WHAT’S A DIGITAL TWIN?
SHAKE HANDS OR THROW HANDS?
EU draws the line on cybersecurity
What component manufacturers, integrators and users need to know about the Cyber Resilience Act and its requirements
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cover story EU draws the line on cybersecurity What component manufacturers, integrators and users need to know about the Cyber Resilience Act and its requirements
Stephen Mitschke, FieldComm Group; Martin Rostan, EtherCAT Technology Group; Holger Zeltwanger, CiA; and Joakim Wiberg, ODVA
machine input
Digital twins affect drive technology
How digital natives and frequency inverters drive energy efficiency
Mike Bacidore, editor in chief
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Huffman Engineering uses core values to steer system integration for more than 40 years
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shake hands or throw hands? Can
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Industrial communications require reliable components
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COLUMNS
7 editor’s page
Modular reactors could power data centers
Mike Bacidore, editor in chief
8 embedded intelligence
How to balance safety and throughput
Jeremy Pollard, CET
9 technology trends Fundamentals of position feedback
Rick Rice, contributing editor
11 component considerations
Make a cable blueprint to avoid rework
Tobey Strauch, contributing editor
34 live wire
Select the right enclosure for fanless IPCs
Joey Stubbs, contributing editor
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Modular reactors could power data centers
THE FIRST RECOGNIZED data center was located at the University of Pennsylvania. The 300-sq-ft facility was home to the Electronic Numerical Integrator and Computer (ENIAC) in the 1940s.
Fast forward 80 years: Data centers are popping up like crocus shoots emerging from the soil. More than 4,000 of them are in operation in the United States alone, a third of those in Virginia, Texas and California, according to Pew Research Center. And 1,000 more are under construction.
Each data center houses from 500 to 5,000 servers.
Cloud computing and data mining have spawned the need for hyperscale data centers, which typically host more than 5,000 servers, some with a footprint of over a million square feet. The artificial intelligence (AI) boom has accelerated that demand.
SMRs. Rolls-Royce SMR is a subsidiary of Rolls-Royce whose investors include U.S.-based Constellation Energy and the Czech utility CEZ Group.
While more than 70 SMR projects exist at various stages globally, most of them in North America and Europe, the only operational SMRs are in China and Russia, according to data from the World Nuclear Association’s tracker.
The surge in energy demand, due in part to an increase in the number of data centers and the interest in artificial intelligence, has incited companies to investigate alternative energy supplies, which include small modular reactors, which can generate around 300 MW per module.
More than 70 SMR projects exist at various stages globally, most of them in North America and Europe.
While the footprint of these facilities can be massive, even more noteworthy is the amount of power they consume. AI-optimized servers with highperformance computing (HPC) nodes can draw thousands of Watts, according to data from Socomec USA, which supplies industrial equipment for the power market. And server operation only accounts for half to three-quarters of a data center’s power consumption.
Driven by that same AI demand and grid insufficiencies, almost 50 U.S. data centers, at last count, are building their own behind-the-meter power stations, often using natural gas as the energy source. That could soon change swiftly, with many small modular reactor (SMR) projects slowly increasing in number.
Yokogawa Electric has entered a strategic relationship with Rolls-Royce SMR to deliver a data processing and control system (DPCS) for its small modular reactor (SMR) program. The agreement covers the provision of control systems for the first units in a global fleet of Rolls-Royce
The scope of the agreement between Yokogawa Electric and Rolls-Royce SMR includes design engineering, validation and qualification, product hardware, building and testing the system, installation and commissioning.
The project will be delivered and supported from Yokogawa’s U.K. office and design facility, alongside work in the Czech Republic and the Netherlands.
Rolls-Royce SMR has been selected as the preferred bidder by Great British Energy – Nuclear (GBE-N) to build the United Kingdom’s first SMRs, by European utility CEZ to build up to three GW of nuclear power in the Czech Republic and is one of two companies to reach the final stage in Vattenfall’s process to identify Sweden’s nuclear technology partner.
GBE-N has announced that Wylfa on Ynys Mon was selected as the site for the United Kingdom’s first SMRs, delivering up to 1.5 GW of low-carbon energy to the grid, supporting the United Kingdom’s net-zero goals and creating significant economic benefit with 8,000 long-term jobs across the United Kingdom. In October 2024, Rolls-Royce SMR announced a partnership with CEZ to deploy up to 3 GW of electricity in the Czech Republic using Rolls-Royce SMR power plants.
embedded intelligence
Jeremy Pollard jpollard@tsuonline.com
How to balance safety and throughput
THE SPACE SHUTTLE had three computers and needed a twoof-three voting system to determine if a sensed variable was real or phantom. This would be a good thing regarding a leaking door seal on the capsule. There are currently many options for creating a safety system for automation instead of the old approach of a master control relay (MCR) circuit. Technology has advanced almost to the point that safety strategies are as important as the control strategy. A safety system has to protect people and machinery during the execution of the process.
I was in charge of the automation systems for a retailer in 1.7 million sq ft distribution system—lots of blind spots and moving parts. Part of the system was a conveyor that brought pallets of goods into a building called a high-bay where automated storage and retrieval system (ASRS) cranes picked up said pallet and deposited it in racking at a pre-determined location.
tivated, the user has to rotate the button head to reset it.
One of the technologies used in safety systems is dualchannel redundancy. There is a low-voltage signal that is passed through the devices to indicate that it is able to perform the required function when acted upon. In the case of a safety e-stop, if a contact block falls off due to vibration or an overzealous operator, the safety system will fail, and the automation control will stop.
The door sensor was removed from the door and tie-wrapped to the receiver.
There are many sensor devices that qualify for use in a safety system. One device we tried to use was called the “eye in the sky.” While unsuccessful, due to production constraints, the intended use was to detect movement within a certain physical area, such as a person walking. It was part of the PSR for the project and had to be officially removed from the PSR since it adversely affected the process.
As part of the project to implement this functionality, a new wrapper was installed. The project required that a pre-start health and safety review (PSR) be completed by a consultant. The operator station was in an office with a door that led to the inspection station for the incoming pallet.
The PSR stated that a safety switch be integrated with the full conveyance system so that, if an operator opened that door, the full conveyance system would come to a halt. This created major issues for the automation because of timeouts and product flow. Productivity suffered greatly.
I’m sure you can figure out what happened next. Yep, the door sensor was removed from the door and tie-wrapped to the receiver so that the issue of stoppage was removed.
Sensor technology for safety encompasses various devices. Part of the mindset for safety is the need for redundancy. A standard mushroom head emergency-stop (e-stop) button in automation would have one normally closed (NC) contact, which when pressed would shut down the system. It was typically used as a stop function as such.
An e-stop button has two NC contacts wired internally so, if one fails, the other contact will sense the act of being pressed and shut down the system. Once that function is ac-
Standard devices and strategies such as e-stops, limit devices, guard-locking switches and light curtains, to name a few, all exhibit the same level of functionality with dual-channel redundancy. These devices will connect to a safety PLC or relay, which will interface with the automation control system. One way to let the automation know that an e-stop has been set is to set an output in the safety system to act as an input to the control system. A second option would be to add a normally open (NO) contact block to the safety device and wire it into the control PLC.
Doing this, however, removes the redundant signaling from the safety PLC to the control PLC. There is a good possibility that the safety system can communicate to the control system over a network, and the full array of safety device status can be made available to the control system, human-machine interface (HMI) and supervisory control and data acquisition (SCADA) system.
Safety is required, and, to be clear, is needed to do its job, but be careful to not to overprotect.
JEREMY POLLARD, CET, has been writing about technology and software issues for many years. Pollard has been involved in control system programming and training for more than 25 years.
Rick Rice contributing editor rcrice.us@gmail.com
Fundamentals of position feedback
IN THE WORLD OF AUTOMATION, it is commonplace to find some sort of position feedback on pretty much every design. Often, the feedback is static in the form of a limit or proximity switch, and this suits many applications. However, sometimes we want to know about the places in between the goal posts. The points along the way can be achieved in several ways. If it is just a few points, we might add additional sensors at appropriate positions but, if those points might change depending on operation, then a more dynamic way to determine position would be appropriate. This might come up when the speed of the movement might require anticipating the position rather than a definite position that is the same, regardless of speed.
in flexible materials but may be limited by length of motion.
A more common way to represent is to monitor the driving device—for example, a motor-driven linear actuator, where we use an encoder mounted to the motor to represent the relationship between motor turns and linear travel of the actuator. In a similar manner, an encoder mounted on a conveyor can translate rotations into linear travel.
On a larger scale, a motor-mounted encoder where the motor has a gearbox can represent the travel of the driven device, like a robot arm or similar device.
Each package has a barcode that needs to be read to determine the destination of the package.
It might also come up if the controlled device only has two options—fully open or fully closed, extended or retracted. While the controller might issue a command to open and one might use sensors to indicate when it is closed, half-open and open, for example, ultimately that device is going to go to full open and stop when the commanded travel reaches the physical limit. Converting motion into an electronic signal is achieved by using an encoder.
There are two main types of encoders, absolute and incremental. The output of an absolute encoder represents the current angular position of the shaft. The position is retained during a power cycle. An incremental encoder, on the other hand, provides output based on the relative position of the shaft. With no particular starting point, the incremental encoder presents the motion of the shaft and that value can be used to represent position, speed and distance. It is important to understand that incremental encoders do not retain their value through a power cycle.
