Digital supplement to
Technology Handbook
CONNECTED MANUFACTURING A look into the products, technologies and solutions shaping the market
Technology Handbook | CONNECTED MANUFACTURING
See How Hollywood Sees Modular Connectivity
HARTING announced a newly developed short film to reintroduce their Han-Modular® product line to the industry. The protagonist of this new 90-second movie is an engineer who is struggling with a design. The solution is HARTING’s Han-Modular® series which is illustrated as a robot that transforms as the engineer’s design changes. The film was developed with a Hollywood agency based in Chicago, IL. “We wanted to do something different, something that the industry hasn’t seen before,“ said Christina Chatfield, Vice President of Marketing Communications and Digital Transformation of HARTING Americas, „At the same time, we wanted to do something that would excite and inspire engineers. We knew we had to do something big.“ This film marks the beginning of a new marketing campaign for the
product that focuses on the benefits of the product line, which includes space-savings, design flexibility, IIoT compatibility, and low-maintenance for the end user. “Han-Modular® is a very important product for the industry,“ said Cory Jenkins, Director of Product Management of HARTING Americas, „It was developed in 1996 with 6 modules. Now there are over 100 modules, and HanModular® remains our fastest growing product line.“
About HARTING The HARTING Technology Group, family owned and based in Germany, employs more than 4,300 people globally with subsidiaries and branch offices in 40 countries. With production facilities in Europe, Asia, Mexico and the United States, the Telephone 1 (855) 659-6653
HARTING.ca 2 MANUFACTURING AUTOMATION · Technology Handbook Connected Manufacturing
HARTING portfolio of connectivity solutions focuses on multiple levels, from the machine to the device and into the communication infrastructure. The U.S. facility in Elgin, Illinois is one of three HARTING locations that manufactures the HIS product line (HARTING Integrated Solutions - backplanes) and custom cable assemblies. HARTING also has custom cable assembly capabilities in Mexico and Brazil. The company’s core business is intelligent and highperformance connection technology. HARTING works in almost all industrial markets with a focus on requirements for robust, reliable connectivity solutions. To view the film and learn more, visit Han-Modular.com
“Industrial Transformation Begins Here...” - Han-Modular® The biggest transformation the industry has never seen before
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Combine Different Media into One Customizable, Plug & Play Connector Solution Space-savings. Flexible. Low-Maintenance. IIoT-Capable. ■ See how you can save cost and time by downloading the Han-Modular® app.
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■ Free up your time by taking advantage of HARTING’s assembly business.
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Technology Handbook | CONNECTED MANUFACTURING
Smart Manufacturing by The Future of Automation The digital age of manufacturing continues to transform businesses, companies, and processes. As more and more internet-connected devices are installed around the world, use of data and analytics will become crucial for business leaders to make informed decisions, reduce downtime, and improve overall plant efficiency and productivity. To stay relevant in the market, businesses are left no other choice than to adapt to this reality. Industry 4.0 and the Industrial Internet of Things (IIoT) are keywords often linked to smart manufacturing. Industry 4.0 stands for vertical & horizontal networking in product and business processes, both within companies and between different companies. In Industry 4.0 models, physical and software components are intertwined to monitor factory processes and make decentralized decisions. The physical systems become the IIoT, communicating and working cohesively with each other and with personnel in real time through the internet. Smart manufacturing offers new ways for decision-makers to optimize their facilities by increasing machine lifecycles and decreasing downtime. While traditional manufacturing used historical data to forecast operations, smart manufacturing uses real-time data. Process data such as temperature, distance, proximity, and flow rate can be collected from smart devices during machine operation and used to identify issues before they pose larger problems. Furthermore, data collected such as wrong sensor, open circuit, overload, and dirty lens provide greater visibility into existing processes and systems. Operators can now collect and filter
the data, enabling them to quickly troubleshoot and repair problems that arise.
