Control Design - January/February 2024 by Endeavor Digital Editions

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Volume 28, No. 1

table of contents

32 cover story

Mighty Microchip Through a global pandemic, supply-chain strains and a surge in automation demand, the integrated circuit stands ready Anna Townshend, managing editor

IMAGE GENERATED BY SHUTTERSTOCK AI / SHUTTERSTOCK.COM

19 61 machine input

OPC UA continues to expand its reach Security, interoperability and speed change industrial networks

product roundup

Take control of your machine automation Easy installation and versatility spearhead a sea change

Mike Bacidore, editor in chief

CONTROL DESIGN (USPS 17792, ISSN 1094-3366) is published 6x annually or bi-monthly by Endeavor Business Media, LLC. 201 N. Main Street, Fifth Floor, Fort Atkinson, WI 53538. Periodicals postage paid at Fort Atkinson, WI, and additional mailing offices. POSTMASTER: Send address changes to CONTROL DESIGN, PO Box 3257, Northbrook, IL 60065-3257. SUBSCRIPTIONS: Publisher reserves the right to reject non-qualified subscriptions. Subscription prices: U.S. ($120 per year); Canada/Mexico ($250 per year); All other countries ($250 per year). All subscriptions are payable in U.S. funds. Printed in the USA. Copyright 2024 Endeavor Business Media, LLC. All rights reserved. No part of this publication can be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopies, recordings, or any information storage or retrieval system without permission from the publisher. Endeavor Business Media, LLC does not assume and hereby disclaims any liability to any person or company for any loss or damage caused by errors or omissions in the material herein, regardless of whether such errors result from negligence, accident, or any other cause whatsoever. The views and opinions in the articles herein are not to be taken as official expressions of the publishers, unless so stated. The publishers do not warrant either expressly or by implication, the factual accuracy of the articles herein, nor do they so warrant any views or opinions by the authors of said articles.

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Volume 28, No. 1

table of contents

Endeavor Business Media, LLC 30 Burton Hills Blvd, Ste. 185, Nashville, TN 37215 800-547-7377 ceo

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June Griffin coo

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COLUMNS

cro

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Keith Larson

9 editor’s page

18 automation basics

What is RS-232?

Motion control relies on feedback sensors

Mike Bacidore, editor in chief

10 embedded intelligence How to design machine reporting systems

Shawn Cox, contributing editor

64 real answers

Jeremy Pollard, CET

Blended languages for industrial control

12 technology trends

66 live wire

Madison Ratcliff

Cabinet design hasn’t changed in 40 years

3 types of proximity switches

mratcliff@endeavorb2b.com

Rick Rice, contributing editor

Joey Stubbs, contributing editor

editorial team editor in chief

Mike Bacidore mbacidore@endeavorb2b.com managing editor

Anna Townshend atownshend@endeavorb2b.com digital editor

contributing editor

Rick Rice rcrice.us@gmail.com contributing editor

Joey Stubbs contributing editor

Shawn Cox brianshawncox@gmail.com

16 component considerations What is pulse-width modulation? Shawn Cox, contributing editor

contributing editor

Charles Palmer charles101143@gmail.com columnist

Jeremy Pollard jpollard@tsuonline.com

ad index A-3 Vision & Imaging.......................................................67

Mitsubishi Electric Automation...........................25, 52

Advanced Micro Controls/AMCI.................... 30, 31, 42

Motion...........................................................................23, 53

Altech Corporation....................................................29, 43

Moxa Americas...........................................................37, 54

B&R Industrial Automation...................................11, 44

Novotechnik................................................................55, 63

Contemporary Controls...........................................14, 45

Pepperl+Fuchs...........................................................15, 56

Local: 847-559-7598 • Toll free: 877-382-9187 email: ControlDesign@omeda.com

DigiKey Electronics...................................................46, 68

RS Americas................................................................17, 57

circulation requests / classifieds

Endress+Hauser...........................................................8, 48

SEW-Eurodrive.......................................................................3

Encoder Products Company..................................39, 47

SMC Corporation of America.................................35, 58

EZ Automation..............................................................2, 49

Strongarm....................................................................27, 59

Hammond Mfg. Co.....................................................38, 50

VEGA Americas..........................................................13, 60

Misumi..............................................................................6, 51

Yaskawa America.................................................................4

design/production production manager

Anetta Gauthier agauthier@endeavorb2b.com ad services manager

Rita Fitzgerald rfitzgerald@endeavorb2b.com art director

Derek Chamberlain

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ControlDesign.com / January/February 2024 / 7

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editor’s page

Mike Bacidore editor in chief mbacidore@endeavorb2b.com

What is RS-232? RECOMMENDED STANDARD 232 (RS-232) was introduced as

RS-232 is used for configuring and troubleshooting rout-

EIA-232 in the 1960s by the Electronic Industries Associa-

ers, switches and other network equipment by using a

tion, which disbanded into multiple sectors in 2011 and

console connection. It still provides a reliable means of com-

remain cohesive as the Electronic Industries Alliance. Ver-

munication between programmable logic controllers (PLCs),

sion C of the recommended standard has remained the most

sensors and human-machine interfaces (HMIs).

current since 1969.