One way to convert linear position or displacement is to convert motion into a proportional electrical signal using a linear variable displacement transformer (LVDT). Highly accurate, this device uses a contactless, electromagnetic transducer to convert position into an ac or dc value. This lends itself to applications like a linear cylinder or to measure properties, such as stress, tension and compressibility,
Encoders have evolved greatly over the years. I remember early encoders that provided individual wires for each bit in the resolution of the encoder. Code in the PLC would convert the incoming signals into a Gray code integer that could be used for position indication. Patented by Frank Gray, the method ensures that only a single bit can change between consecutive numbers to eliminate spurious results. For example, if the binary signals from an encoder represented 00000010, one would expect 00000011 to be the next number so we would not expect to see 00100011.
In the ensuing years from the early 1990s to 2010 or so, many programmable logic controller (PLC) manufacturers came out with instructions that automatically applied the Gray code by mapping the input points into an instruction that produced the Gray-coded value without hard-coding the process. Encoders still use Gray code to maintain accuracy and stability, but we are lucky, in that most encoders communicate on a fieldbus, and we can access registers to give us position and speed, as well as the ability to change the relationship between the encoder counts and the driven device, including considerations for gearbox and pulley ratios, if they exist, via the encoder interface on our programming device.
We can also change the resolution of the encoder and even change it from linear to angular. This last feature is very useful for applications with machinery where we traditionally relate one machine cycle to be 360° of rotation. Timing of the various machine functions can then be
technology trends
activated using a direct value or, more often, a window of activation during a machine cycle. This method can also be used to have a device activated more than once in a cycle, like lobes on a cam shaft.
Carrying the use of an encoder further, we can program an encoder to reset—pass through zero—at a different point than 360°. With a horizontal cartoner, for example, we could have four pouch-making machines feeding the cartoner. While the packing/closing cycle at the cartoner would happen within one machine cycle of 360°, the moving conveyor feeding the packages to the cartoner will be bringing product from four sources.
In order to make sure that each pouch machine only feeds into a single bucket, we would put an encoder on that infeed conveyor using pulleys to multiply the overall cycle count to four times 360°, or 1440° of revolution. With 1440° being four individual buckets of linear travel, each pouch-making machine would be prompted to insert product only during its own window of that 1440° total cycle.
tion from the scanner station, we can determine how many encoder counts relate to that physical distance in linear feet.
Each package, as it leaves the scanner station, will get an associated encoder count to represent the dropping point for the desired sorting spur relative to the starting point. When the main line encoder count reaches the proper value, the diverter at that relative position will turn on for a window of time to divert the package off into the sorting spur.
One prominent use of encoders these days is in collaborative robots. Each joint in a robot arm contains a motor, gearbox and an encoder in one package. This combination provides a high degree of accuracy allowing robots to perform precise motions to handle anything from large components down to extremely small chips in electronic devices.
Encoders have gotten faster and smarter while fitting into increasingly smaller packages.
Pouch 1 at 0-359°, Pouch 2 at 360-719°, Pouch 3 at 720-1079° and Pouch 4 at 1080-1439°. 1440° would be the same as 0°.
Another suitable application for an encoder is to perform product tracking. Let’s say we have a sortation system where we have packages travelling down a conveyor belt. Depending on the identity of the package, we want to divert the package down a specific side spur for further processing. Each identified product would be assigned to a specific lane or one could assign several similar packages to sort to a particular spur for further processing.
In this example, each package has a barcode that needs to be read to determine the destination of the package on the sorting station. As one might imagine, it would get very expensive if we had to have a barcode reader before each of the sorting spurs to interrogate each package and decide if it needs to be diverted off the main line. This is where the encoder comes into consideration.
If we locate a scanning station before the sorting station, we can use the results of each inspection to assign that product to a corresponding divert station. The encoder would be mounted on the shaft of the drive roller for the main conveying line. The relationship between the rotation of the drive roller and the linear distance traveled by the belt being driven by the roller gives us a predictable value. Applying that fixed distance to the length of each divert sta-
These examples show some of the potential uses for an encoder. As with all technologies, encoders have gotten faster and smarter while fitting into increasingly smaller packages. The earlier optical encoders were of significant diameter and could only be used in situations where there was plenty of room around the device. Commonly available encoders for industrial automation are now just 1-2 inches in diameter and with M12 connectors that allow for easy installation pretty much anywhere. Offered in shaft and hollow-shaft versions, encoders are adaptable to most applications.
While we often think of encoders as a device about the size of your palm, encoders can also be incredibly small, as used in small robotics, consumer electronics and medical devices.
Some manufacturers of variable frequency drives (VFDs) have even made versions that allow for feedback via the connection of an encoder, essentially turning a VFD into a less expensive version of a servo drive without the additional cost. These, by nature, aren’t nearly as accurate as a full-on servo application, but they can add some sophistication to movement where fine accuracy isn’t needed.
The cost of encoders and the ease of use by way of fieldbus connections make them an excellent choice for inclusion in a controls package. The potential applications are seemingly endless.
RICK RICE is a controls engineer at Crest Foods (www.crestfoods.com), a dry-foods manufacturing and packaging company in Ashton, Illinois.
component considerations
Tobey Strauch contributing editor tobeylstrauch@gmail.com
Make a cable blueprint to avoid rework
CABLE COSTS ARE NOT just related to material, but also to labor. More runs equal more labor. Longer routes equal more support fixtures, more labor and more materials. This means that, if an integrator does not pay attention to routing on an industrial line, the installation costs skyrocket. Why? The installer takes the risk that the integrator passed on. The solution is to require that routing be part of the construction drawings and completed before bid.
The other problem is rework. The integrator should have a solid design and know where components are going. Rerouting cable can be two to four times the original installation costs. Save yourself the headache, and specify routing.
paths. Reuse of trays may not be convenient in brownfield installations because, if you break a circuit while pulling cable, then there is uncalled-for downtime.
The other considerations for wiring are the type of cable, the cable housing and the protection required for the application. Distances also play a role. This means that an automation system that has a distributed network or uses cameras must be planned out due to the network cables required for the architecture to work.
A cabling hierarchy alleviates some of the problem. There are typically four levels:
Proper planning on paper reduces rework and change orders.
Additional costs to wiring installations include not just conduit but cable tray, J-hooks, sleeves for floors and walls, as well as reinforcement of tray holders. Sometimes this requires structural analysis for trays to be installed for the purpose of making sure cables will not sag or pull off the wall in long runs.
Creating a good layout and understanding where power feeds are currently makes a difference in machine location and looking at costs, as opposed to having to create new runs. Other things to consider are piping for water, HVAC duct work and other plumbing. Machines may require other chemicals or gases or drains. Understanding the context of the machine and thinking through the machine resources will make installation easier.
If the process going in requires air flow or cooling, then cable trays need to work with or around ducting. Proper planning on paper reduces rework and change orders. How do you reduce conflicts between duct work, drains and electrical cables? Have a meeting with the trades and have them review your installation drawing before signing off on the proposal. A change order during the concept phase is less costly than one during the construction phase.
Engineers also forget about the amount of a cable that can go in a tray, the size of cable and that higher voltages may cause issues with communications or cause noise for data circuits. This means deciding on tray dividers or separate
• Level 1 would be power and high-voltage or nonsensitive conductors. This is where main power feeds, variable-frequency drive (VFD) outputs, motor feeds and ac supplies would go.
• Level 2 involves moderate, sensitive signals with lowvoltage control and ac control. Relay outputs, 120-V analog control circuits and solenoid valves would be at Level 2.
• DC control and field signals involving 24-V inputs and outputs, PLC communications, and actuator signals, or level sensors, or proximity sensors would be at level 3.
• Highly sensitive data and analog signals that are susceptible to noise or distance issues or need switching such as fiber, Ethernet and 4-20 mA loops, as well as thermocouple wires would be Level 4.
Unshielded data and power should be separated by 12 inches. Shielded data may be within 6 inches of power circuits. High-voltage, long-distance runs greater than 300 V maintain more than 2 inches and a physical barrier. Metal grounded wireways are essential for data circuits to provide shielding. Using dividers can create distinct compartments. Putting power in bottom or outer trays can help to isolate. Control and data circuits should be in top or inner trays and as far from power sources as possible. It’s also important to not overfill trays. Other considerations for proper wiring are color coding and labels.
Tobey Strauch is an independent principal industrial controls engineer.
machine input
Digital twins affect drive technology
How
digital
natives and frequency inverters drive energy efficiency
by Mike Bacidore, editor in chief
THESE THREE INDUSTRY EXPERTS answered questions about drive technology and digital twins. Chase Davis is director of technology at EOSYS, a certified member of the Control System Integrators Association. Alexandre Coimbra is senior packaging engineer at Nefab. Craig Nelson is product manager for Siemens Industry’s Sinamics S drives.
Can you explain what a decentralized drive is and how decentralized drives differ from centralized drive systems, in terms of installation, wiring complexity and maintenance?
Craig Nelson, product manager, Sinamics S, Siemens Industry: The typical decentralized drive is mounted on or at the motor, rather than in a control cabinet. This saves money in one respect by eliminating the control cabinet and cooling but puts higher demands on the drive protection against the elements, including higher temperatures and vibration, which can reduce the lifespan. Additionally, with on-motor designs, the motor heat dissipation is reduced, and derating is a factor. For wiring and circuit protection, decentralized drives may need special attention, especially depending on the local codes and regulations. On smaller decentralized drives where the motor and drive are encapsulated together, field maintenance may not be feasible.
