such as gearless motor drives, turbochargers, industrial robots, extended control systems, and variable speed motor drives. Scheu said ABB offers power and automation, which account for 40% and 60% of company revenue respectively. Terwiesch discussed ABB’s initiative on delivering the IoTSP. He gave a brief overview of the prior industrial revolutions and the progression to Industrie 4.0:
Industry 1.0-1712: Mechanical production powered by steam in England www.controleng.com
Satoru Kurosu (left) and Simon Wright from Yokogawa discussed creating customer value and cloud-based solutions at the ARC Industry Forum.
Industry 2.0-1870: Assembly lines powered by electricity in 1870
Industry 3.0-1969: Electronics and software-based control powered automation
Industrie 4.0-Today: The IoT connects things, services, and people.
Terwiesch also discussed a growing shift in automation as industrial products become smaller while still delivering increased productivity. Key drivers include affordable sensors, increased computing power, and more sophisticated software algorithms that can process data in new ways. The benefits, he said, include higher uptime and product quality while increasing safety from a worker and process standpoint. Terwiesch also discussed the plant of the future involving IoTSP and what this means for information technology/operational technology (IT/OT) integration. Whether its infrastructure, industry, transportation, or the home, everything will become more integrated and more connected with one another. Terwiesch used several examples from ABB’s recent operations involving the IoTSP including a mine facility in Sweden, a paper mill in Brazil, and a plant in Ohio. Terwiesch also emphasized focusing on customer outcomes by improving operations, maintaining assets, and transforming projects to increase efficiency and improve worker safety as a whole. www.controleng.com
Terwiesch said balancing connections among things, services, and people will add value beyond the IoT to other industries. He cited benefits to mining, pulp and paper, oil and gas, and other applications. “It’s a great time to be in automation. Create it.” Delivering real-time data to companies in the field Don Pearson, chief strategy officer of Inductive Automation, and Travis Cox, co-director of sales engineering, along with Arlen Nipper, president of Cirrus Link Solutions and coinventor of MQTT, demonstrated the addition of Industrial Internet of Things (IIoT) functionality to the existing human-machine interface/ supervisory control and data acquisition (HMI/ SCADA) functionality to Inductive Automation’s Ignition industrial application platform. The modules—MQTT Engine, MQTT Injector, and MQTT Distributor—are designed to accelerate organizations’ ability to leverage the IIoT. Pearson said companies aren’t getting the data they need for decisions. Coupling devices with
Honeywell Process Solutions(HPS) s howed how Pulse mobility software can add productivity to users of Honeywell Dynamo or Uniformance software at the ARC Forum.
CONTROL ENGINEERING
MARCH 2016
|
DE2
DIGITAL EDITION
exclusive
applications stops innovation because systems take too much time to set up and change after that. Nipper explained that Inductive Automation and Cirrus Link Solutions are taking a fundamentally different approach by combining Ignition software from Inductive Automation with all the efficiency of MQTT, a translator used in oil and gas successfully for 10 years. MQTT is a pub/sub messaging transport that’s perfectly suited to the IIoT. MQTT provides fast, bidirectional communication in a very simple
agnostic for data type, application vendor, and service provider. Both discussed the business strategy of advanced solutions that integrate OT and IT to enable industrial organizations to create value, foster sustainable business growth, and build synergies that contribute to a company’s effective transformation. Industrial Internet, mobility applications for increased connectivity Mobile software is available to help users of
manner, so itthe requires network bandwidth. And speed minimal of the new solution is groundbreaking. The modules with Induction technology are designed to connect hundreds of devices in just minutes.
process software be Honeywell more productive smartphones and tablets. Processusing Solutions discussed Honeywell Pulse and the Honeywell IIoT network, called iiOT, at the 20th Annual ARC Industry Forum in Orlando. Mara Weber, global business communications Synergy and customer value through and investor relations, Honeywell Process Solucloud-based solutions, integrated data tions, explained that the digital transformation Cloud-based solutions and how to creconnects people, processes, and assets. The IIoT ate customer value, were among discussions is designed to deliver real-time operating data as from Satoru Kurosu and Simon Wright of Yok- well as cloud-enabled software for greater conogawa, also at the 20th Annual ARC Industry nectivity that also is designed to unify systems Forum in Orlando. Kurosu, director and execand process more data for enhanced decision utive vice president, head of solutions service making. It also uses data analytics to predict business headquarters, discussed creating cusfuture events that can help prevent abnormal sittomer value beyond the plant. Simon Wright, uations and reduce downtime. CEO of Yokogawa’s industrial knowledge business Hilary Gwisdala, global marketing commuunit, discussed cloud-based, customer-connect- nications, Honeywell Process Solutions, demed advanced solutions. Wright was formerly CEO onstrated Honeywell Pulse mobility software,
‘operating data as well as cloud-enabled The IIoT is designed to deliver real-time
software for greater connectivity to unify
showing simple setup in just a few minutes, easily pulling information from Dynamo or Uniformance software from Honeywell Process Solutions. Honeywell Pulse is a mobile application designed to provide immediate notifications and real-time plant performance data and analytics to plant operators and managers.
systems and process more data for enhanced
DE3
|
Technology converging for asset performance monitoring Bentley Systems CEO, Greg Bentley, disdecision making. cussed the convergence of IT and OT and engineering technology (ET) also at the 20th Annual of Industrial Evolution, a provider of cloud-based ARC Industry Forum. Bentley discussed how plant data-sharing services, a company that Yok- this convergence is enabling owner-operators to ogawa acquired in January 2016. go beyond asset performance monitoring to asset Kurosu said the new Yokogawa business unit, performance modeling, and thereby achieve formed after acquisition of Industrial Evolution, demonstrable improvements in asset perforaims to provide synergy and customer value cre- mance. He also explained why digital engineeration through integrated data and analytics. It pro- ing models are critical to realizing the benefits of vides a secure cloud platform, data as a service the IIoT and how new breakthroughs in reality (DaaS), and business applications on top of that. modeling (enabled by way of unmanned aerial Wright said the DaaS effort began in 2000 for vehicles [UAVs], digital imaging, and innovative oil and gas utility companies. It is built on Osisoft software) are making the continuous creation of PI and structured query language (SQL), moves as-operated digital engineering models possible data to a data center, a private cloud, and adds for every infrastructure asset. analytical value. It is scalable to millions of data Bentley also suggested that digital engineerpoints, proven, secure, reliable, and is data source ing model integration is a logical benefit of IT
MARCH 2016
’
CONTROL ENGINEERING
www.controleng.com
and OT convergence. He gave an example of a south Australia gas utility that is adding weather and events to track, optimize, and control consumption with its portfolio for asset performance monitoring. Schematics, 3D models, functional componen ts and specifications, analysis, and network models all feed digital engineering models to create the digital DNA of the organization. Bentley said that IIoT success requires sensors, big data analysis, information mobility
‘
3D, global positioning system (GPS), and other information for asset performance modeling. Mobile technology also can be used to expedite issue resolution in the field when site and field workers can collect and share field feedback. For example, Bentley said, Western Power, in the U.K., is using 3,500 Apple iPads in field with maps software from Bentley.
A gas utility is adding weather and events to track, optimize, and control consumption; schematics, 3D models, functional components and specifications, analysis, and network models all feed digital engineering models to create the digital DNA of the organization.
ce
Edited by Chris Vavra,production editor, CFE Media,
[email protected], with press release information from Yelit, ABB, Inductive Automation, Cirrus Link, Yokogawa, Honeywell Process Solutions (HPS), and Bentley Systems with additional information from Mark T. Hoske, content manager, Control Engineering,
[email protected].
’
Want to receive your Control Engineering magazine as a digital publication ?
Update your subscription, and get our digital edition, on a more interactive and user-friendly platform, in your email in-box. Update now at
www.controleng.com
DIGITAL EDITION
exclusive
Cognitive computing delivers answers, asks new questions In a data-driven age, taking advantage of collective knowledge can be done with very little jeopardy. Just ask Watson. Humans in many industries are taking advantage of cognitive learning and massive data analysis, including 10% savings in aerospace industrial maintenance.
T
he importance of IBM’s Watson computer beating two human contestants in a game of “Jeopardy!” five years ago was better demonstrated the day after the televised event when cancer researchers called to ask if Watson’s computing capabilities could be harnessed to help in that area. That idea evolved into IBM for Oncology, one of more than 500 partnerships, including industrial and maintenance-related applications, developed around the idea of cognitive computing demonstrated by Watson on a game show can be used to help solve the complex problem of complex data in an increasingly complex world. That’s the potential of cognitive computing, according to Rob High, vice president and chief technical officer for the IBM Watson project. As he told the annual ARC Advisory Group forum in Orlando on Feb. 10, the need for such computing power is essential to take full advantage of the knowledge humans are creating. “Cognitive computing comes down to data. There’s been an enormous growth of data,” High said. “We are going to generate 2.5 exabytes of data today. That’s 2.5 billion, billion bytes. By 2020, we’re going to generate 44 zetabytes of data.” The problem with that, High noted, was not the data itself. “We can’t read it all; we only can Rob High,IBM’s vice president and chief technical officer of its Watson computing project, said cognitive computing is essential for humans to make better use of the massive data being created each day. Courtesy: CFE Media
DE5
|
MARCH 2016
CONTROL ENGINEERING
get a small sliver of it,” he said. “ The disparity is between the information and our ability to consume it. We want to tap into that massive volume of information to make decisions, but to do that, we need cognitive systems.” High said there were four main characteristics of cognitive systems:
They are able to learn their behaviors through education.
They support forms of expression that are more natural for human interaction.
Their primary value is their expertise.
They continue to evolve as they experience new information, new scenarios and new responses.
“Our human condition is far too complex to represent mathematically,” High said. “We don’t look up each individual word to create meaning. We derive our understanding through pattern recognition and through those signals gain meaning.” High said the questions are more daunting as humans and the cognitive systems keep learning. He posed three questions for consideration:
How do we use cognitive systems to amplify human cognition?
How do we make it possible to think about a problem you might not have thought about it before?
How do you make decisions in a way you didn’t before?