Sensors That Can Communicate Sensors deliver the big data for the business models of the future, and IO-Link unlocks the full potential of sensors. This open standard paves the way for digital networking by enabling seamless communication and digital data transfer from the control level right down to the sensor level. IO-Link enables access to process data, service data, and event data from sensors. Remote configuration and monitoring, extended diagnostics, and ease of integration are just a few of the key benefits. Damaged sensors can be easily identified and sensor settings can be changed, dynamically reducing downtime and improving
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machine efficiency. IO-Link also makes it possible to store parameters for simple device replacement. If a sensor fails, seamless replacement is possible, getting the new device up and running as quickly as possible. Pepperl+Fuchs offers an end-to-end IO-Link system solution, including a wide range of IO-Link sensors and an Ethernet IO module with integrated IOLink master. This combination facilitates seamless communication between the IO-Link devices at field level and higher-level systems at management and control levels.
Danius Silgalis Product Marketing Manager, Intelligent Systems
dsilgalis@us.pepperl-fuchs.com
Driving standardization. Eliminating complexity. Maximizing performance. Ethernet IO Modules with IO-Link Master One module supports multiple Ethernet
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www.pepperl-fuchs.com/fieldbusmodules
Technology Handbook | CONNECTED MANUFACTURING
HMI WITH CODESYS 3 PLC AND VISUALIZATION
The TX500-HMIs provide masters for the most important industrial Ethernet protocols
TX500 HMI PLCs have high-end touch displays and fast processors, these HMIs are ideal for use in smallto medium-size machines whose processes have to be controlled, displayed and operated locally. Each TX500 is equipped with a PROFINET master and EtherNet/IP scanner, as well as a Modbus TCP and Modbus RTU master. The HMIs can also be run as field devices for both Modbus protocols. Codesys3 allows the lean and simple programming of the PLC and visualization functions. The latest processor technology in the units guarantees the smooth handling of computing intensive processes such as moving image visualizations.
The high resolution TFT display with 64,000 colors enables attractive and high performance of graphics and animations, and the front panel is protected to IP66. Two RJ45 Ethernet ports, a serial interface for RS232 or RS485 as well as two USB ports are provided on the terminal side. An additional SD card slot makes it possible to expand the 128 MB internal data memory. Turck is offering the TX500 series in three variants with different display sizes and resolutions: two 16:9 displays with 7” or 13” (TX507 and TX513) diagonals and one 10” device in 4:3 format (TX510). The two smaller displays offer 800 x 400 pixels, while the large TX513 comes with 1280 x 800 pixels.
Call 1-877-513-7769 or visit turck.ca 6 MANUFACTURING AUTOMATION · Technology Handbook Connected Manufacturing
Your Global Automation Partner
Your productivity is priority number one at Turck. Keeping your automated operation running at peak performance with maximum up time is our mission. We do it by providing an extensive line of durable, dependable products and unsurpassed customer service and support. Turck Works!
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Technology Handbook | CONNECTED MANUFACTURING
Hot Swap Tool Change Connectivity Made Easy by Murrelektronik
W
hile visiting the Hannover Automation Fair, Kevin Lay, a Controls Specialist with Global Vehicle Systems (GVS), was introduced to Murrelektronik’s Modlink Vario System. Our Modlink Vario System was being used to connect and disconnect airlines and I/O signals to different tools during changeovers. Kevin also had the opportunity to see Murrelektronik IOLink products in action. GVS is a company that designs and builds custom automated manufacturing equipment for various industries including automotive. Shortly after Kevin arrived back in Canada, GVS was commissioned to design & build a new machine that required three interchangeable fixtures. The three fixtures required various combinations of I/O from 16 to 48 points, as well as some air-lines. Although GVS had built many tool/ fixture change type machines before, Kevin wanted to design a more robust way to (a) identify the different fixtures and (b) reliably connect and disconnect the air-lines and I/O to the fixtures during tool changes. Over the next few weeks, Kevin worked closely with Murrelektronik Canada to design the improved tool