Chase Davis, director of technology, EOSYS, a certified member of the Control System Integrators Association (CSIA): A decentralized drive refers to a drive installed on a machine, rather than housed within a control enclosure alongside other drives and motor controls. By positioning the drive close to the motor, it eliminates the need for lengthy motor cables and auxiliary equipment such as line reactors. Power distribution and networking are commonly achieved
through trunk-style or daisy-chained cabling, reducing the amount of wire and cabling in the system.
Furthermore, distributed drive systems can provide additional I/O capabilities for field devices, effectively reducing the necessity for extra I/O modules and enclosures. These systems often feature cordset connections, enabling rapid replacements and minimizing downtime. Collectively, these advantages translate into simpler installations, reduced wiring complexity and easier ongoing maintenance for industrial applications.
What are some applications where decentralized drives might benefit an industrial system being designed and built?
Chase Davis, director of technology, EOSYS, a certified member of CSIA: Industrial systems with large footprints or restricted space for control enclosures can greatly benefit from decentralized drive systems. For instance, conveying systems are particularly well-suited for this approach, as decentralized drives streamline power and network distribution. Modular systems are also a good fit, since the flexibility of power and network trunks allows for easy expansion by simply adding new drives as needed. Moreover, decentralized drive systems simplify control panel design. With power and networking as the primary components housed in the enclosure, the overall size and footprint of these panels are significantly reduced. Another notable advantage is the decrease in installation time, as pre-fabricated cables can be utilized to expedite installation and reduce wiring errors. Collectively, these qualities enhance both the efficiency and scalability of industrial automation projects.
Craig Nelson, product manager, Sinamics S, Siemens Industry: In many applications such as conveyors, which would require long motor cable runs from the control cabinet, the decentralized
approach has several advantages. Also, in servo applications, which tend to be smaller power ratings, a decentralized approach can offer advantages over centrally mounting the drives in a control cabinet, but the vast majority of users still prefer the centralized design.
Servo motors have traditionally been preferred for high-precision, high-response applications. How might an inverter affect someone’s evaluation of switching out servos for induction motors?
Craig Nelson, product manager, Sinamics S, Siemens Industry: Permanent magnet synchronous servo motors are very efficient, but at a higher initial cost than induction motors. Many drives are capable of running either type of motor, but, if an encoder is required for closed-loop control, this needs to be taken into consideration. In continuous applications or long cycle times, the payback of a more efficient motor can be attractive, but synchronous reluctance motors should also be considered if the inverter is compatible.
How have frequency inverters evolved over recent generations in terms of control features, communication protocols and energy efficiency?
Chase Davis, director of technology, EOSYS, a certified member of CSIA: Contemporary drive technologies have advanced significantly, now featuring sophisticated control modes that surpass traditional V/Hz methods. Options such as vector control deliver enhanced accuracy and efficiency, often incorporating encoder feedback for superior performance. Network interfaces for drive integration have replaced hardwired control signals, streamlining installation and setup and also enabling richer diagnostic capabilities and making both configuration and replacement processes faster and more reliable. Manufacturers are also embedding predictive maintenance features into their drives, allowing the early detection of irregularities in both machines and motors. Additionally, many drive systems are now equipped with regenerative front-end power capabilities, which allow them to recover and reuse energy.
Craig Nelson, product manager, Sinamics S, Siemens Industry: New-generation frequency inverters are characterized by ease of use. This includes setup, diagnostics and integration into controllers. Simple user interfaces and built-in web pages, along with remote access, have limited on-site commissioning. Features such as auto tunning and startup wizards have also helped remove complexity. Clean power drives, featuring active infeed, increase energy efficiency, while reducing the harmonics, but built-in firmware functions such as automatic flux adaption.
What sorts of emerging technologies are being integrated into drives and inverters?
Craig Nelson, product manager, Sinamics S, Siemens Industry: The expansion of drive-based safety integrated functions are enablers for a sea change in plant-floor functional safety. Functions such as safe stops, safe speeds and safe position are used in today’s production environments with robotics and mobile units becoming the norm. Another emerging technology that is becoming the new norm thanks to incoming regulations is security integrated in drives, which are an integral part of the plant’s defense-in-depth concept to protect the integrity of operations.
How are digital twins utilized within the development and commissioning processes, and what impact have digital twins had on reducing project lead times?
Alexandre Coimbra, senior packaging engineer, Nefab: We are actively exploring how this concept could be integrated into our development processes. The digital twin is closely linked to collaboration with customers by connecting their latest product models with our packaging designs. Having access to the latest product models while customers can access our packaging designs allows both sides to work on a shared virtual environment. Combined with our virtual testing capabilities, this makes it possible to simulate transport hazards such as vibration and shock and predict potential failure points before a physical prototype is available. This enables engineers to optimize packaging earlier in the process and can significantly accelerate time to market.
EU draws a line in the sand
Device-level protection for CRA-ready industrial networks
AS THE NUMBER of companies undergoing digital transformation continues to grow and the Industrial Internet of Things becomes ubiquitous, companies find their OT networks more susceptible to cyber attacks, even at the component level.
The Cyber Resilience Act (CRA) is designed to set cybersecurity requirements for hardware and software products with digital elements placed on the market of the European Union (EU), which could lead to similar global standards or, at the very least, force manufacturers to follow the rules if they plan to sell products in the EU.
The EU CRA took force in December 2024, and many of its vulnerability reporting requirements go into effect in September 2026, while the main obligations don’t apply until December 2027. Representatives from four global technology groups shared their thoughts on the impact of the EU CRA.
Industrial connectivity for cybersecurity requirements
By Stephen Mitschke, FieldComm Group
Cyber assaults on industrial operations have resulted in all kinds of mayhem, ranging from minor inconveniences to significant production or data loss, and even physical damage due to kinetic attacks on operating equipment. Unfortunately, due to very long lifecycles, operational technology (OT) cybersecurity provisions for industrial automation have lagged in comparison with developments in commercial and consumer areas of the information technology (IT) world.
One regulatory response aimed at strengthening cybersecurity across digital systems and applicable to both hardware and software products sold into the European Union (EU), is the EU Cyber Resilience Act (CRA). Implementation of the CRA has already started, as it entered into force on December 10, 2024, and manufacturers of all digital products, including legacy, on the EU market are required to report actively exploited vulnerabilities and severe incidents beginning on June 11, 2026. Starting on December 11, 2027, full application of the CRA takes effect for all new digital products placed on the EU market, mandating CE marking, conformity assessment and lifecycle support.
The CRA is designed to strengthen cybersecurity of digital systems throughout their entire lifecycle, from initial design to eventual decommissioning. Notably, the CRA defines what outcomes are required but not how to achieve them. This gap must be addressed through industry standards and best practices, underscoring the
vital role of standards organizations.
Even before the CRA, industry has been progressively improving the cybersecurity of OT hardware, software and communications, for example, with the addition of local password storage right on-board instruments. The IT world has had much more experience with handling secure authentication strategies. Fortunately, just like many other IT and commercial-grade technical developments have been adapted for reliable use in demanding industrial-grade OT applications, cybersecurity technologies are following the same path.
FieldComm Group is a standards development organization (SDO) and has actively collaborated with other SDOs for years to establish cybersecure technologies from the industrial communications protocol perspective. Technologies are actively evolving to improve cybersecurity, and FieldComm Group is working to provide the tools and frameworks needed for supporting product suppliers and implementers with CRA compliance.
Identifying cybersecurity needs
The CRA is a wide-ranging initiative generally applying to products with a digital component and connectivity to other devices or networks. It requires secure-bydesign development for new products, while a risk-based approach will permit existing products with compensating measures. Consideration for product lifecycle management will provide complete transparency surrounding the features and associated updates. This harmonized approach is intended to make it more straightforward for users to identify and implement appropriate cybersecurity features, resulting in safer and more resilient critical infrastructure, along with modern manufacturing and other digital systems. Products sold into the EU market will need to be CRA-compliant, and there are penalties associated with non-compliance.
One of the most relevant OT cybersecurity standards is IEC 62443, recognized as a global benchmark focused on industrial automation and control systems (IACSs). This standard provides
Figure 1: IEC 62443 OT cybersecurity standards identify requirements, practices and processes, which can provide a practical approach for systems and product suppliers to demonstrate alignment with CRA’s essential requirements.
IMAGE COURTESY OF FIELDCOMM GROUP.
requirements for secure product development, system-level security practices, organizational processes throughout the IACS lifecycle and a structured risk management framework with definition of security levels (SLs). For manufacturers, adopting IEC 62443 practices is a practical way to demonstrate alignment with CRA’s essential requirements (Figure 1).
Cybersecurity challenges for OT applications
Until the past few decades, OT installations were commonly air-gapped systems and largely standalone, a method that provided a degree of cybersecurity protection. However, the ability to interconnect all types of industrial assets together and with IT resources, to improve efficiency, data sharing and decision making, has become a fundamental requirement of modern systems.
Proven IT practices for secure authentication, encryption and layered access management are finding their place in the OT domain to address cybersecurity needs for increasingly connected and networked monitoring and control applications. Because most industrial automation systems integrate a multitude of devices from various manufacturers, often using different communication protocols and even relying on different host systems within a single plant, it is essential that cybersecurity measures are both effective and easy to manage at the enterprise level.