If that sounds a little too mechanical, some of the new cognitive systems under development also will include contextual, linguistic and even emotional analysis, such as robots www.controleng.com
that can evaluate body language and cognitive systems that can recognize puns and innuendo. Those latter skills were important for Watson’s foray into “Jeopardy!” “We had to interpret the context in which the question was intended, but use that context to look for information,” High said. They also loaded about 200 million pages of literature into Watson to help prepare the computer to play the game. While the (“Jeopardy!” demonstration was a Ken cultural phenomenon champion Jennings famously wrote, “I for one welcome our new computer overlords,” for his “Final Jeopardy!” question at the end of the second game). High said the real breakthrough was demonstrating the potential of cognitive computing. “The real breakthrough was that we could tackle problem of human reasoning,” he said. Today, that concept that evolved into 530 business partnerships, including more than 100 universities, and 80,000 de velopers using cognitive services on IBM’s Bluemix platform. That includes Austin, Texas-based SparkCognition, which works with aerospace companies to resolve maintenance issues more
‘
The cognitive system sifts through the information to find what is most important to us and helps inform our decisions.
’
MORE
ADVICE
quickly based on t he context of the problems faced. High said this effort has lowered maintenance costs by up to 10%. “Cognitive systems do the research for you so you can do your thinking better,” High said. “On our behalf, the cognitive system sifts through the information to find what is most important to us and helps inform our decisions. It changes the way we as humans think.”
KEY CONCEPTS Cognitive computing demonstrated by Watson can be used to help solve the complex problem of complex data. Cognitive systems can learn through education and evolve as they gain more information. The challenge going forward will be using cognitive computing to amplify human cognition.
content manager, Plant Engineering, CFE Media,
[email protected].
CONSIDER THIS What otherapplications could cognitive computing be used for?
ce
Bob Vavrais
eNewsletters
Control Engineering covers relevant topical articles in a variety of eNewsletters each and every month: CE’s Top 5 Reader Favorites
New Products for Engineers Showcase
Energy Automation
Oil & Gas Engineering
IIoT Report
Planning and Design
Industrial Networking
Process & Advanced Control
Industry News & Products
Process Instrumentation & Sensors
Automotive & Transportation Chemical Manufacturing Packaging
Safety & Cybery Security
Products For Engineers
PE ControlSystems
SHOWCASE ProcessManuf acturing
One Chip. One Company. All Your Network Solutions.
www.controleng.com/newsletters
InfoMana gement
Kepware Releases KEPServerEX V5.16 with New Local Historian Plug-In The plug-in captures data at the s ource to pre ve ntdata los s and im proveope rationale fficie ncywith an e as yto configure ,fle xible ,ope n, andcos t-e ffe ctives olution. Downloadafre eDe m o.
Engineers' Choice Awards finalists
S olutionsDire ctoffe rsdis counte d price s onove r8,000 Ele ctrical Enclos ure sandThe rm al Manage m e ntProducts .S ize srange from 2”x 2”to 86”x 187”and m e e t NEMA/ULRatings . Click to le arn m ore .
-
Subscribe today by visiting
Netwroking&Secur ity
Wednesday, October 22, 2015
Information Control Machine Control
SystemIn tegration
The ne tX ne twork control le r chip fam ilyfromHils che r inte grate s fie ldbusandindus trialEthe rne ts fortrans pare ntprotocol conve rs ion. One chip,12ne tworks , 24protocols tacks . Alls tacks have thes am eDrive rInte rface .Mas te r s tacks include FDT-bas e d ConfigurationTool. Re gis te rtole arnm ore .
System Integration Whitepaper Connection
DiscreteManufacturing
One Chip. One Company. All Your Network Solutions.
OfficialEngine e rs ’Choiceballotsare ope n for voting for Control Engine e ringNorthAm e ricanprint anddigitale ditionqualifie d s ubs cribe rs.Bas e don your e xpe rie nce ,vote forthe be s t Engine e rs ’Choicefinalis ts of94 products in26cate gorie s . VoteNow!
.
. .
It' nv r n i rt rn ntinuin u tin rit! ttn ur1hurln tn vi ll n n. L rn r.
h nt nt r ntrllr h i f ilyfr ilhr int rt fil u n i nutril t hrnt fr trnrnt rt l nvrin . n hi, 1 nt r, rt lt .l lt hv th rivr Intrf . tr t inl u nfiurtin l. itr t lrn r.
HMI high-performance design
High-performance HMIs, efficiency, process safety Using high-performance HMIs is a powerful way to streamline how operators manage processes and allows them to react to process upsets as efficiently as possible.
B
MORE
ADVICE
KEY CONCEPTS High performance HMIs can make operators more effective and reduce overall downtime and time spent on troubleshooting. High performance HMIs can also be helpful under normal operating conditions by using trends embedded into process object graphics to show conditions over time. Many companies are implementing high performance HMI applications in their facilities as they see gains in their process efficiency.
GO ONLINE See more information about high performance HMIs at www.controleng.com. CONSIDER THIS What other applications and industries could benefit from high performance HMIs? 44
|
MARCH 2016
efore computers were widely available in manufacturing, operator interfaces consisted of lights, rotary readouts, and control charts. These components were mounted on a wall in the control room and required operators to physically interact with them to run the process. Early computer graphics were used to shrink the operator interface to fit on a monitor but were rudimentary and made it easy for the operators to be overwhelmed with data. As computer graphics progressed, and the world at large became familiar with general business computing, industrial graphics followed suit, leading to the 3D rendered process environments common in most human-machine interface (HMI) marketing materials over the past
The major hurdle in designing high-performance HMI systems is that high-performance graphics are not conventionally attractive for use as marketing collateral and are not as easy to advertise.
few years. While these graphics look great in a brochure, they can get in an operator’s way leading to confusion and additional productivity losses during process upsets.
flood of alarms, leaving the operator a pile of information to sort through to find out what the problem is before he can take steps to fix the issue. Even for someone who is familiar with the process, finding out the root cause of an upset can be a time consuming task. High-performance HMI applications are designed to reduce the amount of time spent looking for the root cause. This is accomplished by simplifying the graphics, removing animation, flashing, and color under normal operating conditions. This even extends to accessibility concerns by not relying on color as the sole source of information. In the case of an alarm, different shapes and symbols can be used to indicate the equipment that is not running normally. When a process upset occurs, the offending portion of the process can be highlighted, immediately drawing the operator’s attention to it, and increasing his or her situational awareness to reduce the amount of time it takes to troubleshoot the problem. High-performance HMIs can also be helpful under normal operating conditions by using trends embedded into process object graphics to show conditions over time. They can use standardized
Process control system complexity On a parallel path to the advancements in computer graphics, process control systems have become more complex over the past few decades. The amount of data collected from a manufacturing process is constantly growing, and the industry push towards continuous improvement places more responsibility on process operators. High-performance HMIs are a relatively new design methodology designed to combat the confusion present in HMI applications with enhanced graphics by focusing on situational awareness as a primary motivator behind design decisions. Situational awareness is an operator’s ability to understand the information critical to his job at any given time, derive the correct actions, and reduce information overload through the use of simplified graphics by using color and animation only to convey process upsets.
CONTROL ENGINEERING
Sound the alarms In non-high-performance applications, normal process conditions are usually some combination of green and red for running or stopped motors, open and closed valves, and so on. There might be flashing animation to show items moving down a conveyor belt or fans spinning. Colored lines are used to show the different process connections, usually based on the process’s piping and instrumentation diagram (P&ID) drawing. When something goes wrong, there might even be a
www.controleng.com
scales to see if a large number of different devices with different operating ranges are in or out of spec at a glance. High-performance development, benefits One benefit to more complex HMI architectures is the introduction of objectoriented programming techniques. This approach allows developers to create tem-
plates for graphics, scripting, alarms, and communication structures. Using a template approach to developing high-performance HMI applications can reduce overall conversion time by building templates for the graphics and scripting that can then be placed in the application along with parameters for each instance of the graphics. If changes need to be made to any of the objects after the application has been developed, they will automatically be applied to all of the objects, saving time and hassle during commissioning and operation. Many companies are now implementing high-performance HMI applications in their facilities. As they see gains in their process efficiency, other companies are taking note. In the past 18 to 24 months, the tide has started to turn, with high-performance HMIs making their way back to the system vendors and in marketing materials; the major vendors also are offering graphics, scripting, and even control logic as out-of-the-box templates to further reduce the complexity and learning curve required to implement high-performance HMI applications at any facility. High-performance HMIs are a powerful tool that can make operators more effective, reduce overall downtime and lost-time spent on troubleshooting, and reduce the stress involved in handling process upsets. By reducing thegraphic interface’ s complexity, high-performance HMIs have the added benefit of being able to convey more information than a typical HMI application because it takes less work for the operators to get their bearings with the increased focus on situational awareness. ce
Alex Marcy, P.E., is the owner and president of Corso Systems, a system integration firm based in Chicago. Edited by Chris Vavra, production editor,Control Engineering,
[email protected].
‘
Graphics, scripting, and even control logic are available as out-of-the-box templates to reduce the complexity and learning curve.
’
Rugged Precision The MAQ®20 Industrial Data Acquisition & Control System
Signal Integrity, Compact Design 2 Software Packages for DAQ or T&M • $17 per Channel Possible – Lowest Cost in Industry • Up to 384 Channels in 19” Instrumentation Rack • Application Software from $250 • ±0.035% Accuracy • 15 00Vrms Channel-to-Bus Isolation • PID Software Control - Up to 32 Loops with ReDAQ ® Shape - Unlimited Loops with IPEmotion • –40°C to +85°C Operating Temperature
Instrument Class® Signal Solutions dataforth.com • 800-444-7644
CONTROL ENGINEERING
MARCH 2016
|
45
input #16 at www.controleng.com/information
HMI high-performance interfaces
Using programming standards to leverage modern HMIs
Modern human-machine interfaces (HMIs) can benefit from automation technology (AT) and information technology (IT) convergence solutions.