change connection system for the new machine. For connectivity of the I/O back to the PLC, an EIP version of the Impact 67 I/O Module with IO-Link was chosen. The Impact 67 IOL module has four standard I/O ports and four IOLink Master ports. Three of the IOLink ports were used to connect to the 16-point IO-Link hubs installed on the fixtures. Some of the key benefits of using the 16-point IO-Link hubs include: • Faster fixture changes for the end-customer • Simple 3-wire connection from the hubs to the main Impact 67 I/O block • Hot-swap reconnection of I/O signals during tool changes without disconnecting the network • The ability to use the “Device ID” attribute on the IO-Link hubs to identify the fixtures • Substantial cost savings over using multiple EIP I/O modules on each fixture The Modlink Vario system was chosen because of the flexibility it would give Kevin to connect air and I/O in a single unit. The 8-port version that GVS used enabled them to combine different combinations of air hose and M12 inserts in the same housing. And
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just in case you’re wondering, the air hose inserts include auto-shutoff valves on both sides of the connector so there’s no air blow-off when disconnected. As you can see in the photos (Figure 1), GVS needed 8 air lines to the fixtures so they ended up using two Modlink Vario connector systems side-by-side. By combining Murrelektronik’s Modlink Vario system with a single Impact 67 IO-Link module and some IO-Link hubs (Figure 2) on the fixtures, GVS were able to simplify and reduce the cost of the I/O system while increasing the reliability of the air and I/O connections during tool changes. GVS were also able to use the Device ID attribute of the IO-Link hubs to identify and confirm which tool is connected and are now confident they have found the solution for that age-old problem of reliably disconnecting and reconnecting air-lines and I/O during tool changes. Murrelektronik products used: Modlink Vario, Impact 67 IOL, IOLink Hubs, Cables & Connectors. To learn more about Global Vehicle Systems visit http://www.globalvehicle.ca Written by Colin Cartwright – Murrelektronik System Sales Manager
CONNECTIVITY SOLUTIONS From the Technology Leader
Plug and Play with
MURRELEKTRONIK IO-LINK! ¡ 4 IO-Link Ports Version 1.1 Class B Ports ¡ Integrated webserver and easy IOL set up ¡ IO Link Channel Fault Protection = Single channel shutdown with short circuit ¡ IO Link ports can also be high current (1.6amp) digital IO ¡ 4 channel power available = North American Standard
MODLINK VARIO ¡ M12 - sensor cable (5, 8 pins) ¡ Cube 67+ compatibility ¡ Fieldbus B and D coded ¡ Integrated shielding ¡ Integrated seal ¡ Simultaneous coupling of media and electrics ¡ Hose diameter 4, 6, 8, and 10 mm ¡ Up to 16 bar/-0.8 bar (vacuum) ¡ Drip-free coupling under pressure ¡ Assembly without tools
MURRELEKTRONIK CANADA Head Office (Ontario): 1 905-362-2211 Quebec & Maritimes: 1 514-461-7282 * info@murr.ca à www.murr.ca
CONNECTED MANUFACTURING
ENTERING THE IIOT to start. However, experts suggest that by taking some small first steps, manufacturers will begin to see results.
Critical first steps to achieving results in the Industrial Internet of Things BY MARY DEL CIANCIO
T
he Industrial Internet of Things is on track to revolutionize the manufacturing industry. Using sensors, software and other advanced technologies to accurately capture and communicate data from the plant floor promises to decrease costs and downtime for manufacturers, increase quality and savings, and make them much more efficient. The advantages are
clear. Yet many manufacturers have been slow to adopt the technology that will give them these results. Why? The Industrial Internet of Things, also called the IIoT, is still in its infancy. Jumping on board requires an investment and, because it’s an emerging space, it’s difficult to determine the ROI. With so much excitement surrounding the IIoT, many simply don’t know where
$195B The IIoT market was valued at US$113.71 billion in 2015 and is estimated to reach US$195.47 billion by 2022, according to a MarketsandMarkets report.
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Getting started The IIoT is no different than the journey manufacturers have been on for years, explains Paul Farrell, senior vice-president of product marketing with NetSuite, likening the IIoT to Lean manufacturing and a company’s efforts to add value and remove dead costs. Like Lean, it’s about driving quality and driving cost effectiveness, he says. With that in mind, the first step is to look at where the value is going to be added, and what you want to accomplish. Do you want to reduce costs, reduce waste, increase productivity, increase efficiency?
For companies that can gain value from the IIoT, they will be at a competitive disadvantage over time if they fail to adopt technology. It will become more difficult for businesses that are in the IIoT space to work with them, and they will also be less efficient than their competitors.