Just as commercial technologies like Ethernet and PCs were successfully adapted for industrial environments, cybersecurity practices originating in IT are now evolving to meet OT’s unique demands for long system lifecycles, uncompromising reliability
Figure 2: The Industrial Ethernet Security Harmonization Group, established by standards development organizations FieldComm Group, PI, ODVA and OPC Foundation, is actively collaborating to define security concepts and technologies for industrial automation environments. IMAGE COURTESY OF FIELDCOMM GROUP.
and seamless interoperability across multi-vendor ecosystems.
Collaboration is central for
OT cybersecurity
The Industrial Ethernet Security Harmonization Group (IESHG) was established by FieldComm Group, Profibus & Profinet International (PI), ODVA and the OPC Foundation to address security challenges. Over time, this group has evolved to be called the Industrial Security Harmonization Group (ISHG), hosted by the same four standards organizations but opened to participation from their extended member communities (Figure 2).
Initially, the ISHG members collaborated to define cybersecurity concepts, establish guidelines and share best practices associated with industrial communications cybersecurity. In 2022, the team produced an FAQ document defining security concepts for industrial automation environments. More recent publications include white papers on the topics of human user authentication in the OT environment, and on harmonized initial device identifiers (IDevIDs) for industrial
automation devices.
Moving forward, the ISHG will continue to collaborate on development of common specifications to enhance authorization and authentication. NAMUR Working Group 4.18 “Automation Security” has published recommendation NE 201 “Identity and Access Management on Automation Devices,” which will play a role in development of necessary authentication and authorization for OT devices.
The actions outlined above are all important first steps toward standardizing industrial-grade OT security implementations. Upcoming developments are planned for secure deployment of industrial communication covering process and factory protocols:
• EtherNet/IP
• Profinet
• OPC UA
• HART-IP
• WirelessHART
• Foundation Fieldbus
• ProfibusPA
• IO-Link
• HART 4-20mA
• DeviceNet.
Many IT technologies are relevant for OT use, and, by adapting proven IT practices into standards designed for OT, the industry is building a foundation for CRA-compliant cybersecurity that is strong and practical for deployment in complex, multi-vendor environments. Implementing effective cybersecurity throughout OT installations will require effort, but a well-trained pool of IT talent will be positioned to assist.
Supporting industrial cybersecurity readiness
FieldComm Group defines industrial communication interoperability and performs conformance testing.
Addressing cybersecurity, both in general and in support of CRA, is just another facet of this work. By leveraging proven enterprise-grade IT security technologies to support the unique requirements of industrial OT systems, FieldComm Group is helping establish a transparent, standardsbased framework for OT cybersecurity, with two critical objectives.
• For members: delivering standards, tools and software to ensure CRA compliance and readiness for global markets
• For industry: providing interoperable, secure solutions that protect infrastructure, strengthen resilience and enable digital transformation.
A solid foundation is developing for industrial cybersecurity, formed by the convergence of regulation, standards and collaboration. CRA sets essential requirements but not implementation guidance. IEC 62443 provides domainspecific practices, while initiatives such as ISHG are translating these into a practical, interoperable framework.
FieldComm Group provides the leadership to ensure both manufacturers and end users are equipped with the standards, tools and technologies needed to safeguard critical infrastructure, meet compliance and accelerate digital transformation in an increasingly connected industrial landscape.
Stephen Mitschke is director—standards development & conformance at FieldComm Group. Mitschke also leads the organization’s product security incident response team. He holds a bachelor of science degree in electrical engineering from the University of Texas at Austin.
Cybersecurity without overengineering
By Martin Rostan, EtherCAT Technology Group
Industrial applications place very specific demands on cybersecurity. Availability and deterministic behavior are paramount, and the primary protection goal is usually data integrity—ensuring that commands, setpoints and feedback data cannot be manipulated—rather than strict confidentiality of process data. A realistic, risk-based approach is therefore essential.
Risk-based cybersecurity
Regulations and standards reflect this necessity. Both the EU Cyber Resilience Act (CRA) and the IEC 62443 series for industrial automation and control systems are built on the principle that cybersecurity measures must be proportionate to risk. Risk is defined by the combination of the potential impact of an attack and the likelihood that such an attack can realistically occur under “reasonably foreseeable” conditions.
This approach explicitly avoids exaggerated threat scenarios and blanket requirements that drive up cost and complexity without improving real security. Overengineered cybersecurity can easily backfire: excessive authentication steps, complex certificate handling or performance-reducing encryption may interfere with commissioning, diagnostics, maintenance and 24/7 operation. Experience shows that measures that are impractical in daily operation are often bypassed, ultimately reducing, rather than increasing, security.
EtherCAT and cybersecurity
Cybersecurity has become a central concern in industrial automation; take intralogistics as just one prime
example. Conveyor systems, sorters, automated storage and retrieval systems (AS/RS) and mobile robots form the backbone of modern distribution centers and production supply chains. These systems are highly automated, performance-critical and increasingly connected, yet they are typically not operated in physically protected environments.
Operators, maintenance staff, contractors and service personnel often have direct physical access to equipment, sensors, drives and control cabinets. As a result, cybersecurity is not a theoretical concern but a practical requirement.
IEC 62443 therefore allows different ways of meeting its foundational requirements. Integrity, availability and even confidentiality can be achieved through architectural means, physical measures, and protocol characteristics, not exclusively through cryptography.
Machine automation
EtherCAT is widely used in many industries due to its high performance, precise synchronization, flexible topology and scalability. Long machine lines, large numbers of drives and I/O modules and distributed motion applications benefit from its deterministic behavior and efficient use of bandwidth.
Beyond performance, EtherCAT’s functional principle has important cybersecurity implications. EtherCAT operates directly at the Ethernet layer using its own EtherType and does not rely on the Internet protocol (IP). Process data are processed “on the fly” in hardware by dedicated EtherCAT SubDevice controllers, without the use of switches. This design not only enables short cycle times and precise
synchronization, but also fundamentally limits the attack surface.
Integrity by design
In environments where physical access to machines is common and personnel cannot automatically be considered fully trustworthy, preventing manipulation of control data is often the most important security objective. EtherCAT addresses this requirement inherently.
Only valid EtherCAT frames are accepted and processed by SubDevices. Any non-EtherCAT traffic, regardless of its content, is identified in hardware and discarded immediately. Malware, ransomware or other IP-based attack traffic cannot propagate within an EtherCAT network because such traffic depends on IP and higher-layer protocols that EtherCAT does not use.
Communication follows a strict hierarchical model: all communication is initiated and controlled by the MainDevice, and SubDevices merely insert or extract their data at predefined positions within a frame. SubDevices cannot send frames autonomously, cannot listen to traffic not intended for them and cannot modify data outside their assigned process data area. Even a compromised or faulty SubDevice firmware cannot violate these rules, as they are enforced by hardware.
This means unauthorized manipulation of commands or feedback data at the field level is inherently prevented. Attempting to inject or alter process data through standard cyberattack methods is simply not possible within the EtherCAT network.
Cyber vulnerability?
While physical access increases the theoretical attack surface, it does not
automatically translate into effective cyberattacks. Adding an unauthorized SubDevice to an EtherCAT network, for example, does not grant any influence over communication unless the MainDevice explicitly configures and enables it. Unused ports can be disabled in hardware, further reducing that threat.
If an attacker has extensive physical access and malicious intent, there are usually far simpler ways to disrupt a control system than attempting a sophisticated cyberattack at the fieldbus level. From a risk perspective, this reinforces the importance of focusing on realistic threats rather than extreme scenarios.
System architecture
Cybersecurity is not only about protocol features. System architecture plays a decisive role. EtherCAT supports a clear separation between the real-time automation network and higher-level IT or plant networks. In typical industrial architectures, protecting the controller and its northbound interfaces, using established IT security measures such as firewalls, access control and secure remote access, addresses the dominant attack vectors.
By contrast, architectures in which every field device is directly exposed to IP-based networks require each node to implement complex security mechanisms. This significantly increases system complexity, lifecycle cost and operational risk. The industry is increasingly returning to structured, compartmentalized architectures that align well with EtherCAT’s design philosophy.
Tomorrow’s requirements
From a standards perspective, EtherCAT already meets the requirements typically associated with IEC 62443
Security Level 2, which covers protection against most intentional attacks and is sufficient for the vast majority of industrial applications. Importantly, this is achieved without any changes or extensions to the EtherCAT protocol.
For applications with even higher security requirements, the EtherCAT Technology Group is defining additional measures that remain backward compatible. These enhancements focus on software-based solutions in the MainDevice and optional extensions, avoiding technology breaks and protecting existing investments. EtherCAT’s history of strict backward compatibility ensures that systems installed years ago remain interoperable with new devices and future security concepts.
Pragmatism as security
Cybersecurity is not about applying every possible countermeasure, but about making informed, risk-based decisions. EtherCAT demonstrates that a technology designed for deterministic, real-time automation can also provide strong inherent protection against cyber threats, particularly against data manipulation.
By combining EtherCAT’s built-in characteristics with sound system architecture and proportionate security measures, machine builders and operators can meet regulatory requirements, maintain high availability and avoid unnecessary complexity. In industries where downtime is costly and reliability is critical, this pragmatic approach is not just efficient; it is essential.
Martin Rostan is executive director of EtherCAT Technology Group. Contact him at info@ethercat.org.
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How EU CRA and IEC 62443 impact CANopen device manufacturers
By Holger Zeltwanger, CiA
The EU Cyber Resilience Act (CRA) is the first European regulation to set a minimum level of cybersecurity for products comprising digital elements or software. CAN interface implementations comprise digital elements— protocol controllers—and software, for example, higher-layer protocol stacks and application programs. Therefore, a system-and-applicationrisk assessment is required.