MORE
ADVICE
KEY CONCEPTS Programming standards have been a major reason for the convergence of automation technology (AT) and information technology (IT). Companiesare leveraging IT standards such as Microsoft Visual Studio for engineering, HTML5 for design, and WebSockets and HTTPS for secure communication instead of proprietary systems. HMI logiccan be implemented on the client side in JavaScript or as a server extension, which opens up the possibility of writing extensions in .NET or C++, which can protect and enhance intellectual property. GO ONLINE See additional stories about the IIoT, Industrie 4.0, and Big Data at Control Engineering’s Networking and Security channel.
CONSIDER THIS What otherdevelopments are possible with today’s HMI solutions and what future developments are likely? 46
|
MARCH 2016
he rapid adoption of programming standards has been a core driver of the convergence of automation technology (AT) and information technology (IT). Significant advancements in control and automation technologies have been developing this way for years, combining traditional programmable logic controller (PLC) code with standards from the computer science realm. Controls vendors have been careful to capitalize on IT standards for automation without losing the confidence of the average PLC
T
HTML5 also helps designers create modern and ergonomic HMI pages and enables numerous browser types to display these webpages. This means that HMI solutions can be highly adaptable: Web-based HMI solutions based on HTML5 and JavaScript can modify the display to best suit the screen in use regardless of the operating system, browser, or device. The same HMI software used in a factory can be deployed across multiple machine types, viewed on numerous industrial display screen formats, including multi-touch displays, and can even be
programmer and controls engineer. Humanmachine interfaces (HMIs) can benefit from this kind of balanced AT/IT interplay. Instead of the traditional, proprietary systems for HMI engineering and communication that industrial engineers are most familiar with, companies are leveraging IT standards such as Microsoft Visual Studio for engineering, HTML5 for design, and WebSockets and HTTPS for secure communication. It is also possible to connect HMI projects to a source code repository tool such as Team Foundation Server, GIT, or Subversion. This means engineering teamwork and collaboration can be simpler and easier to comprehend as well. It also takes the best standard technologies, proven by a wide range of innovative companies in the business and consumer tech industries, and applies them in new, exciting ways for industrial HMI purposes. HTML5 is designed to provide simple, highperformance and globally available technology for webpage design. Many major webpage developers and tech companies use it to mitigate many of the previous issues with “living” webpages. Of course, not all controls engineers are well versed in website programming and design, so the HMI programming environment should go well beyond being “user friendly.”
scaled to facilitate comfortable viewing on tablets and smartphones.
CONTROL ENGINEERING
Secure communications The client or the browser also can communicate with the HMI server and helps bridge the gap between Web-based clients and industrial control technology hardware. Familiar standards such as HTTPS and WebSockets Secure are designed to help guarantee security f rom the client to the server. The HMI server, on the other hand, can connect to the respective controller(s) via the appropriate protocols. As an example, the OPC UA protocol could be used for HMI to communicate to a wide range of industrial controllers, along with communication with PC-based control software platforms using a protocol such as Automation Device Specification (ADS), BACnet, and IEC 61850. Powerful HMI architectures facilitate numerous application scenarios—from local HMI panel solutions to multi-client, multi-server, and multi-runtime concepts. ce
Daymon Thompson is automation product specialist, Beckhoff Automation. Edited by Chris Vavra, production editor, Control Engineering ,
[email protected]. www.controleng.com
Integration of human-machine interface (HMI) with tools such as Visual Studio and HTML5 enables feature-filled HMI concepts to be directly configured in a familiar engineering environment with little or no programming. Courtesy: Beckhoff Automation
MONITOR VISCOSITY SIMPLY SENSE MIXER MOTOR HORSEPOWER WITH UNIVERSAL POWER CELL EASY INSTALLATION
PROFILING A PROCESS
• No holes in tanks or pipes • Away from sensitive processes VERSATILE
• One size adjusts to motors, from small up to 150hp • Works on 3 phase, fixed or variable frequency, DC and single phase power SENSITIVE
• 10 times more sensitive than just sensing amps
24
• Power changes reflect viscosity changes • Good batches will fit the normal “profile” for that product POWER DECREASE
22
SHOWS BATCH IS DONE
20 18
POWER SENSOR
16
14 12
10
DRY MIX
ADD LIQUID
HIGH SPEED
LOW SPEED
MIXER MOT OR
8
CONVENIENT OUTPUTS
• For meters, controllers, computers 4-20 milliamps 0-10 volts
BEGIN HIGH
6
SPEED MIX 4 2 0
BAT C H1
BAT C H2
BAT C H3
CALL NOW FOR YOUR FREE 30-DAY TRIAL 888-600-3247 WWW.L OAD CON TRO LS. CO M
input #17 at www.controleng.com/information
INFORMATION INTEGRATION TOOLS OPC and DDS
Using connectivity software to integrate the IoT with existing systems As the number of Internet of Things-enabled devices grows, connectivity becomes the biggest hurdle. Open platform communications (OPC) and data distribution service (DDS) provide two approaches to bridge the communication gap by reducing the complexity required to integrate with new devices. (See IIoT section of articles in this issue.)
T
he difficulties of integrating the Internet of Things (IoT) with existing systems are similar to radio and television. Both radio and television use radio waves to transmit their signals, with hardware on either side to encode and decode the signals into audio and images. While the overall concept is the same, the results are very different. This is analogous to configuring a device from
MORE
ADVICE KEY CONCEPTS OPC and DDSare designed to connect devices that use any number of protocols by implementing a standard set software interface. OPC is a client-server-based architecture whereas DDS has a decentralized architecture that distributes messages in a peer-to-peer fashion. Easier integratiowith n the industrial world will benefit manufacturers everywhere and speed up the return on investment. GO ONLINE See more information about open platform communications (OPC) and data distribution service (DDS) online at www.controleng.com. CONSIDER THIS What other technologies or concepts could be used to integrate with the IoT? 48
|
MARCH 2016
hardware combined with location-aware devices to track how far away people are from the beacon itself. This technology has been widely used in consumer retail applications to send customers relevant coupons or notifications when they are near a store or restaurant. This concept can be applied to the industrial world for safety and/or emergency alert systems. For example, with a geo-fencing system in an industrial facility combined with location track-
one manufacturer that uses one type of communication protocol to communicate with a system from a different manufacturer that uses a different protocol. Unless specific translations are present, the two devices won’t be able to effectively communicate with one another. This is where connectivity software like open platform communications (OPC) and data distribution service (DDS) comes into play.
ing of operators, alerts can be sent to the control room’s human-machine interface (HMI) when operators enter a specific area of the plant. In the event of an emergency, it is easy to track down the exact location of everyone in the facility using this information. This data can also be integrated with the control system when using mobile devices for data collection. As an operator moves throughout the facility, his or her device can automatically load the correct data entry screens Reducing complexity to collect readings as the operator moves to difWhile their technical details differ, OPC and ferent process areas. DDS are similar in their ultimate goal, which is Using the geo-fencing example, integrating making it simple to connect devices that use any a technology not built with the industrial world number of protocols by implementing a stan- in mind can require a huge amount of effort, dard set software interface. This not only simpli- requiring development work and testing with a fies the lives of industrial automation companies large number of systems architectures. Instead, that supply control system hardware and software if the geo-fencing vendor designs its system to by building support for these protocols, but also integrate with the control systems using OPC or makes it easy for new device and instrumentation DDS it only needs to develop one or two integracompanies to integrate with existing systems that tions to open itself up to communicate with any were developed prior to the concept of the IoT. control system that uses OPC or DDS. This can One example of this type of integration immediately increase a vendor’s potential market between new technology and existing systems share without any additional work. is the concept of geo-fencing and beacons. Geofencing is where a software system uses speci- Safety is the number one priority fied locations on a map to track when people are While OPC and DDS are similar in theory, in a particular area; beacons are similar, using they have different technical backgrounds. OPC
CONTROL ENGINEERING
www.controleng.com
Object Management Group on Data DistributionService
T
he Data Distribution Service (DDS) from Object Management Group (OMG) is a protocol for the IoT that enables network interoperab ility for connected machines, enterprise systems, and mobile devices, according to the OMG website. DDS provides scalability, performance, and quality of service required to support IoT applications. DDS can be deployed in platforms ranging from low-footprint devices to the cloud and supports efficient bandwidth usage as well as agile orchestration of system components. It provides a global data space for analytics and enables flexible real-time system integration. It lets software developers focus on the purpose of applications rather than the mechanics of passing information between applications and systems. www.omg.org
is a client-server-based architecture where the OPC server communicates with clients, typically industrial control systems. DDS has a decentralized architecture with devices using the protocol and creating a type of network to distribute messages in a peer-to-peer fashion. OPC has a long history of being developed for and used in industry, with many protocols offered by a variety of OPC solutions, along with database integrations, serial device communications, and hooks for Web-based system integrations. DDS, on the other hand, was initially developed from more IT-centric applications simplifying communication across networks and is moving into industry as broader scope technologies are adopted into control system architectures. Both OPC and DDS act as middleware between end devices or overall systems and other systems and enable standardized communication configurations to transfer data to where it needs to go. The choice between the two will likely be dictated by the systems and end devices in place, and what integrations are offered by each of the solutions. A final system design will likely include both as the IoT becomes more and more prevalent in manufacturing. Integrati on benefits OPC and DDS can be great tools to increase the overall capabilities of industrial control systems (ICSs). They can help integrate new devices into a facility, providing more information and context about a process and enabling operators and staff to make more informed decisions about how to operate. The main questions to ask are what information would be most useful to have, where does that information come from, and what is the easiest way to get it to where it needs to go? This might mean using some combination of standard protocols within a control system and both OPC and DDS to integrate nonstandard devices. www.controleng.com
OPC Foundation on OPC Unified Architecture
T
he OPC Unified Architecture (UA), released in 2008, is a platform independent service-oriented architecture that integrates all the functionality of the individual OPC Classic specifications into one extensible framework, according to the OPC Foundation website. OPC UA provides the necessary infrastructure for interoperability across the enterprise, from machine-to-machine, machineto-enterprise and everything in-between. This multi-layered approach accomplishes the srcinal design specification goals of:
‘between OPC The choice
or DDS will likely be dictated by the systems and end devices in place, and what integrations
Functional equivalence: all COM OPC Classic specifications are mapped to UA
are offered by
Platform independence: from an embedded micro-controller to cloud-based infrastructure
each of the
Secure: encryption, authentication, and auditing
Extensible: ability to add new features without affecting existing applications
Comprehensive information modeling: for defining complex information.
solutions.