IIoT space who provide frameworks and technologies to help businesses get started, says Farrell. Manufacturers should do their research and carefully consider partnerships and solution providers that can help them along their journey.
It’s not for everyone Where are the areas within your facility that you can gain the most benefit from the IIoT? Perhaps it’s driving real-time scheduling, optimizing maintenance schedules or parts ordering. Maybe it’s managing capacity, catching quality issues or reducing waste. “There is a massive amount of opportunity out there for companies to become a lot more efficient and a lot more effective,” Farrell says. “Look at where you need to add the value, or where you think it’s going to take out the cost, and concentrate on doing that.”
Agree on the goal Success in the IIoT space requires co-operation between the interested parties within a company. What they are trying to achieve and how they are going to achieve it must be agreed upon at the beginning, explains Aiden Mitchell, the vice-president of IoT global sales for Arrow Electronics. Mitchell participated in a recent panel discussion at the Harting Business Conference (HBC) that discussed how to make the IIoT a reality today. “The guys who run the operations, who run the factory floor, have typically had a pretty closed-loop, tight working environment for years. The last thing they would ever want is to let an IT guy into the middle of it,” explains Mitchell. “But now that you’re talking about data coming off their shop floor and going into some ubiquitous data environment in the Cloud, you’ve really got to get them aligned in terms of how that is going to work.” An IT lead must be involved in the discussion from the start, he says. Otherwise, you go through a lot of gyrations in the definition of what the customer is seeking to achieve, wasting precious time.
Key considerations In these early discussions, there are
several key factors to consider, and important decisions that need to be made. First, explains Farrell, think about how you are going to connect your machine to the IIoT. What sensors and software are you going to use? What is the protocol? What is the network? If you have legacy equipment, how are you going to bridge that serial to digital divide? Second, consider how you are going to gather the huge amount of data coming from your equipment. Is the data streamed, sent on an event or sent at a certain time? Where are you storing it? Is it a Cloud solution or are you building the infrastructure to deal with the data locally? And third, think about how you are going to analyze the data and make sense of it. Is your system of record, ERP software or MES open enough to action the data that comes in from the IIoT? The concern for many manufacturers is that the IIoT is still evolving. Standards are emerging and technology is rapidly advancing. “There are many companies working on producing solutions that will simplify the ability to connect, integrate, analyze, understand and optimize,” explains Farrell. “There is a massive amount of investment here, so we will see standards and simplification emerge over the next couple of years.”
Find the right partner It’s a team effort, and partners — whether vendors or system integrators — play a large role in the IIoT. A good partner can make recommendations on the best products to meet the application’s requirements. After all, having the right solution that makes sense for the application is critical, explains Nick Hassan, the director of the advanced development group at Texas Instruments, who also participated in Harting’s HBC panel discussion. Indeed, there are companies in the
While the IIoT holds a lot of promise for many manufacturers, it may not be right for all, Farrell says. For example, the food and beverage industry is one market that can gain a lot of value from the IIoT because there is a great deal of information regarding quality, temperature and other variants that are gathered throughout the manufacturing process. But for a company that is assembling two components together quickly and easily, there may be less advantage, he says. “Don’t think, ‘I have to go and get IIoT implemented or I’m going to fall behind,’” explains Farrell. Instead, think, “Is it going to add value to your processes? There are some industries that are very machine intensive that absolutely it can. But if you’re not in an industry that is, then is it going to add that value?”
Walk, don’t run For companies that can gain value from the IIoT, they will be at a competitive disadvantage over time if they fail to adopt technology. It will become more difficult for businesses that are in the IIoT space to work with them, and they will also be less efficient than their competitors. But that doesn’t mean companies should do everything at once. “There’s lots of noise out there about [IIoT] and...the fantastic things it’s going to be able to do for you. But this should be no different than any other project that a manufacturer does when it’s looking at where the value is,” says Farrell. “Take key projects, implement them, retrieve the value...and let’s get a real robust ROI behind it.” Take it one, small step at a time, he suggests. “Walk the pace rather than run.” | MA Mary Del Ciancio is a business writer who has been covering industrial topics for more than 15 years. She is the former editor of Manufacturing AUTOMATION magazine.