Many legacy devices rely on RS-232, and converters/adapt-

RS-232 standardized serial communication between com-

ers are often used to bridge the gap between RS-232 and

puters and peripherals. Data is transmitted one bit at a time

other communication standards to integrate those legacy

over a single wire or pair of wires,

components into systems.

which is different from parallel communication, in which multiple bits can be transmitted simultaneously over distinct wires in both directions—transmit and receive.

RS-232 connections are used

Many legacy devices rely on RS-232, and converters/adapters are often used to bridge the gap.

RS-232 defines voltage levels for

for interfaces to monitor and troubleshoot devices during the development and testing phases in the development of hardware and software. Many develop-

binary data. Connectors with a fixed

ment boards and microcontroller

number of pins, such as DB-9 and DB-25, are most common.

modules feature RS-232 interfaces for programming and

RS-232 serial interface cables should be shielded, low-capaci-

debugging purposes.

tance cables, grounded at both ends. RS-232 also defines sev-

Despite its advantages, RS-232 is not without its limita-

eral control signals, such as request to send (RTS) and clear to

tions. With a maximum data rate around 115.2 kbps, its

send (CTS). These signals enable handshaking and flow control.

high-speed data transfer capabilities are no match for USB

Because RS-232 operates asynchronously, there’s no shared clock signal. Devices are able to synchronize com-

or Ethernet. It also uses higher voltage levels, which requires level shifters or converters when interfacing RS-232.

munication using each character’s start bit, stop bit and data

RS-232 was instrumental in connecting mainframes

bits. The transmitting and receiving devices must agree on

and computers to external devices, such as printers, dumb

a baud rate—bits/second (bps)—to time data transmission.

terminals for remote data entry, modems, data acquisition

It is designed for short-distance communication up to 50 ft.

(DAQ) systems and scientific instruments. This connectivity

Data errors can occur over longer distances due to signal

led to the development of local area networks (LANs), which

degradation. For longer distances, RS-485, which is derived

follow the IEEE 802 standards that include Ethernet and

from RS-232, is often used.

other means of connecting multiple devices. Ethernet allows

Although RS-232 had been replaced by universal serial bus (USB), Ethernet and wireless technologies for connecting peripheral devices, such as modulator-demodulators (modems), printers and mice, to computers, it remains in

for data transmission over longer distances and at higher speeds than RS-232. Ethernet uses packet-switching technology and operates in a full-duplex mode.

use in many industrial, scientific and telecommunications applications because of its reliability and relative immunity to electrical interference.

ControlDesign.com / January/February 2024 / 9

embedded intelligence

Jeremy Pollard jpollard@tsuonline.com

How to design machine reporting systems WE CAN YELL all we want, but what if no one hears us? We

any one time because the alarm design calls for the smallest

are in distress but have no way of letting anyone know that

minutiae of indications to the system/process, which tends

we have, in fact, fallen, but we can’t get up.

to swamp the operators with needless information and take

The need for distress reporting is widespread, and we

their focus away from the real deal.

always need an avenue to get access to the help we need.

A stack light will be able to give you an alarm structure

There are many ways to alarm our situations, and they take

such as Level 3/2/1/0. When a 0 alarm shows up, you need to

many forms. Visual, audible, smell and touch come to mind.

act now. Most programmable-logic-controller (PLC) develop-

Visual and audible are the two main sensory responses

ers group alarms together in process elements, not in a way

that a plant-floor process or machine can implement to get

that says, “This is important, so don’t ignore me.”

the attention of someone—to get

Many times, I have heard a car

the attention of anyone. But as always it has to get to the person who can help. During one project I worked on, which was designed by others, I might

alarm in a parking lot indicat-

Visual and audible are the two main sensory responses that a plant-floor process or machine can implement.

add, I was required to put alarm-

sound a horn when the process was in alarm.

could mean someone bumped into your car or someone is stealing it. You would think that the level of urgency would be

ing on the human-machine interface (HMI)—standard procedure—but I was also required to

ing an issue—you have to. This

reflected in the beeping. Nope. It’s all the same to the point where no one even reacts. SCADA alarming is no better. Alarms are active on a page

The problem was that this control panel and system were

forever. They don’t even acknowledge them because they

independent and in a remote location, which brings to mind

just keep coming back. No one changes the alarm setpoints

the predicament of a tree falling in the forest.

to reduce the frequency of the alarm point, or they put it

The system could be going up in flames, and, yes, the

to a ridiculous number, so it never comes on. People will

beeper would beep, but there would be no one to hear it.

always find a way to make their daily life or job easier.