’
www.opcfoundation.org
One of the main benefits of the IoT is the ability to integrate with any number of new technologies, some which have not yet been imagined. Making it easier to integrate with the industrial world will speed up the return on investment (ROI) in this technology and benefit manufacturers everywhere. ce
Alex Marcy, P.E., is the owner and resident of Corso Systems, a system integration firm based in Chicago. Edited by Chris Vavra, production editor, CFE Media,Control Engineering,
[email protected]. CONTROL ENGINEERING
MARCH 2016
|
49
Where decision makers go Come to Hannover Messe 2016 and meet the people who can say, “Yes.”
The world’s most important industrial trade fair attracts more than 6,500 exhibitors from 70 countries representing the entire industrial value chain. Nearly 70 percent of those attending will be decision makers. No other industry event can deliver that kind of business-to-business saturation. Join them all in Germany. Phoenix Contact will be there, too, with our wide range of electrical engineering, electronics, and automation systems, components, and solutions.
Hannover Messe’s 2016 partner country is the U.S.A: • Hear from industry-leading experts • Access foreign investment • Expand your export business
Integrated Industry – Discover solutions! Hannover Messe, April 25-29, 2016.
© 2016 PHOENIX CONTACT
To learn more: www.phoenixcontact.com/GoMesse input #18 at www.controleng.com/information
THE ROAD TO
HANNOVERMESSE 2016 American manufacturing on a global stage
F
or nearly 70 years, Hannover Messe has been the world’s leading industrial trade show, bringing manufacturing innovation from around the world to Hannover, Germany, each spring. The United States takes center stage at Hannover Messe 2016 as this year’s Partner Country. The event takes place April 25-29, providing an opportunity to bring American manufacturing strategies to a global audience. In the months leading up to this year’s show, we’ll look at the key trends in global manufacturing and offer insights as to how U.S. manufacturers can benefit from attending Hannover Messe in 2016.
Getting the right data helps company decide to exhibit By Bob Vavra Content Manager, CFE Media
Frontier Technology Inc. (FTI) is a company well-known in the federal government for being able to assist its customers in making data-driven decisions. In an era of the Industrial Internet of Things (IIoT), FTI’s skill set seemed like a great match for the manufacturing sector. The U.S. Commercial Service approached FTI offi cials about exhibiting at Hannover Messe April 25-29 in Germany as part of the Partner Country USA pavilion, and the potential was clear. “We have a lot of Internet of Things technologies around predictive analytics,” said Michael Weatherly, PhD, direct of data analytic s for FTI. “Energy a really market us. We do a lot withFTI training, and weishave someinteresting rea lly unique andfor innovative products.” was looking to expand its business beyond the work it has done with the Department of Defense (DOD) and other agencies. The play into the IIoT was clear, and incentive packages from Virginia, where one of FTI’s six U.S. offices are located, and from the Commercial Service, will give the company its first entr y into Hannover Messe. The message around data An employee-owned business based in Santa Barbara, Calif., FTI provides information and research methodology for complex system analysis. Its Operational Decisions Solutions tool helps transform data into actionable information and point users toward solutions. Weatherly said the data-management lessons it has learned over the years translates very well to a global audience that’s learning more about IIoT and its European parallel str ategy, Industrie 4.0. “We are swimming in data, but what are we doing with it?” Weatherly said. “We’ve got tons of information, and we’re tr ying to get to the data that makes sense. The big trick is not just telling where we are and where
we’ve been, but a lso getting into the predictive side through data. “A lot of time you’re only as good as the data you get,” he added. “We’re trying to help customers determine the failure of a system before it fails.” The move to Hannover gives FTI exposure to discuss how its datamanagement offerings play on a global basis. The chance to get in front of some of the world’s top manufacturers is an exciting one for Weatherly and his team. “We’re really looking forward to show,” he said. “We’re looking to diversify into other markets, and we have some really smart folks on our team. It’s fun to be around other innovative folks.” www.controleng.com
CONTROL ENGINEERING
MARCH 2016
|
51
HANNOVER MESSE 25 – 29 April 2016 Hannover ▪ Germany The USA will be highlighted at the world’s largest industrial technology trade fair. To explore opportunities at HANNOVER MESSE, call +1 (773) 796-4250 or visit www.hannovermesse.de. Sign up for free tickets: www.hannovermesse.events/cfemedia
Get new technology first
input #19 at www.controleng.com/information
NEW
THE ROAD TO
HANNOVERMESSE 2016
SFA 500 All-pole sine filters
c
Frontier Technology Inc. director of data analytics Michael Weatherly called Hannover Messe 2016 “a great opportunity” for the company to expand globally and into new manufacturing markets. Image courtesy: FTI
The interest in the U.S. pavilion at Hannover provides companies such as FTI a captive and curious audience. Because 2016 is the first time the United States has been the Partner C ountry at Hannover Messe, it also provides many small and mid-sized manufacturers (a group the Germans ca ll “mittelstand”) a week-long introduction to U.S. opportunities. “That means additional exposure and a prime location for U.S. companies, institutions, and economic development organizations, particularly those exhibiting in the U.S. Pavilions, ” said Daniel Gaines, senior international trad e specialist for the U.S. Commercial Service. “It means that manufacturers of any size will stand out promi nently.” Among the opportunities offered by the Commercial Servi ce are: • Pre-show educational webinars that help companies prepare for the event. • Pre-show company promo tions to potential overseas partners, helping U .S. exhibitors get maximum exposure to t he potential buyers, partners, and investors at the show. • Onsite executive marketing counseling with commercial experts from U.S. embassies from across the globe, helping U.S. exhibitors create custom strategies for approaching key global markets. • Post-show follow-up support to make sure U.S. exhibitors know how to take the next step with t he new connections they ma ke at the show. “It’s a great oppor tunity,” Weatherl y said. “B etween t he U.S. Commercia l Servic e and the state of Virgini a, we have mee tin gs already set up wit h p otential business partners. We already have a good network overseas, so we’re definitely looking forward to the show.” PE www.controleng.com
CONTROL ENGINEERING
MARCH 2016
|
53
o coming soon
OPTIMIZED EFFICIENC Y
OF DRIVE SYSTEMS
BEST IN CLASS
SWITCHING FREQUENC Y ð 4 KHZ
500 V
a M
e k
le
n a
it
The new all-pole sine filter SFA 500 series eliminates high-frequency common mode voltages and bearing currents.
Hall 13 Booth C34
input #20 at www.controleng.com/information
blockusa.com
THE ROAD TO
HANNOVERMESSE 2016
Rittal helps spur global revolution around IIoT Manufacturers with long histories in both Germany and the United States are especially excited about the U.S. having Partner Country status at the 2016 Hannover Messe on April 25-29. Rittal is one such company, with a long association with the show, and a expanding footprint in the U.S. Glenn Wishnew, senior product manager at RittalCorporation, discusses both the historic ties Rittal has with Hannover Messe and the ne w prospects surropunding the Industrial Internet of Things (IIoT) and its potential impact on global manufacturing.
customers. The underlying concept is an outgrowth of a variety of production processes made possible by new technologies. The focus is no longer simply on optimizing individual engineering, production or logistics stages separately but rather on integrating them to establish efficient, cost-effective processes with maximum flexibility and high customer benefit. Customer requirements need to be understood and applied at the engineering stage to keep product and production data consistent.
CFE MEDIA: Rittal has had a long association with Hannover Messe. In this year w ith the U.S. as the Partner Country, why By linking people and information with design and producshould Hannover Messe be important to the U.S. market? tion equipment, IIoT tools provide Rittal and its enclosure How is that market different than its German counterparts? customers enormous advantages: WISHNEW: Germany, where Rittal is headquartered, has a long history as a center of machine technology and for industrial innovation. Hannover Messe is where the whole Industrie 4.0 concept was born, which has had a particu larly profound effect on Rittal in the United States because Rittal embraces manufacturing on a global level.
With the world’s largest economy, the United States has been experiencing a manufacturing in a few areas. our perspective, Industrie 4.0 isresurgence part of what’ s making thatFrom resurgence possible, by making us more responsive to emerging customer needs and eliminating rework and waste. CFE MEDIA: We’ve seen a surge of interest inIIoT and Industrie 4.0 in Germany. Our research shows a lot of interest, but not a lot of awareness of specific benefits. What is Rittal’s message about IIoT and its importance to the fu ture of manufacturing? WISHNEW: The IIoT is the next step in the evolution of integrated design and production. It will impact how all manufacturers build their products, as it is already affecting the way Rittal designs and builds customized enclosure solutions for its
• They make it easy to modify enclosure designs to meet customer requirements precisely and know what all the ramifications of a design change will be quickly. That includes changes to costs, production timetable, impact on other aspects of the manufacturing process, etc., long before production of the enclosure begins. • They al low for faster design and production turnarounds for significantly shorter delivery and commissioning times. That allows Rittal customers to get the new equipment they need to support thei r own operations in place fa ster, and have greater confidence about meeting their own deadlines. • They allow engineers to predict how a design will perform in the field before the enclosure is ever built so design modifications can be incorporated early and inexpensively. • They ensure greater energy efficiency enclosure.
of the completed
To remain profitable, al l manufacturers need the ability to integrate data f rom a growing array of sources to gain a “big picture” of operations. Although commercial tools
The IIoT concept goes well beyond real-time condition monitoring and fault
“
diagnosis. Tools for peer-to-peer comparison and factory health information gathering from systems and their components will allow triggering maintenance activities and process adaptation. IIoT will ultimately link all aspects of production from engineering to manufacturing in one valueadded chain.
”
54
|
MARCH 2016
CONTROL ENGINEERING
Glenn Wishnew,Rittal
www.controleng.com
Visit Beckhoff at Hannover Messe 2016 in Hall 9, Booth F06! input #21 at www.controleng.com/information
THE ROAD TO
HANNOVERMESSE 2016 have long been available to provide overall equipment effectiveness (OEE) information to factory management, they tend to be focused on finding root causes for problems that have already happened rather than on providing predictions that managers can use to prevent problems.