Technology Handbook Connected Manufacturing · MANUFACTURING AUTOMATION 11
CONNECTED MANUFACTURING
BETTER DATA DELIVERED How the IIoT is revolutionizing the manufacturing plant BY KAY JENKINS
A
sk any number of plant executives what their greatest pain point is and chances are ‘inefficiency’ will be a common response. Executives are expected to produce more with less, cutting out time-consuming practices while maintaining optimal customer service. The problem is this strategy often fails to factor in downtime and inefficiencies out of the crew’s control. But what if we could transform the plant manager into a pseudo-psychic,
addressing equipment failures days, or even weeks, before they interrupt operations? To some extent, the Industrial Internet of Things (IIoT) has already made this possible by providing deeper access to critical data. But soon, the IIoT will deliver a level of data analysis that will radically change the way we approach plant operations. It’s no wonder the IIoT market is expected to reach more than US$900 billion by 2025, according to a 2017 Grand View Research study. The answer to how IIoT will affect your plant lies in how you manage data.
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Take a closer look at what the IIoT means for your maintenance operations and, ultimately, your bottom line. The data doesn’t lie Before the IIoT, maintenance looked backward instead of forward — responding to machinery errors after they happened. Data capture gave the maintenance team an idea of what went wrong, but this information was only available after the fact. Plants could be saddled with costly repairs on top of the revenue already sacrificed to downtime.
The benefits of an IIoT-enhanced plant touch all corners of the operation. The IIoT has helped refocus maintenance priorities on prevention. Sensors located on critical machinery talk to the plant’s Enterprise Asset Management system through a Predictive Maintenance Module (PdM). These sensors learn what optimal operation feels like, so as a critical part begins to malfunction, they can alert the crew while it is still functional. By isolating maintenance data from operational data, the PdM declutters information, helping the plant manager make a more informed decision on how to approach preventive maintenance. The benefits of an IIoT-enhanced plant touch all corners of the operation. Your maintenance team can reduce the amount of time it spends identifying errors, which in turn increases productivity and may be able to repair parts rather than replace them, slashing the maintenance
budget. Your operations staff doesn’t spend their workday waiting for an outof-commission machine to come back online. Your management faces fewer roadblocks in the quest to meet everincreasing customer expectations. Much like how AI-enabled assistants have already simplified our everyday tasks, IIoT-enabled technology will help cut down on redundant processes and resource-consuming repairs. As IIoTenabled devices become more affordable and pressure for greater efficiency rises, there is no better time to invest in a connected plant. Where do I start? If you’re interested in implementing IIoT-enabled tech, you’ll need to do some background work first. Consider these three steps to gain better data: • Determine your pain points Spend a few days examining every plant process and observe the machinery in action and speak with its operators. Gathering this information helps you make a more informed decision during the buying process. You want to make sure your IIoT investment is right for your unique problem. • Prioritize areas for IIoT implementation Create a roadmap for IIoT imple-
mentation and start with the pain points that need to be addressed immediately. Ensure your initial sensors are placed on machinery that malfunctions irregularly or require the most time to repair. • Consider moving to the Cloud If you’re looking to implement IIoT on a budget, maintaining advanced technology in-house will be costprohibitive. Whichever solution you choose to interpret your IIoTenabled devices, Cloud-based Enterprise Asset Management systems are cheaper to implement and can turn around data analysis faster than onsite solutions.
Investing in efficiency It won’t be long before IIoT is a plant standard — demands on production will be too great to function without it. The good news is IIoT is now prevalent enough that upgrading your plant is an affordable process. If you need to glean more information from your operational data, it’s time to consider how IIoT-enabled devices can improve your processes. | MA Kay Jenkins is business leader at AssetPoint, where she directs the software developer’s TabWare EAM solution, as well as parent company Aptean’s Axis ERP and Activplant MES solutions. Prior to her current role, she served as AssetPoint’s EVP of Research and Development for 13 years.
Technology Handbook Connected Manufacturing · MANUFACTURING AUTOMATION 13