The CAN data link layer protocols— classic (CC), flexible data-rate (FD) and extended data-field length (XL)—as standardized in ISO 11898-1:2024, as well as standardized higher-layer protocols such as CANopen CC/FD (CiA 301/CiA 1301), do not provide intrinsic cybersecurity measures. Cybersecurity measures can be added depending on the required security level (SL) as
defined in the IEC 62443 standard series—security for industrial automation and control systems. Therefore, suppliers of CAN-connectable devices, vendors of products based on CAN networks and CAN network designers need to evaluate which SL is required by the targeted application.
The following CAN-connectable products do not fall under the CRA: free-of-charge open-source software and nonprofit products. Additionally, medical products, vehicles, in-vitro diagnostic devices, civil aviation, as well as marine equipment, and products used in the context of national security, such as military equipment, are not in the scope of the CRA, when specific cybersecurity-related EU regulations are in place.
EU regulations for medical device cybersecurity require manufacturers to implement secure-by-design prin-
CiA board of directors statement
The CiA board of directors, Magnus Hell (Infineon), Christian Schlegel (CHS Consulting), and Holger Zeltwanger, has worked out the following statement, evaluating the EU CRA regulation and impacts on CAN networks:
The nonprofit CiA (CAN in Automation) international users’ and manufacturers’ group informs its members that products using CAN and placed on the EU markets fall under the European Cyber Resilience Act (EU CRA), unless the relevant cybersecurity aspects are covered by application-specific EU legislation. In most cases, the required risk assessment may be a self-assessment, unless the product is considered critical (as
defined in the CRA Annex III).
It remains to be seen, which future standards best reflect the EU CRA requirements. For now, suppliers of CANconnectable devices are requested by their customers to comply with a dedicated SL (security level) as defined in the IEC 62443 standard series (security for industrial automation and control systems).
CiA is confident that SL 2 can often be reached with minimal effort for CAN networks. Achieving SL 3, requires more advanced security measures involving cryptography at CAN data frame (data link layer entity) or CANopen message (application layer entity) level. CiA’s
ciples across the product lifecycle. There are also other regulations in power that might need to be complied with, such as the U.S. Food & Drug Administration (FDA) cybersecurity guidance for medical devices—Quality System Considerations and Content of Premarket Submissions. This guidance, issued in the summer of 2025, adds Section VII to address FDA’s recommendations regarding Section 524B of the U. S. Federal Food, Drug & Cosmetic Act for cyber devices. This document supersedes the final guidance “Cybersecurity in Medical Devices: Quality System Considerations and Content of Premarket Submissions,” released September 27, 2023.
CANopen and security
CAN in Automation (CiA) has a long history in developing security measures against unintended misuse, as well as intended manipulation of CANopen communication. This also covers unauthorized access to
assessment is that CAN networks with restricted and limited physical access usually comply with SL 2 or lower, not needing additional cybersecurity measures. This assumes that gateway functions to other networks and external interfaces are protected by means of firewalls or are made not accessible (e.g., the JTAG interface, named after the Joint Test Action Group).
If restricted and limited physical access is difficult to enforce, cybersecurity measures do not necessarily require cryptography. In CiA’s view, a security monitoring entity that scans communication on abnormal behavior, detecting and reporting attack, is an efficient security measure as indicated in the CRA regulation and the IEC 62443
CANopen devices and CANopen networks. There are password options for the CANopen object dictionary access. Furthermore, there will be an authentication signature option in CANopen messages specified, indicating that they are from the right origin; that, in case of service data object (SDO) transmission, SDO segments belong together; and that they have not been manipulated. Some CANopen specifications already provide dedicated security measures— for example, the CiA 710 generic CANopen bootloader or the CiA 417-1/ CiA 814-1 CANopen lift bootloader.
According to the open systems interconnection (OSI) model, security controls can be applied to each of the seven OSI layers, depending on the required SL and expected attack scenarios. This is defined in the ISO 7498-2:1989, Information processing systems — Open Systems Interconnection — Basic Reference Model — Part 2: Security Architecture, framework.
standard series. It reduces overall risks for undetected attacks, having a positive influence on the risk assessment and showing a defense in-depth approach. If cryptography is necessary, its use can be limited to core functions. While a secure software update mechanism might be mandatory for CRA compliance, in many cases, further use of security functions can be reduced to secure CAN node authentication and device configuration protection (e.g., by means of passwords). Such core security functions are currently under discussion in the CiA SIG (special interest group) HLP (higher-layer protocol) cybersecurity and expected to be integrated into CANopen CC and CANopen FD specifications.
For the CAN XL data link layer, CiA members are developing the CANsec approach, a cybersecurity extension specified in CiA 613-2, CAN XL add-on services — Part 2: CANsec data plane.
Holger Zeltwanger is managing director of CAN in Automation (CiA). Contact him at headquarters@can-cia.org.
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Device-level protection for CRA-ready industrial networks
By Joakim Wiberg, ODVA
For years, industrial suppliers have progressively improved the cybersecurity aspects of operational technology (OT) hardware, software and connectivity products. This has been prompted and directed in part by end users and by various standards and guidelines such as ISA/IEC 62443 developed to manage and reduce cybersecurity risks. Most recently and prominently, the European Union (EU) has created the Cyber Resilience Act (CRA) to strengthen all types of digital system cybersecurity, in products as different as household robotic vacuums and industrial factory robotic arms.
The increasing availability of compute power, even in the smallest and most remote of devices, and the proliferation of digitalization projects for gathering and analyzing data, mean that connectivity among these devices and systems is a fundamental need for any solution. Widespread connectivity creates even greater cybersecurity exposure and risks. Fortunately, in
many cases cybersecurity solutions developed and proven throughout information technology (IT) implementations are forming the basis for achieving robust OT cybersecurity.
Guidelines and regulations
Cybersecurity guidelines and regulations are not new. The U.S. National Institute of Standards and Technology (NIST) Cybersecurity Framework (CSF) is a set of guidelines developed in 2014, acting as a tool for achieving cybersecurity in critical infrastructure sectors. The EU Network and Information Systems (NIS) Directive, introduced in 2016 and then expanded as NIS 2 in 2022 with stronger enforcements and broader sector coverage, were established to regulate critical sectors in member states.
The CRA is even more comprehensive in several ways. However, the CRA is a legal framework and not a detailed technical implementation guide, although work is ongoing to enhance the CRA with clear technical requirements based on product
type. It mandates secure-by-design principles, vulnerability management processes, robust documentation practices and a rigorous product development lifecycle.
ODVA was founded in 1995 as a standards development organization (SDO), whose members are global suppliers for industrial automation applications. A key ODVA technology is the Common Industrial Protocol (CIP), which is an industrial communications protocol deployable on various media. CIP, in the form of EtherNet/IP, DeviceNet, and other protocols, is widely used throughout industry to provide an object-oriented approach for messaging and data presentation. Just as ODVA has progressed the CIP standard to take advantage of newer media, CIP cybersecurity aspects have also been enhanced via the CIP Security network extension for EtherNet/IP.
Cybersecurity for industry
For digital communications purposes, the confidentiality, integrity and availability (CIA) triad outlines three objectives which must be considered. In addition, establishing the authenticity of users, applications and devices is crucial; basically, ensuring that proper and expected elements are interacting with each other without any undesired outside influence.
Banking, purchases, email and other networked and internet-connected IT applications require effective confidentiality. This is why internet browsing, which was once completely “open,” has been enhanced over the years by the addition of Transport Layer Security (TLS) and public key infrastructure (PKI) to issue, validate and manage the certificates that enable authentication and encrypted
Figure 3: Proven, open and accepted IT cybersecurity standards such as TLS and PKI form the basis for cybersecure industrial and OT EtherNet/IP communications.
OF ODVA
communication (Figure 3). The result is that almost all web browsing is performed with the familiar encrypted and secure “https://” address prefix to prevent eavesdropping and tampering. This progression has been almost completely transparent for end users.
CIP Security for EtherNet/IP
In the context of OT industrial communications, ODVA has progressively developed the CIP standard to meet the evolving needs of industry. DeviceNet uses CIP over the proven controller area network (CAN) media layer at a selection of speeds and distances to interconnect devices for deterministic data exchange. ODVA conformance testing and device profiles ensure consistency among products. DeviceNet has been a foundational digital communications protocol for countless industrial installations, including programmable logic controllers (PLCs), input/output (I/O) modules and valve manifolds, variable frequency drives (VFDs).
As Ethernet media became physically practical for industrial installations, ODVA adapted the proven and familiar CIP standard to create the EtherNet/ IP protocol, with enhanced bandwidth and node counts as compared to DeviceNet. For users with more demanding requirements, CIP has been extended with services for security, safety, motion control, time synchronization and energy usage. These extensions are carefully architected to add the new functionality, including suitable determinism for a wide range of industrial applications, while remaining compatible to avoid “breaking” existing applications.
Following the same evolutionary pattern of IT-based security, the CIP Security extension has added a TLS layer and PKI handling to EtherNet/IP (Figure 4). Using CIP Security, designers can incorporate more secure EtherNet/IP communications with devices when and where it is needed, and devices can be offered with different profiles supporting varied security levels.
Because CIP Security for EtherNet/ IP is built on proven, open, and wellestablished OT and IT standards, users preserve their investments in training and knowledge, and they will realize
a straightforward path to incorporate the new technologies. Security can be designed into new projects, or it can be added in the form of a top-level proxy device to protect existing underlying devices or systems that would not otherwise be upgraded.