The IIoT concept goes well beyond real-time condition monitoring and fault diagnosis. Tools for peer-to-peer comparison and factory health information gathering from systems and their components will allow triggering maintenance activities and process adaptation. IIoT will ultimately link all aspects of produc-
Visit Us 25-2 9 April PDM MONITORING SERVICES
US Pavilion, Digital Factory Hall 7 | Stand E12
tion from engineering to manufacturing in one value-added chain. In essence, IIoT is all about data, software and interfaces and the ability to use them to model and simulate the final product in a virtual environment to optimize the design and eliminate errors prior to actual manufacturing. Rittal isbringing IIoT technology to electronic enclosure and panel manufacturing by integrating the offerings of several sister companies to create a seamless value chain. A seamless value chain can make it possible to slash engineering/production costs by up to 50%. Some manufacturers have also been able to shorten design times by up to 60% by reducing delays caused by repetitive rework involved in design changes. CFE MEDIA:What should U.S. manufacturers, regardless of size, be focused on today to get stronger?
of PdM expertise and technology
WISHNEW: Embracing the principles of Industrie 4.0 and IIoT and making the investments needed to make them a
reality especially need to focusare oncritical. makingThey the capital improvements necessary to make that happen now, when the cost of borrowing for these improvements in the United States is at historic lows—interest rates are only going to go up from here. CFE MEDIA:Manufacturing has faced challenges in the early stages of 2016. What’s the message to your customers today about why it’s still important to continue to invest in manufacturing?
2015
Machine condition-based monitoring at its finest. WATCHMAN delivers actionable information about machine health to plant engineers and managers tasked with clear performance goals. input #22 at www.controleng.com/information
Call or email today to find out how: +1 781.938.0707
www.AzimaDLI.com
[email protected]
WISHNEW:A big part of the challenges in terms of investment in manufacturing has really been driven by the drop in the oil and gas market. With gasoline now at less than $2.00 per gallon and a
lot of supply on the market, this has put a damper on investment for that sector. Fortunately, it appears that drop has bottomed out, and it’s limited to a single sector. But from our perspective, i mproving your manufacturing capabilities and integrating your systems to serve your customers better and faster is always a good investment. PE 56
|
MARCH 2016
CONTROL ENGINEERING
Pritzker: Largest delegation to Hannover shows U.S. is ‘open for business’ U.S. Secretar y of Commerce Penny Pritzker will lead the largest-ever U.S. delegation to Hannover Messe April 25-29, in Hannover , Germany. For the first time in the Fair’s history, the United States will be the Partner Country, which provides the more than 270 businesses and economic development organization s (EDOs) in the U.S. delegation an unprecedented opportunity to be prominently featured in U.S. exhibitio n halls and during specia l events. President Obama will also participate in this year’s event, themed “Integrated Industry—Join the Network.” “The United States is home to the most innovative and forward-thinking companies in t he world. But in today’s global ec onomy, it is not enough to s imply be the be st. We must also let the world know that America is open for business,” said Secretary Pritzker. “Hanno ver Messe i s a unique opportuni ty for American companies to showcase their products and capabilities to thousands of global advanced manufacturing representatives.” “The U.S. manufacturing industry has strong bonds to Germany and our countries have been vital partners i n
many geopolitical priorities. The 2016 Hannover Messe will be a milestone in our trans-Atlantic trade relations and an example of the Obama Administration ’s commitment to strengthening the U.S.-Germany economic par tnership, ” Commerce department officials said in a press release. The Department of Commerce also wi ll host the U.S. Investmen t Pavilion, a centerpiece of the fair and host to state and local EDO exhibitors. The International Trade Administra tion will have international trade specialists available on the show f loor to provide insights into global industry trends, identify the best market opportunities for U.S. products, and facilitate introducti ons to international P E buyers, distributors, and investors. To learn more and register for the event, visit http://export.gov/hannovermesse/. A list of all exhibitors in the delegation can be downloaded at http://export.gov/hannovermesse/exhibitors.
Our Heart Is Set On Your Productivity! FORCAM Never misses a Beat . Hannover Fair 20 16 April 25 – 29 I Hall 7 I Booth A11 input #23 at www.controleng.com/information
Winner 2015
We Deliver Results In Productivity www.forcam.com
INSIDE PROCESS advanced process control
Part 1: Neural networks in process control Neural networks have been used in process control strategies for years and have been applied with great success. This two-part series examines the process of producing a neural network. Part 1 covers neural network architecture, control space, model range, data types, and dataset selection.
A
MORE
ADVICE KEY CONCEPTS Neural network models can be beneficial in industrial processes. The choiceof architecture depends on the application. An important aspect of developing neural network models is the concept of measurement and control space. It is possible to do some historical data mining to acquire a data set for training. GO ONLINE Link to additional online resources, neural networks, advanced process control, and related content at www.controleng.com/archives, under March 2016.
s the name implies, neural networks are composed of a network of neurons programmed to produce a response from external stimuli. The neuron is the basic building block of the network. It gets its name from its biological namesake. But in this case, the neuron is modeled by a small segment of computer code called a “perceptron.” Several neurons are interconnected in a network that is taught how to respond to stimuli by training. It’s an iterative process: present the stimuli, compare the response to a reference, and make the correction. The ability to learn gives neural networks great flexibility to capture the underlying function of a process, even with attributes that are not readily obvious, such as installation, age, fouling, or some other unmeasured parameter.
The purpose of using neural network models stem from their ability to:
Model a linear or nonlinear process
Model a process that is difficult to understand
Model a process that is difficult to model using f irst-principle equations
Model a process based on indirect measurements
Shorten model development time for a complex process.
There are several cases where neural network models may be beneficial for industrial processes.
CONSIDER THIS Understand how the abstract concepts of neural networks and advanced process control can be applied to real-world control scenarios.
Figure 1: The diagram shows a simplified view of a four-input, approximate-function, neural network with three neurons in the hidden layer. All images courtesy: Process2Control LLC
P1
|
MARCH 2016
CONTROL ENGINEERING
www.controleng.com
My operators have poor visibility to potential issues. They need to view, process, and make informed decisions - clearly and quickly.
YOU CAN DO THAT Improve operations performance. Operator performance can impact plant safety and process availability. Emerson sets your operators up for success by using best-of-class technology, proven processes, and an understanding of human limitations and strengths. The DeltaV distributed control system can help reduce operator stress, limit human error, and provide intuitive data to run your plant more efficiently. Better visibility – better performance. Learn more at www.emersonprocess.com/operationsperformance/
The Emerson logo is a trademark and a service mark of Emerson Electric Co. © 2016 Emerson Electric Co.
input #24 at www.controleng.com/information
INSIDE PROCESS advanced process control R e c o rd #
Ta rg e t
I n p u1t
I n p u2t
R ec 1o r d
25
42
62
R ec 2o r d
65
25
31
Figure 2: The shape of the control space depends on the point vector distribution of the data records used for training. Assum e two inputs for this example: two data records used for the model (table), the point vector formed from record 1 (left), each record forms a point vector (middle), and the point vector distribution takes form (right).
Applications where a model can be substituted for an unreliable measurement can impact profitability. In some cases, a controlled process may be manipulated only at discrete intervals due to lag in obtaining a control measurement. For example, a process may use lab analysis as feedback. The lab measurement has an inherit lag time. The neural network may be trained with the lab data to produce a virtual instrument the process can use for control on a continuous basis. Model-based controllers can use neural network models in place of first-principle models. This can shorten development time and still allow control of multiple control variables where simultaneous setpoint and trajectory control are needed. And there’s always the case of the process that is poorly understood, too complicated, or rapidly changing to apply first-principle models. Neural networks excel at finding the underlying process response from input stimuli.
and analyzed. The choice of architecture depends on the application. In industrial control applications, generally speaking, models seek to mimic the function of some process variable; the target, based on the process conditions; and the inputs surrounding it. The simplest architecture for this task is the multilayer function approximation network architecture (see Figure 1). The number of neurons in the hidden l ayer depends on the complexity of the target function, but in general, they range from three to nine. Control space An important aspect of developing neural network models is the concept of measurement and control space. “Measurement space” is the multidimensional limits defined by the measurement range of each input representing one dimension. An array of inputs is called the “input vector.” “Control space” is within measurement space, and its limits and shape depend
Neural network architecture Since the 1980s, different types of learning neural network architectures have been designed
Figure 3: The graphs show a valid control space (left), an invalid control space (middle), and the target range (right).
P3
|
MARCH 2016
CONTROL ENGINEERING
www.controleng.com
input #25 at www.controleng.com/information
INSIDE PROCESS advanced process control
Inputs
Temperature
Control system
Distance
Inputs
Mode Flow rate
Noise
Temperature
Mode
Transport delay
Level
Flow rate bpc
Target
Target
dp Flow rate
Percent open Mixing
Percent open
Valve position
Valve position
Figure 4: The fishbone diagram on the left shows all possible influences that could affect the target measurement. The goal is to reduce the variables to those that have significant influence on the target as shown in the fishbone diagram on the right.
Figure 5: This neural network significance analysis graph shows significant inputs above zero. Inputs below zero are either insignificant or in the noise band.
‘should
Model inputs be robust, independent variables that have the most influence on the target.
P5
|
’
MARCH 2016
on the point vector distribution of the input vector data records used for training. For example: There could be a number of independent inputs, p1 … pk, into a model, and each would form a dimension in control space. For simplicity, assume only two inputs (see Figure 2). The control space coverage is determined by the point vector distribution in Figure 3 (left). If the inputs form a point vector outside the control space as shown in Figure 3 (middle), a neural network model may not be valid. This is because no training existed in that space. Dataset selection Of primary importance when selecting records for training a neural network is to ensure the record set covers not only the range but also the target response throughout the input range. Figure 3 (right) shows an example
CONTROL ENGINEERING
of how the target response to the inputs reveals its range and function. Steps in acquiring a dataset suitable for training a neural network include choosing the target variable, selecting the input vector elements, handling of data types, historical data mining, and/or parametric testing. Data types: Binary, integer, and floating point are the primary data types recommended for the function approximation architecture. Enumeration and string-type data are special cases but may be used if broken it into individual binary inputs. Selecting target variable model input elements: Arguably, the most difficult task in creating a neural network model is selecting the process variables that make up the model input vector data elements, p1 … pk. Model inputs should be robust, independent variables that www.controleng.com
have the most influence on the target. Experience is usually enough to perform the selection when the process is simple. However, in some cases, the process may have more than a few variables, and choosing the right ones may be challenging. In addition, care must be given to minimize the number of inputs because every unnecessary input used in a model reduces the model’s robustness,
Some prerequisites to consider before parametric testing include:
Perform a hazard analysis prior to manipulating the process. Define the limits of valves, speed controller, and so on, used in performing the test.
Have a safe condition to place the process in case of an unusual event.
Record any noise filter settings.
Define settling time after each parametric test maneuver.
adds increases Several tools noise, exist toand help excludecost. less significant inputs. Figure 4 (left) shows a fishbone diagram with all possible influences that could affect the target measurement. Strive to reduce the variables to those that have significant influence on the target as shown in Figure 4 (right). A reduction of this kind can result in significant savings in modeling cost and instrumentation needs. In addition, it simplifies the model. There are commercially available programs that perform analysis of variances (ANOVA) to determine each variable’s significance to the target. However, generating an ANOVA becomes much more difficult as the number of variables increases. Another commercially available program uses neural networks to determine an input’s significance. This method allows the user to use a shotgun approach. That is, as shown in Figure 5, the program uses a dataset containing all the inputs as shown in Figure 4 (left) and identifies the significant inputs as in Figure 4 (right). Historical data and parametric testing: It is possible to do some historical datamining to acquire a data set for training. However, process conditions and the state of the system aren’t always known from when the data was generated. It is highly recommended to create a measurement and control baseline before acquiring a data record set. To create a measurement and control baseline:
Calibrate all transmitters used as inputs into the model.
Check that valves, drives, and heaters are in good working order.
CONTROL ENGINEERING
MARCH 2016
|
P6
input #26 at www.controleng.com/information
INSIDE PROCESS advanced process control
Figure 6: For new processes or retrofits, datasets are usually generated during system parametric testing after startup. These graphs show the manipulation of two valves (top) and three flow measurement responses from three flowmeters (bottom).
Controller outputs 100
75
e g ta n e c r e p 50 l, a n
C1 C2
s ig V M
25 Plot area
0 0
10
20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180190 20 0 210 220 230 240 250
Time, seconds
Flow rate 40
30 n i / m g k , te a r 20 w lo f s s a M 10
F1 F2 F3 F3 SP
0 0
10 20
30 40 50
60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250
Time, seconds
1
2
3
4
5
67
1
Start time
12:00:01
2
Stop time
23:59:59
Timestamp
Date
Target tagname
Input 1 Tagname
Input 2 Tagname
6
12:00:01
1/6/2012
20.2
12.6
22.8
70.170
7
12:00:03
1/6/2012
20.4
12.5
22.6
70
3 4 5
...
InputN Tagname
Figure 7: A training record set was extracted from a historian to this partial spreadsheet.
P7
|
MARCH 2016
CONTROL ENGINEERING
www.controleng.com
Know safety limits and constraints when executing the parametric test.
Note any expected measurement lag or transport delays.
Make sure all data points are being recorded by the historian.
Make sure operations is aware of and agrees to the test procedure.
‘
Ensure the historian records all data points and that operations is aware of and agrees to any test procedures.
’
a record dataset for training the neural network. There are several historian software packages available on the market. Many have plug-ins for
For new processes or retrofits, datasets are usually generated during system parametric testing after startup and tuning (see Figure 6). Experience has shown the best data for the model is collected after a variable has reached steady-state after a parametric test maneuver. Realize that datasets are coupled to the current equipment and process configuration; consequently, datasets acquired prior to a retrofit or process change may not live up to expected performance. If the performance degrades a parametric test may be required again. Acquiring training dataset records: Now that the parametric test is complete and the data is stored in the historian, the objective is to obtain
spreadsheet packages. Figure 7 shows a predesignedsoftware spreadsheet. “Part 2: Neural networks in process control” will focus on preparing the dataset for training, neural network model training and validation, implementing a neural network model on a control platform, and human-machine interface (HMI) requirements. ce
Jimmy W. Key, PE, CAP is president and owner of Process2Control, LLC in Birmingham, Ala. Edited by Jack Smith, content manager, CFE Media, Control Engineering ,
[email protected].
CONTROL ROOM CONSOLES THAT PUT YOU IN CONTROL From single control room consoles to the largest integrated command centers, only Winsted has more flexible solutions for you to meet your exact requirements for function, style andcost. Select the configuration, design and features you want in modular, modified or full custom console environments.WITH WINSTEDYOU’RE IN CONTROL. Choose from 6 modular platforms built to order, or design your custom consoles Versatile Slat-Wall Accessory Mounting
Monitor Mounts to 63-inch, Up to Full Video Walls
19-Inch Rack Mount Solutions
Articulated Tilt/Pivot Monitor Versatility
3 Monitor Mount Post Heights
Curved, Corner or Linear, Multi-Bay Configurations
Integrated Power and Data
Multiple Work Surface Options and Styles
Accessible Cable Management Solutions
Dozens of Accessories, Hundreds of Configurations, Unlimited Possibilities
End Panel Color, Material and Graphics Options
PC/Device/Instrument Security with Swing-Out Authorized Accessibility
WEB:
winsted.com
•
Standard Modular, Modified or Full Custom Console Solutions
Multiple Depths and Configurations
EMAIL:
[email protected]
•
TEL:
800.447.2257
FREE 3D DESIGN SOFTWARE & DESIGN SERVICES Download our free WELS 3D software that lets you design, visualize and cost your ideal control room solution. Or contact us for free design ser vices. GET IT AT:WINSTED.COM/WELS
input #27 at www.controleng.com/information
•
FAX:
800.421.3839
INSIDE PROCESS case study: beverage filtration
Filtration process improves vermouth drinks A food and beverage equipment manufacturer designs and builds rotating dynamic crossflow filter systems to replace traditional vacuum filters.
A
n Italian food and beverage processing equipment manufacturer, TMCI Padovan, uses distributed drives on rotating dynamic crossflow filter systems. These machines feature a calibrated back-pulse system and a new filtration method for the wine and juice industries that allows a low-energy, low-labor, and continuous system for turning pressed wine or fruit juices into clear liquids with optimum results. This method, which uses mechatronic drives, does not require the use of filtration aids. Vacuum filter challenge The customer, a well-known Italian producer of vermouth-fortified wines, needed to replace a traditional vacuum filter , which typi-
cally has a low-cycle cleaning requirement that hindered the processes they wanted to perfect. Due to the large volumes processed, a reliable and low-energy machine was required to operate an average of 8 to 10 hours per day, 24/7. A particular filter was identified as a possible solution to the problem, and the customer asked the equipment manufacturer to test the filter system in its production plan t.
MORE
ADVICE
KEY CONCEPTS A customerof an equipment manufacturer needed a rotating dynamic crossflow filter system. The equipment builder tested a possible solution in its plant. The customer selected a system equipped with mechatronic drive units. GO ONLINE Link to additional online resources, process filtration, mechatronic drive systems, and related content at www.controleng.com/archives, under March 2016. CONSIDER THIS Understandthe requirements of the process or application before selecting system components. P9
|
MARCH 2016
Crossflow filtration solution After successful testing at TMCI Padovan, the customer selected a rotating dynamic crossflow filter system equipped with mechatronic drive units. The customer chose this solution because the flexibility of the system’s software allows operators to select the appropriate operating parameters to ensure product quality. In addition, the compactness and cleanliness of the crossflow filtration system allows hygienic operation and reduces the overall footprint. Because the system operates without filtration aids and modifiers, product quality is improved, there is less environmental impact, and less waste. In addition, energy consumption during filtration is decreased compared to conventional models, the process tempera ture rise is negligible, and the closed system ensures that product
CONTROL ENGINEERING
oxidation is almost zero—important factors for making great tasting wines and juices. Rotary crossflow filter operation The rotating dynamic crossflow filter used is the first with a calibrated back-pulse system for evacuating the filtrate. This design has been hailed as one of the most valid technologies for filteri ng must and wine grounds—and other liquids that have high levels of suspended solids—without filter aids or modifying agents. The rotation dynamic crossflow filtration system consists of a sealed chamber fed by a peristaltic pump and a series of spinning porous ceramic disks. Spinning membranes are responsible for the filtration instead of a forced liquid flow used in conventional crossflow fil-
tration systems. This low energy consumption process prevents lockups and allows easy cleaning. It a lso enables long filtration cycles of up to 72 hours without interruptions, with high flow rates between 25 l/m 2h to 50 l/m 2h with lees. The available models are compact, easy to operate, and are supplied with filtration membranes with total surface areas between 1 m 2 and 80 m2 and multiples thereof. The filtered product can be bottled directly as is the norm with traditional crossflow filters. However, the absence of red color reduction and the low oxygen absorption make the process especially interestin g to the industry. Maximizing mechatronics Filter system can be developed and produced competitively due in part to the selected mechatronic drive units. Depending on the size, each model contains several parallel shaft-geared motors. As they rotate the filtration disks, their number varies as a function of the number of disk-holding shafts; one machine can hold from one to 16 shafts. In addition, the machines have one or two tanks for the product, and each tank has four drives, each of which includes a motormounted decentralized frequency inverter. The www.controleng.com
sensorless inverters ensure tight speed control and maintain the high quality process. The drive speed is adjusted through the machine’s programmable logic controller (PLC) via fieldbus communications. Finally, a separate motor
cy directly influences the quality of the system’s overall performance. The energy saving function adjusts consumption to a fraction of the rated power during partial-load operation. Their compactness
TMCI Padovan’s Dynamossystems employ a gentle filtration method for musts, wine grounds, and other
drives the circulation pump. The aforementioned distributed inverters are available as models either for installation close to the motor or integrated within the motor. In addition to offering an overload capacity of 200%, the distributed inverters can be placed close to the application for compact and efficient operation with less wiring than conventional panel-mount solutions.