Certainly, there is some additional work and complication involved with implementing secure communications, just as there was when moving from simple DeviceNet node numbers to the complexity of IP addresses introduced with EtherNet/IP. System integrators and OT network engineers will need to understand, install and manage a PKI host server with appropriate CIP routing at the site and create authentica
Figure 4: CIP Security for EtherNet/IP has been progressively developed by ODVA since 2017, building on the best OT and IT standards. IMAGE COURTESY OF ODVA
tion certificates. Good physical and logical network segmentation, which has always been important, is now even more essential from the factory floor up to the enterprise.
Multivendor support and alignment are central to ensuring security integrity. Procedures, testing and documentation are necessary to validate the design because an apparently normal-working system might still be vulnerable from a cybersecurity standpoint.
Proven cybersecurity
Considering all of this, CIP Security for EtherNet/IP offers tremendous value for designers tasked with fulfilling CRA cybersecurity requirements for new products and systems
and for retrofits, as well. The entire stack has been built upon existing and proven technologies and standards, continually enhanced since around 2020. There is a large installed base of EtherNet/IP products, along with significant end-user awareness of and expertise with the TLS and PKI technologies used throughout IT. CIP Security makes PKI and other cybersecurity technologies as easy as possible to deploy in an OT setting.
CIP Security offers device-level protection for critical applications where a cyberattack could result in significant economic, environmental or physical harm. Used as a part of a defense-in-depth approach, along with other security methods including appropriate network architectures and segmentation, firewalls, deep packet inspection, zones and conduits, updated device patching, employee training and physical access restrictions, CIP Security can help prevent bad actors from disrupting business operations (Figure 5). Device-level security is the last mile of protection for industrial automation motion devices such as valves, drives and grippers.
The Industrial Security Harmonization Group (ISHG) is one of many collaborative activities in which ODVA is engaged to ensure that end users across industries benefit from a consistent application of the technologies they utilize. As a part of the ISHG, ODVA joins other industrial automation standards development organizations including FieldComm Group, OPC Foundation and PI to work to harmonize cybersecurity strategies and concepts, so that end users do not face unnecessary complexity when using security concepts in their automation systems. Providing common education resources and defense-in-depth network options, such as CIP Security, enables adoption and more secure facilities.
Joakim Wiberg is the director of technology at ODVA. He has gained extensive experience over almost three decades of technology and product development for industrial network systems, with about half of that duration associated with aspects of cybersecurity. Wiberg holds a bachelor of science degree in electrical engineering and a master of science degree in computer systems engineering from Halmstad University, Sweden, and also holds two patents. Contact him at jwiberg@odva.org.
Figure 5: As part of a comprehensive defense-in-depth strategy, CIP Security helps protect business operations from bad actors. IMAGE COURTESY OF ODVA
How to make automation and control work
Huffman Engineering uses core values to steer system integration for more than 40 years
by Mike Bacidore, editor in chief
“MAKING IDEAS WORK” at highly regulated businesses has its own set of unique challenges. “We take someone’s ideas for their manufacturing plant, pharmaceutical and life sciences organizations, water, wastewater, electrical or compressed natural gas utility or food and beverage plant and make them work,” says Wendy Huffman, co-owner, founder and CEO/CFO of Huffman Engineering, a certified member of the Control System Integrators Association (CSIA).
Headquartered in Lincoln, Nebraska, Huffman Engineering is full-service custom engineering services firm focused on automation and control system integration from design to build, installation, testing, qualification and validation and training (Figure 1). The system integrator was founded in 1987 and now includes more than 60 employees, including 37 engineers, six computer
science specialists, six project management professionals and eight automation technicians.
Huffman and her husband Howard, co-owner, who is the founder and president, answered several questions about the company they’ve built and grown over the past 40 years.
“We take someone’s ideas for their manufacturing plant, pharmaceutical and life sciences organizations, water, wastewater, electrical or compressed natural gas utility or food and beverage plant and make them work.”
— Wendy Huffman, CEO/CFO, Huffman Engineering
Describe the machines you integrate. How many machines do you integrate on average each year?
Howard Huffman, president, Huffman Engineering: We complete about 100 full-scale projects annually and within those are control systems on multiple machines, devices and processes. We work with both IT and OT, software and hardware. Specifically on the machine side, almost all of those are on the industrial filling, packaging, forming machines and winders, extruders and material handling, and they are only a part of the processes we control. We do more automation and process control than machine control.
Figure 1: Huffman Engineering is full-service custom engineering services firm focused on automation and control system integration.
PHOTO COURTESY OF HUFFMAN ENGINEERING INC.
PHOTO COURTESY OF HUFFMAN ENGINEERING INC.
system integration
Highlight some of your most innovative integrations. What makes them unique?
Wendy Huffman, CEO/CFO, Huffman Engineering: We do more full process integrations than individual machine integrations, and nearly every process integration we do is unique. We have the benefit of entering each client’s industry, taking stock of what ide, they need to make work and helping them achieve that level of automation and control using hardware and software to help them grow their business.
As an example, we’ve taken someone else’s idea about taking dangerous compressed natural gas tanks and provided some proof stations for testing to ensure the safety of these tanks. We’ve helped control a winder application for making natural gas tanks and then tested them to ensure safety to all of their clients which is paramount to their business success.
Howard Huffman, president, Huffman Engineering: In another example, we can talk about how we utilize sustainability and renewable processes and
helping with that. In the irrigation industry at a global manufacturer right here in the heart of the United States, we can automate a lot of things in terms of producing irrigation pivots now that could not be done years ago. Not only can we automate the process, but we can get information and data back to them during the process to help them know how product is being made and give them business intelligence on making their process more efficient. That in turn allows them to produce more at a lower cost. So, the processes we control really have a ripple effect on how these companies manage their businesses and the outcomes they can produce.
What percentage of your projects are standard vs. custom? What is the focus?
Howard Huffman, president, Huffman Engineering: One of the strongest selling points for our systems is that every system is unique, and so, even though there are similarities, we take great pride in listening to each client as if they were our first one. For example, we might do water or wastewater treatment and simulate the systems from
Figure 2: Ever-changing safety strategies require training on lockout/tagout (LOTO) procedures and arc-flash precautions.
location to location; we still have to listen to the client and make sure they’re getting what they truly want.
The process of treating water may be the same, but one location may need a software upgrade with additional data management capabilities, one water system may be looking to manage PFAS (per- and polyfluoroalkyl substance) outcomes, and another may be looking for methane gas capture, so although we may bring the knowledge of water or wastewater treatment from one plant to another, what the client is looking for and the operators need may be vastly different. In that way, in our eyes, it is still a custom project.
We really approach each project in every industry we work with like that. Gaining a true understanding of what our client needs first and then bringing our expertise in technology, software and hardware processes to the table is important to us.
What is your core business? What industries do you work in? What type of manufacturers do you work with?
Wendy Huffman, CEO/CFO, Huffman Engineering: Our core business is fullservice custom engineering focused on automation and control system integration. We work in highly regulated industries in the Midwest including pharmaceuticals/life sciences (human and animal health), water/wastewater, manufacturing/material handling, food and beverage, electrical utilities and natural gas, networking/data analytics/cybersecurity. Many of our
PHOTO COURTESY OF HUFFMAN ENGINEERING INC.
clients are repeat clients because of the relationships we build with them.
We hold fast to our core values:
• do the right thing
• embrace difficult challenges
• simplify the complex
• make others successful
• display anticipatory initiative
• be committed and disciplined start to finish.
And we strive to work with clients who embrace similar core values, so we can make a significant difference in the communities we live in and work in.
Where does your integration take place?
Wendy Huffman, CEO/CFO, Huffman Engineering: The majority of our work is in the Midwest part of the United States, although we have been asked to do consulting and project work in other states and countries because of the success of our projects. We have completed projects in 23 states, Puerto Rico, Canada, Asia, Europe and South America. Our headquarters is in Lincoln, Nebraska with additional offices in Omaha, Nebraska, and Denver.
What are important trends affecting the industries you work with and types of machines you integrate?
Howard Huffman, president, Huffman Engineering: Data, it’s all about data. We are seeing more and more integration between machines and data reporting. With continued focus on IIoT, our clients want to see their manufacturing and enterprise resource planning (ERP) systems tied together throughout all levels of their organization. There is a greater emphasis on machine learning, AI and cybersecurity and smaller robotics or collaborative robots.
There used to be communication and interaction and safety strategies put in place, and the philosophy around safety used to be “don’t die, don’t lose an arm, don’t get a finger caught.” But now the qualification and validation requirements are more stringent and, in some industries, ever-changing (Figure 2).
Manufacturers have moved from individual machines performing automation tasks to islands of automation held within silos to floors of automation reporting to other equipment. They’re looking to us as seasoned system integrators with the experience with both hardware and software to tie them together with manufacturing execution systems.
How much time does it typically take to go from design stage to installation? Do you have other projects that vary?
Howard Huffman, president, Huffman Engineering: Nothing is typical when you’re doing custom work. The kind of project makes a big difference, and the complexity of the system defines the timeline. Some smaller projects could be one month to six months, but we have very few projects where we’re
“One of the strongest selling points for our systems is that every system is unique, and so, even though there are similarities, we take great pride in listening to each client as if they were our first one.”
— Howard Huffman, president, Huffman Engineering PHOTO COURTESY OF HUFFMAN ENGINEERING INC.
system integration
seeing the same panels and building them over and over.