makes mounting the distributed drives particularly easy. The local storage of programming data on removable EEPROM facilitates commissioning. In addition, the optional matching of safety standards such as EN 61508, SIL3 was fundamental to this application. The ability to communicate with the PLC through fieldbus specified by the customer using a single node for multiple users resulted in cost savings by allowing the drives to interface with the CANopen-based fieldbus. A smaller main control cabinet and simplified machine commissioning, which resulted from using decentralized geared motors and separate motors, saved additional costs. Other features include the configuration options that are available through the distributed inverters. The customer was able make use of simple solutions for addressing the distributed nodes and benefitted from the status LEDs and the diagnostics that can be read via EIA-232 both on inverters and on distributed nodes.
liquids with high levels of suspended solids. The system uses mechatronic drive units from Nord Drivesystems. Image courtesy: Nord Drivesystems
Relative, absolute positional Relative or absolute positional values can be controlled by binary values from the PLC entered through the inverter’s inputs and stored in the drive. As an alternative, they can be set through a choice of fieldbus systems. Position feedback can be provided through incremental encoders with the standard level of supply including an onboard reference function for this purpose, or it is possible to directly set positional values with an absolute encoder via CANopen. For the alternative control options, configuration requires only few parameters for commissioning and optimization. Various features of the drive products contributed to the successful implementation of the filtration machines. The high rotation accurawww.controleng.com
ce
Jörg Niermann is marketing manager at Nord
Drivesystems in Bargteheide, Germany. Edited by Jack Smith, content manager, Control Engineering , CFE Media,
[email protected]. CONTROL ENGINEERING
MARCH 2016
|
P10
MEDIA SHOWCASE FOR ENGINEERS Your place for new products, literature, Apps, Videos, Case Studies and White Papers. ISO5167 Multivariable Mass Flow Computer
• Mass ow measurement under ISO5167 standard for orice plates, nozzles and venturi tubes. • Arian Flow Cad software with uid physical properties based on: NIST Standard Reference Database, IAPWS-IF97, AGA 8 DC92. • Reliable in tough environments. more information: www.arian.cl/fow
Input #100 at controlengineering.hotims.com
Input #101 at controlengineering.hotims.com
SAFETY PLUGS
TM
Input #102 at controlengineering.hotims.com
Flexible Temperature Sensor Saves Time and Money
PROTECT FROM ARC FLASH OFF BUTTON Safely breaks load UL Switch-Rated
BOA Spot TM
The WORM, an innovative exible sensor, installs in minutes into most thermowells. It bends and slides right in without having to remove the transmitter enclosure or assembly components.
NEW
Low Cost Integrated Vision Sensor BOA Vision System Performance at Vision Sensor Affordability
Rated up to 200A 600V
Watch the video SAFETY SHUTTER
View the BOA Spot Features Guide:
(on receptacle)
http://goo.gl/VXb98V
Protects from live parts Simplifies NFPA 70E compliance meltric.com 800.433.7642
Input #103 at controlengineering.hotims.com
68
|
MARCH 2016
CONTROL ENGINEERING
www.miinet.com/TheWORM or call 800-999-2900
Demand Moore Reliability A company of MARECHAL ELECTRIC GROUP
Input #104 at controlengineering.hotims.com
Input #105 at controlengineering.hotims.com
www.controleng.com
MEDIA SHOWCASE FOR ENGINEERS Your place for new products, literature, Apps, Videos, Case Studies and White Papers. Loop Powered 4...20ma Isolating Conditioners
PUMP CONNECTORS Simplify Service Work Switch-Rated Plugs & Receptacles Quickly connect & disconnect power to motors
Rated up to 75hp
Simplifies NFPA 70E
•
compliance
Safe and reliable inputs for PLC’s. Protects from surge voltages and eliminates ground potential differences.
•
4kV and 10kV isolation.
•
5 years guarantee.
distributors wanted, more information: www.arian.cl/din
OFF Button FREE SAMPLES VISIT MELTRIC.COM/FREE
A company of MARECHAL ELECTRIC GROUP
800 433 7642 • meltric.com Input #106 at controlengineering.hotims.com
Input #107 at controlengineering.hotims.com
eNewsletters
stay
informed
Control Engineeringcovers relevant topical articles in a variety of eNewsletters each and every month:
CE’s Top 5 Reader Favorites
Input #108 at controlengineering.hotims.com
Industrial grade off-board DC/DCconverters 20 to 60 Watt.
Energy Automation IIoT Report Industrial Networking Industry News & Products Automotive & Transportation Chemical Manufacturing Packaging Information Control
Stay current with technology and trends in electrical, mechanical, instrumentation
Machine Control New Products for Engineers Showcase Oil & Gas Engineering Planning and Design Process & Advanced Control Process Instrumentation & Sensors Safety & Cybery Security System Integration Whitepaper Connection
and automation. Subscribe t oday by visit ing
www.controleng.com/newsletters
Reliable. Available. Now.
To subscribe, visit
www.controleng.com/subscribe Input #109 at controlengineering.hotims.com
www.controleng.com
tracopower.com Input #109 at controlengineering.hotims.com
Input #111 at controlengineering.hotims.com
CONTROL ENGINEERING
MARCH 2016
|
69
NEW PRODUCTS and software See more products daily at www.controleng.com/products.
Robot series designed for fast, repeatable movements ABB’s IRB 910SC line of selective compliance articulated robot arm (SCARA) robots is designed for a variety of general-purpose applications requiring fast, repeatable, and articulate point-to-point movements. It can be used in applications such as small parts assembly, material handling, parts inspection, and laboratory automation. It has a maximum payload of 6 kg and is available in reaches of 450, 550, and 650 mm. The single-arm robot is able to operate in a confined space and is tabletop mountable. All variations are modular, with linking arm lengths that allow end users to specify the optimum reach required for a specific application. Each SCARA variation is IP54-rated for optimum protection from dust and liquids. ABB, www.abb.com Input #200 at www.controleng.com/information
Programmable alarm trips for process, chemical applications Moore Industries’ SPA2IS programmable alarm trips with built-in intrinsically safe (IS) field connections are designed for the chemical, petrochemical, oil and gas, and pharmaceutical industries. They monitor, control, and measure signals in hazardous areas and have an alarm to reduce wiring, installation, and maintenance costs. It has built-in IS field connections for current/voltage, resistance temperature detectors, and a thermocouple. It has a universal ac/dc power supply, provides on/off control, warns of unwanted process conditions, alarms on rate of change, and assists withor performs emergency shutdowns.
Particulate monitoring system with multichannel configurations The PM 100 Pro from FilterSense is a particulate monitoring system that has single- and multi-channel configurations. It is designed for sensing performance requirements ranging from detection to monitoring and concentration measurement in the power, cement, metal, and chemical industries. It features technology that allows for measurement sensitivity as low as 0.1 mg/m3. It also features an advanced digital signal processor and full-color display as well as an on-screen trending alarm management system and options for an integrated historian and EPA quality assurance checks.
Moore Industries,www.miinet.com
FilterSense, www.filtersense.com
Input #201 at www.controleng.com/information
Input #202 at www.controleng.com/information
PRODUCT & LITERATURE SHOWCASE 5B / 7B / 8B Signal Conditioning Solutions More Models, More Protection, Less Noise, Lower Cost
580+ different 5B, 7B, and8B signal conditioners provide accurate, isolated Instrument Class® performance to ensure the integrity of your industrial automation, data acquisition, process control, and quality assurance systems. Custom modules available. • ± 0.03 to ± 0.05% Accuracy
• ANSI/IEEE C37.90.1 Transient Protection
• 1500Vrms Isolation
• 3- to 6-Pole Low-Pass Filtering
• Up to 240Vrms Input Protection
• -40°C to +85°C Operating Temperature • CSA C/US Certied & ATEX Compliant (5B, 7B) • C-UL-US Listed (8B)
Acromag Signal Conditioners & Ethernet I/O We have the experience to help improve reliability, increase productivity, & reduce your costs. Get your new product g uide today. • 4-20mA Isolators andSplitters • Ethernet, Modbus, Profbus Remote I/O
877-295-7057 www.acromag.com/ce ■
Input #101 at www.controleng.com/information
Sensor Brackets
m o c e z o n ft o s
and so much more... Call 800-444-7644 or visit www.dataforth.com Input #100 at www.controleng.com/information
Place your Class ified, Literature Showcase or Product Mart ads today! Contact: Iris Seibert at 858-270-3753 or
[email protected]
70
|
Please request your... 2D / 3D CAD Files Catalogs Stock & Customs
Mount | Apply | Position | Protect
Input #102 at www.controleng.com/information MARCH 2016
CONTROL ENGINEERING
T
TM
Advertising Sales Offices ContentStream
Patrick Lynch, Director of Content Marketing Solutions 630-571-4070 x2210
[email protected] AL, FL, GA, MI, TN
ad index Company
Page#
RSN
Web
Maggie Hatcher, Classified oduct Mart, Media Showcase 630-571-4070, x2221
[email protected] AR, IL, IN, IA, KS, KY, LA, MN, MO,
Advantech Corporation . . . . . . . . .16A-16D . . . . . . . . . . . . . www.advantech.com
MS, NE, ND, OK, OH, SD, TX, WI,
Allied Electronics . . . . . . . . . . . . . .7 . . . . . . . . . . 5. . . . . . . . www.alliedelec.com
Central Canada
AutomationDirect . . . . . . . . . . . . . .C2 . . . . . . . . . 1. . . . . . . . www.automationdirect.com Azima DLI . . . . . . . . . . . . . . . . . . . .56 . . . . . . . . 22 . . . . . . . www.AzimaDLI.com Beckhoff Automation LLC. . . . . . .16, 55 . . . . 9, 21 . . . . . .www.beckhoff.com BLOCK USA, Inc . . . . . . . . . . . . . . .53 . . . . . . . . 20 . . . . . . . www.blockusa.com CC-Link Partner Association. . . . . .11 . . . . . . . . . 8. . . . . . . . www.G2A.CCLinkAmerica.org CFE Media’s Global System Integrator Database . . . . .13 . . . . . . . . . . . . . . . . . .www.cfemedia.com/global-si-database Control Engineering
Information Integration Research .17 . . . . . . . . . . . . . . . . . .www.controleng.com/2015InfoStudy