Our clients traditionally come to us in one of two scenarios. Sometimes they have a current system that is running and something is not working or working as well as they would like it to, and they need our help to fix it, upgrade it or solve their pain point.
The other scenario they bring to us is that they are building something from the ground up, and they need our help with it from the very beginning—the design to the implementation—and, depending on how large the manufacturing line or the process, that could be a multi-year project incorporating various partners from additional engineering firms to electrical contractors and others. The complexity of each project determines the timeframe, but honestly there is no typical timeframe because we’re a
system integration
How do you use digital twin software or other technology for the design process?
Howard Huffman, president, Huffman Engineering: The industry is definitely moving toward digital twin, and we’re seeing it more and more. As far as controls go, we will more often use Elan for 3D modeling or SolidWorks for machine design.
What are your supplier preferences?
How often do you rely on clients to dictate component choice?
Wendy Huffman, CEO/CFO, Huffman Engineering: We work with suppliers and manufacturers whose goal is to serve the end user. We want to partner with manufacturers and partners who are looking to give the best solutions to our clients. Oftentimes the end users have a preferred vendor they already use. Sometimes they ask our advice on
which software/ hardware platform might work best in any given project. In that case our answer is always we want to do what the client wants and truly needs even if occasionally that means suggesting they use spare parts they already have on hand.
That’s also why we maintain expertise across multiple platforms and with multiple vendors because it’s really important to us to serve our clients well. We spend a lot of time and effort on professional development so we can continuously train on the latest technologies and platforms to be informed for our clients. We do work really hard at building and maintaining partner relationships with vendors we trust and we want to honor those at the end of the day, so we are both providing the very best solution for the end user. For Huffman Engineering it goes back to two of our core values—”Do the Right Thing” and “Make Others Successful.”
3: Highly regulated industries such as pharmaceutical or healthcare pose unique challenges that require customized ideas.
How does data enhance your machine integration? Do you integrate machines that use edge computing? Do you integrate remote connectivity to machines? How do the machines you work with use analytics?
Howard Huffman, president, Huffman Engineering: Data analytics are fundamental to everything we do in control system integration. We are consistently monitoring, reading, reflecting and recording data from a variety of machine interfaces that we have programmed to produce. That might be a manufacturing line, a pharmaceutical consumer or animal health line (Figure 3). It might be a food product line, or it might be a water or wastewater treatment facility, but all of the complex systems we design build and install require data inputs and data outputs. How we do that is based on our clients’ needs and their requirements for their operators. Much of that now includes remote access. And many of the systems we use allow us to provide actionable insights to automatically inspect and simulate a system before even building it.
What is required for typical maintenance on the machines you work with? How do end users limit downtime?
Howard Huffman, president, Huffman Engineering: Because we’re system integrators, much of this depends on the end user. Our goal at the end of the project is that we’ve trained their operators so well on their new or existing
Figure
PHOTO COURTESY OF HUFFMAN ENGINEERING INC.
and improved system that they really don’t need us. So, the first question is, do they need support from us? If so, it may be a service call on an existing system, and we’re happy to help.
But our primary goal is to work on large-scale projects with companies and become a trusted partner to their existing automation teams. We are known for our expertise and experience, quality, integrity and responsiveness, so, when they do need us, they can count on us for sure. And from a project standpoint, our careful planning and execution of factory acceptance tests (FATs) and consistent communication with the client is carefully crafted to catch any issues before we’re ever on site for startup. This is to ensure that we limit downtime as much as possible and are as efficient of a team as we can be.
Clarifying internal expectations early on, paired with direct communication about any changes in schedule or scope, can help streamline projects and ensure limited downtime. We know, the earlier we are able to become a part of the planning for process execution, the better we can help, especially on large complex systems with multiple players.
What other products or services do you manufacture or offer in addition to system integration?
Wendy Huffman, CEO/CFO, Huffman Engineering: At Huffman Engineering, we are a full-service engineering firm focused primarily on automation and control systems integration. This
means we consistently do automation and controls engineering, compliance for regulated industries, networking, analytics and reporting and engineered designs and studies. This includes electrical and arc-flash studies, integration studies, cybersecurity analysis, and analysis and pre-design of automation projects large and small.
We have two UL-certified panel shops where we design and build our own panels, as well, so we really do mean from start to finish we can execute automation projects in-house (Figure 4).
Can you please highlight a recent client integration project with innovative design? How did it help the client achieve better production or quality?
Howard Huffman, president, Huffman Engineering: Just one example would be this—a global pharmaceutical company was working to strengthen the consumer health product line and consolidate manufacturing and packaging operations. It was announced that they would
system integration
be closing one of their plants. The new site, located in Lincoln, Nebraska, was set to pick up the manufacturing and packaging operations for this line as the other plant is closed. Brand improvements include SKU rationalization to reduce the number of product varieties worldwide, reformulation to reduce the total number of raw material ingredients and the conversion of a bi-layer tablet to a single-layer tablet. This brand was considered a “power brand” within the organization. It was estimated that the new plant in Lincoln will produce more than 1 billion tablet doses per year. Lincoln production would serve the North and South American markets. This project included moving two packaging lines and designing, engineering and building a brand-new manufacturing line to handle aggressive production goals. Production ultimately realized 2 billion tablets a year exceeding the goal by two times and achieving 2.5 million tablets in a single cycle, all while conservatively saving the company a half a million dollars.
Figure 4: Huffman Engineering has two UL-certified panel shops where it designs and builds its own panels.
PHOTO COURTESY OF HUFFMAN ENGINEERING INC.
Can these components exchange data?
How can Siemens Simatic ET 200SP and SoftPLC-500 communicate?
by Mike Bacidore, editor in chief
CAN THE SIEMENS Simatic ET 200SP and the SoftPLC-500, an upgrade for Allen-Bradley’s obsolete SLC-500, communicate and exchange data? Which network protocol would they use to “shake hands”? If they cannot communicate without translation using middleware or a gateway or API, how would you fashion a solution to allow these devices to communicate and exchange data?
The Siemens Simatic ET 200SP I/O is scalable—a highly flexible, modular system. It can exchange I/O data from the connected I/O modules with a higher-level programmable logic controller via interface modules. Its compact design includes modular configuration, with up to 64 modules, up to 16 channels per module, permanent wiring, support for hot-swapping module replacement without tools and flexible connection. It offers flexible fieldbus connection via BusAdapter, including RJ45, M12, FastConnect, plastic or glass fiberoptic cables in single-mode or multimode, and it provides wiring accessibility with the spring release and measuring tap next to the conductor opening. Both its modules and terminal boxes can be replaced during operation. Thanks to mechanical coding of its modules with the BaseUnit, mix-up is prevented during installation. Its height is approximately 115 mm, providing space for 16 channels with a single-line connection, without AUX terminals.
The SoftPLC-500 controller, part of the NeoPAC controller family from SoftPLC. provides an upgrade for the obsolete Allen-Bradley SLC-500 CPU to a modern CPU without investment in I/O wiring, engineering and spare parts. It can reside in an SLC-500 rack and communicate to Allen-Bradley 1747
I/O modules. Its central processing unit has Ethernet, two USB ports, two ports for DH+ and Allen-Bradley universal remote I/O, all user-configurable for popular protocols. Existing SLC-500 application programs and documentation can be imported with a utility included with its programming software. It includes extensive ladder logic capability for control and computations/data manipulation. It supports up to 16 simultaneously active user-selectable Ethernet/serial/proprietary protocols, and it includes 512 megabytes of RAM for virtually unlimited logic. It has 8 gigabytes of onboard flash for applications, web pages and data logging and an internal MicroSD slot for removable flash. It uses TOPDOC NexGen software for programming, configuration and troubleshooting. A free TOPDOC NexGen license is included with your first purchase.
Patrick Bunn, owner. Bunn Automation Consulting, system integrator: The Simatic ET 200SP and the SoftPLC 500 don’t naturally “shake hands” unless you’ve dressed the ET 200SP for the occasion. In its most common form—the standard Profinet interface module—the ET 200SP behaves exactly like Siemens designed it: it needs a Profinet IO controller to assign its device name, load its module configuration, and start the cyclic I/O exchange. The SoftPLC 500, meanwhile, speaks EtherNet/IP and Modbus TCP, not Profinet, so the two will sit there blinking at each other like coworkers who brought incompatible slide decks to the same meeting.
But the ET 200SP platform is more flexible than it first appears. Siemens offers the MultiFieldbus interface module as an additional module in the lineup, and that’s the one that brings EtherNet/IP capability to the table. If that module is installed, the ET 200SP can talk EtherNet/IP directly, and the
SoftPLC 500 can communicate with it without any protocol mediation. If you’re working with the more common Profinet flavor, though, the cleanest solution is still a Profinet EtherNet/IP gateway. The gateway presents EtherNet/IP assemblies to the SoftPLC 500. With the right interface module, or the right gateway, the two systems don’t just shake hands, they exchange data predictably, report diagnostics cleanly and get back to work without anyone rewriting a control strategy.
Terrance Brinkley, director of Michigan operations, Patti Engineering, CSIA-certified member of the Control System Integrators Association: The Siemens Simatic ET 200SP and SoftPLC-500 can communicate directly thanks to Siemens’ MultiFieldbus module. This module lets the ET 200SP speak protocols beyond Profinet—including Modbus TCP and EtherNet/IP, both of which the SoftPLC-500 supports natively.
This means you don’t necessarily need a separate gateway. With the MultiFieldbus module installed, the ET 200SP can connect to the SoftPLC using shared protocol language, making integration more straightforward than it would be with standard ET 200SP configurations.
One thing to watch: existing ET 200SP modules may need firmware updates or may have to be replaced with a newer module to work with the MultiFieldbus module. Check compatibility before implementation to avoid surprises during setup.
The cleanest approach still keeps roles clear—use the ET 200SP for distributed I/O and the SoftPLC for control logic— but now they can talk directly without translation layers.
Cindy Hollenbeck, vice president, SoftPLC: Yes, these products can communicate, as both support multiple common protocols. The SoftPLC-500, like all SoftPLC controllers, provides ethernet and serial ports to communicate to many vendor’s I/O options. For users that need to support both the old Allen-Bradley I/O and want to add non-obsolete I/O of their choice the SoftPLC-500 is a good fit. However, for users that want their systems to only use one brand of I/O, one of the other SoftPLC NeoPAC, Smart or Micro models are better options. All of our controllers are the same except the Smart has an embedded Ethernet switch and more other ports, so the model choice is pretty application-dependent.
SoftPLC controllers include many ports, each of which are user-configurable, to support up to 16 protocols simultaneously. Connections not only to I/O, but to HMIs, drives, robots
and other PLCs are easily done without the need for gateways or protocol converters. Support for standard industry protocols like Ethernet/IP, Modbus TCP, DF1 and Modbus plus proprietary protocols like Allen-Bradley Remote I/O and Data Highway Plus are available in all SoftPLCs.
We don’t do Profinet, the royalties for Profinet Master make it unattractive when Siemens products also support Ethernet/IP and Modbus TCP. If Profinet is a must, then we would recommend using a hardware gateway.
Raj Rajendra and Juliette Sardin, sales specialists, Siemens Digital Industries: Yes, the Simatic ET 200SP can communicate with the SoftPLC-500, provided a common protocol is established. The ET 200SP natively supports Profinet, while the SoftPLC-500—designed for Allen-Bradley SLC-500 migrations—typically uses EtherNet/ IP. These protocols are not directly interoperable, so a gateway or protocol converter is required. Siemens offers solutions such as the Simatic IoT2040 or third-party gateways to bridge Profinet and EtherNet/IP, enabling seamless data exchange between the two systems.
For applications requiring higher-level interoperability and secure data exchange, the Simatic ET 200SP Open Controller provides integrated OPC UA functionality. OPC UA enables interoperability across heterogeneous systems, supports IIoT architectures and provides a future-proof approach for connecting devices and exchanging data reliably and securely.
Tobey Strauch, contributing editor: The question is whether these two devices will communicate. Directly, no. It’s a throw hands. A Simatic ET200SP with an interface module IM 155-6 MF HF (6ES7155-6MU01-0CN0) would be required. Why is this? The protocols for Allen Bradley Universal Remote I/O are not the same as Siemens. Thus, if you use the Multifieldbus on the ET-200SP setup, choose Ethernet IP or Modbus TCP and then connect the remote I/O to the network. Configure the SoftPLC’s built-in Ethernet/IP or Modbus TCP driver to talk to the ET-200SP interface. Then, in the SoftPLC, define the communications channels and map the I/O points according to the configuration directed. Order and addressing have to be set. Ideally, a controls engineer would set it up on a bench test and validate this works before field installation. Otherwise, the SoftPLC has the possibility of talking to the Siemens remote I/O via the interface module.
Put the work in network
Industrial communications require reliable components
ProSense signal conditioners
AutomationDirect has added ProSense
SC6 series high-density pulse isolators and frequency input signal conditioners, which handle a variety of discrete, pulse and frequency signals. Pulse isolator models split a single input into two independent outputs, while frequency input models convert a wide range of frequencies into usable analog or relay signals for downstream devices. The SC6 series features an ultra-narrow design for high-density mounting, intuitive DIP switch configuration and full isolation between input, output and power.
AutomationDirect / www.automationdirect.com
MISUMI communication hub
The IESH-MB208G-R communication hub from MISUMI is designed to expand your Ethernet network. Its eight ports support Gigabit Ethernet, providing data transmission. Featuring a built in DIN rail mount, overcurrent/reverse polarity protection and a metal casing with an IP30 rating, this switching hub can provide reliable operation in a wide variety of industrial environments.
MISUMI / us.misumi-ec.com
Beckhoff terminals
Beckhoff’s ED series EtherCAT terminals offers a new housing format in the I/O portfolio and expanded functionality while retaining full compatibility with existing Beckhoff hardware. Internally, the ED series terminals offer the same high performance, expansive functionality, and built-in diagnostics capabilities offered by all EtherCAT devices. The DIN-rail mounted ED series EtherCAT Terminals are characterized by a modernized design, tool-free installation via push-in wiring connections and additional app-based diagnostics via a scannable product data matrix.
Beckhoff / www.beckhoff.com
Pepperl+Fuchs
Ethernet-APL rail field switches
Pepperl+Fuchs’
Ethernet-APL rail field switch from FieldConnex combines common communication technology with Ethernet-APL. The rail field switch simultaneously transmits power and data on an Ethernet wire into hazardous areas of the process plant. Ethernet-APL rail field switch for DIN rail mounting is designed to make migration from fieldbus to Ethernet easy and cost-effective. In addition to Ethernet-APL, the switch is the product can optionally handle the Manchester bus-powered physical layer (MBP), and it can be flexibly configured to connect to an existing Profibus PA instrument base.
Pepperl+Fuchs / www.pepperl-fuchs.com
SoftPLC edge gateway
SoftPLC Gateways can be user-configured to support a mix of industrial protocols such as Ethernet/IP, ModbusTCP, Modbus, DF1, Allen-Bradley Remote I/O (RIO) or Data Highway Plus (DH+), as well as internet protocols like MQTT and HTTP, allowing data to be sent from the manufacturing location to the cloud, commonly called edge computing. For systems located in remote areas, by using a SoftPLC gateway, a cellular modem and SoftPLC’s TagWell cloud platform, users have bi-directional access to equipment for maintenance and data collection.
SoftPLC / www.softplc.com
Phoenix Contact NearFi couplers
Phoenix Contact NearFi is a contactless real-time transmission technology. NearFi couplers can transmit up to 50 W of power and 100 megabits of data per second, all
without physical contact. NearFi couplers can replace plug-in connectors and slip rings in high-wear-and-tear applications. When transmitting data alone, NearFi can communicate across an air gap of 40 mm. Power and data together or just power can be transmitted across an air gap of 12 mm. NearFi is protocol-independent and can transmit time-critical Ethernet protocols such as EtherNet/IP, Profinet, Modbus, and EtherCAT. NearFi’s low latency is designed to make it suitable for standards like time-sensitive networking.
Phoenix Contact / www.phoenixcontact.com
Metz M12 X-code field-installable jacks and plugs
Metz’s M12 X-code field-installable jacks and plugs are designed for reliable 10 Gbit/s Ethernet performance. Their design, stability and tool-free, reusable construction is designed to make on-site assembly fast and dependable. They feature Cat.6A, as per ISO/IEC 11801; are suitable for 10 Gbit/s Ethernet; have connection of four pair, 22 -26 AWG; no special tools required; are vibration-proof (IEC 61076-2-109); are shock-proof (IEC 61076-2-109); rated at IP67+; have 360º shielding concept; are designed to be easy to assemble and reusable.
Metz / www.metz-connect.com
Mencom unmanaged
Ethernet
switch
Mencom’s entry level
DIN-rail-mount unmanaged Ethernet switches are designed for most of the simple network topologies. With IP30 rating, all of the unmanaged switches are certified for industrial EMC (EN61000-6-4 and EN61000-6-2) and support redundant power-input for enhanced safety that can be connected simultaneously to a wide range of dc power sources. If one of the power inputs fails, the other live source acts as a backup to provide the power needs automatically. They can operate in temperatures ranging from -10 to 70 °C with steel and aluminum housing, and 0 to 60 °C with the plastic housing. Selected products support packet prioritization for Profinet. During normal use, broadcast packets will be forwarded to all ports except the source port.
Mencom / www.mencom.com
product roundup
Softing DeviceNet communication module
The Softing 5069-SDN, officially named the compactLink HW-DN, is a DeviceNet communication module designed for in-chassis installation in Rockwell Automation’s current 5380 controller platform. It is designed to enable Rockwell Automation users to migrate from legacy AllenBradley PLCs, such as the PLC-5, SLC-500 and 1769 CompactLogix, to the 5380 platform while maintaining connectivity with existing DeviceNet devices. The 5069-SDN is designed to enable seamless DeviceNet integration within the 5069 chassis architecture.
Softing / industrial.softing.com
Balluff network block
The Balluff BNI004F networking block is an I/O product for industrial Ethernet/IP systems. With eight M12 connection slots supporting 16 configurable digital inputs and outputs, it enables device integration. Its die-cast zinc housing and IP67 rating are designed for durability in harsh environments. Supporting up to 9 A for sensors and actuators, it’s designed for reliable power distribution.
Galco / www.galco.com
Lumenite level controls
Lumenite’s patented auto sensitivity, self calibrating liquid level controls, the LASC series, provide on/off point sensing control with a self calibrating auto sensitivity feature. Single- and multilevel designs are packaged in DIN rail enclosures for compact panel mounting and powered by 12 Vdc, 24 Vdc, 24 Vac, 120 Vac or 240 Vac line voltage.
Lumenite / www.lumenite.com
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