Bailey Rice (630) 571-4070 x2206
[email protected] AK, AZ, CA, CO, H I, ID, MT, NV, NM, OR, UT, WA, WY, Western Canada
Iris Seibert (858) 270-3753
[email protected] CT, DE, MD, ME, MA, N C, NH, NY, NJ, PA, RI, SC, VA,
Control Engineering Webcasts. . . .15 . . . . . . . . . . . . . . . . . .www.controleng.com/webcasts
VT, WV, DC, Eastern Canada
Dataforth Corp . . . . . . . . . . . . . . . .45 . . . . . . . . 16 . . . . . . . www.dataforth.com
Julie Timbol (978) 929-9495
[email protected]
eWON. . . . . . . . . . . . . . . . . . . . . . . .10 . . . . . . . . . 7. . . . . . . . www.ewon.us EZAutomation. . . . . . . . . . . . . . . . .Bellyband . . . . . . . . . . . www.EZAutomation.net FORCAM . . . . . . . . . . . . . . . . . . . . .57 . . . . . . . . 23 . . . . . . . www.forcam.com Global System Integrator Database Featured Integrators . . .21 . . . . . . . . . . . . . . . . . .www.controleng.com/global-si-database HANNOVER MESSE . . . . . . . . . . . .52 . . . . . . . . 19 . . . . . . .www.hannovermesse.events/cfemedia iDS . . . . . . . . . . . . . . . . . . . . . . . . . . 20 . . . . . . . . .11 . . . . . . .www.ids-imaging.com/usb3 KepwareTechnologies . . . . . . . . . .1 . . . . . . . . . . 2. . . . . . . . www.KEPWARE.COM Load Controls Inc.. . . . . . . . . . . . . .47 . . . . . . . . 17 . . . . . . . WWW.LOADCONTROLS.COM Moore Industries - Intl. Inc. . . . . . .4 . . . . . . . . . . 4. . . . . . . . www.miinet.com Moxa Technologies . . . . . . . . . . . . .3 . . . . . . . . . . 3. . . . . . . . www.moxa.com Phoenix Contact . . . . . . . . . . . . . . .50 . . . . . . . . 18 . . . . . . . www.phoenixcontact.com/GoMesse Red Lion Controls . . . . . . . . . . . . . .37 . . . . . . . . 15 . . . . . . . www.redlion.net/IIoT Sealevel Systems Inc . . . . . . . . . . .19 . . . . . . . . 10 . . . . . . .www.sealevel.com SEW-EURODRIVE, Inc. . . . . . . . . . .C4. . . . . . . . 29 . . . . . . . www.seweurodrive.com Teledyne DALSA . . . . . . . . . . . . . . .9 . . . . . . . . . . 6. . . . . . . . https://goo.gl/efflC9 TRACO POWER. . . . . . . . . . . . . . . .24 . . . . . . . . 13 . . . . . . . www.tracopower.com Turck Inc. . . . . . . . . . . . . . . . . . . . . .23, 25 . . . . 12, 14. . . . . .www.turck.com Yaskawa America, Inc. . . . . . . . . . .C3 . . . . . . . . 28 . . . . . . . www.yaskawa.com
Inside Process
Emerson Process Management. . .P2 . . . . . . . . 24 . . . . . . .www.emersonprocess.com/operationsperformance Maple Systems Inc . . . . . . . . . . . . .P6 . . . . . . . . 26 . . . . . . . www.maplesystems.com WAGO Corp. . . . . . . . . . . . . . . . . . .P4 . . . . . . . . 25 . . . . . . . www.wago.us Winsted Corporation . . . . . . . . . . .P8 . . . . . . . . 27 . . . . . . . www.winsted.com
CFE Media Contributor Guidelines Overview Content For Engineers. That’s what CFE Media stands for, and what CFE Media is all about – engineers sharing with their peers. We welcome content submissions for all interested parties in engineering. We will use those materials online, on our website, in print and in newsletters to keep engineers informed about the products, solutions and industry trends. www.controleng.com/contribute explains how to submit press releases, products, images 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 c omparative tables may be accepted if non-promotional and if contributor corroborates information with sources cited.) * If the content meets criteria noted in guidelines, expect to see it first on our Websites. Content for our e-newsletters comes from content already available on our Websites. All content for print also will be online. All content that appears in our print magazines will appear as space permits, and we will indicate in print if more content from that article is available online. * Deadlines for feature articles intended for the print magazines are at least two months in advance of the publication date. Again, it is best to discuss all feature articles with the appropriate content manager prior to submission. Learn more at: www.controleng.com/contribute
REQUEST MORE INFORMATION about products and advertisers in this issue by using
the http://controleng.com/information link and reader service number located near each. If you’re reading the digital edition, the link will be live. When you contact a company directly, please let them know you read about them inControl Engineering. www.controleng.com
CONTROL ENGINEERING
MARCH 2016
|
71
BACK TO BASICS tutoria l on PLCs
Ladder logic 105: PLC scanning Understanding how scanning works in a programmable logic controller (PLC) is something that needs to be addressed for a user regardless of the program being used.
Almost all programmable logic controllers
After executing all code, evaluating the logic, and (PLCs) worldwide handle scanning in the same updating all of the tables (except for the input tables, way. First, the CPU reads the physical inputs into a which were written at the beginning of the scan), the memory table, usually called the “input table.” This resulting output table or register contents are written
A Figure 1: Example of a programmable logic controller (PLC) scan with a requested packet interval (RPI). Graphics courtesy: Automation Primer
3
table is then used program evaluated. physical outputson (Figure 1). are different typesasofthe registers thatis are used inThere dif- to the How long depends the platform (speed of the ferent platforms; these registers are updated as the processor), how much code is in the program, and logic is processed left to right on each rung and top the types of instructions used. Sometimes programto bottom within each routine. This includes updat-mers will use loops in the program or make repetiing an output table, which will later be used todrive tive calls to the same routines. All of this effects total the physical devices connected tothe PLC. scan time. Documentation usually isavailable indiThe program might call different subroutines forcating the execution time for different instructions, different purposes; order can be important. Depend-but there’s no point in trying to addthem to estimate ing on where memory registers and output tables arelength. It is simply available for reference. updated, the physical outputs could be delayed by up Scan time can take as long as 80 ms. If the scan to two scans. In either case, the program meanders time is longer than about 50 ms (for a machine conthrough different routines as they are called before trol project) then the usershould seek a more powreturning to wherever they were called from and erful processor or ways to make the code more eventually ends up at the end of the srcinal cyclic efficient. Beyond 50 ms, the effect on output reacroutine. Most programs use an initialcyclic routine tion for a machine control project starts to be noticeused to call all other routines. Some programs run able; for process control, this may not matter. periodicallyinstead of continuously . Most use a conIn Figure 1, the scan time is shown as 56 ms in tinuous program that runs as fast as it can. this rather large program. While scanning works the
1
1.
Write physical inputs to input table
C
2.
B
3.
Write output table to physical outputs
Example scan Time = 56ms
A
2
Solve logic left to right, top to bottom, updating all tables
A
B C
- 20ms - 40ms - 60ms Output 1
MORE
S
ADVICE
Output 1
KEY CONCEPTS Almost allprogrammable logic controllers (PLCs) handle scanning the same way. The lengthof a PLC scan depends on the platform and whether it is for a machine control project or a process control project. GO ONLINE See more stories from Frank Lamb at www.controleng.com. CONSIDER THIS What programdo s you use for a PLC scan and what challenges have you encountered that aren’t mentioned in this article? 72
|
MARCH 2016
CONTROL ENGINEERING
Output 2
Output 1 R
way described for every platform, this is an exception (shown by A, B, and C).This platform works on a producer-consumer model where input cards produce information for CPUs, and the CPU produces information for the output cards. The CPU can then be said to “consume” information, and the output cards consume information fromhe t CPU. The production and consumption of information is scheduled within each input/output (I/O) card by setting what is known as a requested packet interval (RPI). RPI is set at 20 ms (A) in Figure 1; the program will get a couple of updates from the physical inputs each scan and will update the physical outputs twice per scan also. This is typical for digital I/O; analog inputs are usually set at 100 ms or more and also usually are updated more slowly than digital. Updates happen at different points within the scan cycle, which varies in duration quite a bit. Figure 2 is from a training manual that asks: “Will output 2 ever turn on?” There are three common answers: It will never turn on, it will always be on, or it will briefly flicker every scan. See this article online to find out the answer. ce
Figure 2:Example from a training manual that asks whether Output 2 will ever turn on.
Frank Lamb is the
founder of Automation Consulting Services Inc. Automation Primer is a CFE Media content partner. Edited by Chris Vavra, production editor,
[email protected]. www.controleng.com
ENTER THE MATRIX Using complicated systems for low harmonics or power regeneration? Try the efficient way with the U1000 Industrial Matrix Drive. Our greenest drive ever, the U1000 goes beyond the performance of conventional drives. Enjoy extremely low harmonic distortion and regeneration in a space-saving design, completely without the need for additional components.
12/18-PULSE SYSTEM
U1000 INDUSTRIAL MATRIX DRIVE 12/18-Pulse Transformer
Input Fuses
Standard Drive
ACTIVE COMPONENT SYSTEM
U1000
Input Fuses
LC Filter
Active Rectifier
Standard Drive
input #28 at www.controleng.com/information
For more info: http://budurl.me/YAI876
YASKAWA AMERICA
DRIVES & MOTION DIVISION
YASKAWA.COM
1-800-YASKAWA
The key to productivity... Stop wasting valuable time on the phone or fumbling through catalogs, price books and emails to specify a gear unit for your pump. Simply go online to the PT Pilot® selection tool from SEW-EURODRIVE! PT Pilot® quickly provides quotes, parts lists, 3D CAD drawings, motor options, gear options andvariable frequency drives with just afew keystrokes. It is also compatible with smartphones andtablets. So, you can literally obtain animmediate quote at your fingertips anytime, anywhere!
seweurodrive.com / 864-439-7537 input #29 at www.controleng.com/information