I am fascinated by the self-checkouts in stores that have

And we give them the ability to change those setpoints

stack lights at the self-scanning registers. Most don’t know

via the HMI, but who reviews the logs to say that should not

that green means it’s available, that yellow means it is occu-

have been done based on time of year and ambient condi-

pied and that red means the current user needs assistance.

tions? I submit: no one.

I have seen stack lights with as many as seven lights.

Alarming is one of the main periscopes into any machine

Who even remembers what they all mean? Oh, sure, there is

or process that we can have. Stack lights work well for sim-

a sheet on the panel.

plistic alarm strategies, but, for that level of sophistication

I also have experienced both audible and visual alarming prompts that are inside an area that no one knows

that some need, they can’t cut it. SCADA/HMI and a PLC/distributed control system (DCS)-

about, which brings me to the whole concept of alarming

generated audible alarm will quickly be taped over or dis-

and messaging.

connected if it is in that area of where people are.

“Line 3 Down” is not a very intuitive message, regardless

It is important to create an alarm strategy that works so

of how it is delivered. Ian Nimmo is an individual who runs

that the red light isn’t always going off or that siren isn’t be-

a company called User Centered Design Services. He recom-

ing heard for all alarms similar to that car alarm.

mends supervisory control and data acquisition (SCADA)/ HMI design and alarming priorities. When I had the chance to talk with him, he was lamenting oil-and-gas refineries that have 20 alarms plus active at

10 / January/February 2024 / ControlDesign.com

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.

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technology trends

Rick Rice contributing editor rcrice.us@gmail.com

Cabinet design hasn’t changed in 40 years WHEN DESIGNING a control system, one of the things that we

like the protective device, so locating them below the pro-

cannot get away from is the need for an industrial enclo-

tective device would make sense and reduce the length of

sure. Often forgotten in a world where hardware evolves at

wire needed to accomplish this.

lightning speed, enclosures take a back seat but fill a necessary role in our systems.

Speaking of protective devices, most manufacturers have a group of auxiliary devices that can be used to daisy-chain

The general design of an enclosure really has not changed

the wiring path to reduce wiring. To use these shortcuts,

in the past 40 years or so, but let us take a stroll through the

the devices must be mounted adjacent to each other as the

showroom, as it were, and review what is out there and why.

jumper components are specifically designed based on this

The physical design of an enclosure serves multiple

assumption. The same is true of some relays and contactors.

purposes. First, it provides a

The same shortcut assemblies

physical barrier between the user of the equipment and the electrical components used to control it. Second, it provides protection of the components from contami-

are available to reduce the wir-

Change the design of the door to bring the flange of the cabinet out to the inner edges of the door profile.

nants in the environment that

Generally, enclosures are square- or rectangular-shaped.

While this helps with panel building and footprint, it has another challenge. Older variable-frequency

the machine or process reside. This is the primary purpose of an enclosure.

ing for these devices, as well.

drives (VFDs), for example, would have the input terminals at the top of the drive and the output—motor—terminals on the bottom. However, newer

They may or may not have a back panel to which com-

VFDs often have all of the terminations on the bottom of the

ponents are mounted so that the integrity of the outer

device. This means that power and control wiring will be

enclosure is not breached by drilling through the structure.

adjacent to each other and the routing of wires from the pro-

Multiple interior panels may be mounted to make use of the

tection device may not be as advisable as, perhaps, mounting

sides, top and bottom in addition to the larger back surface.

the protection device immediately adjacent to the drive.

The choice to use side panels must include an understand-

The environment in which the enclosure resides deter-

ing of the restriction on which components can be mounted

mines some of the fine details of the physical construc-

on the adjacent surfaces, so as to not have interference.

tion of the enclosure, as well as the materials used in the

While the size and layout of a panel is generally designed

construction. For example, mild steel is a common material

to mount all of the components that will reside in the enclo-

used to make a control box. It is rigid and resists a fair bit of

sure, additional consideration needs to be applied to con-

abuse due to normal operation activity.

sider the routing of wires within the enclosure. High-voltage

However, if that control system is in an environment

wires generally should not be routed with low-voltage or

where water or water vapor is present, mild steel would

communications cables to protect against electrical noise

likely rust or corrode quickly. Stainless steel would be a bet-

being induced by the high-voltage conductors.

ter construction material in this case.

Further consideration should be applied to the flow of the

What about corrosive environments? Stainless steel

circuits. For example, a fuse or breaker will normally have in

would also be a good choice, but powder-coated aluminum

and out terminals that are on the opposite end of the device.

would also provide ample protection. While less resistive to

It would make sense to mount the contactor, relay or

physical abuse, polycarbonate would also be a good choice

drive below the protection device, but that depends on

for an environment where corrosion exists. A consideration

the configuration of the input and output terminals on the

during the construction phase, however, stainless steel is

controlled device. Relays and contactors generally have the

not easy to work with compared to mild steel, aluminum

input and output terminals located to the top and bottom,

and polycarbonate.

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technology trends

Tools used in the construction will

cabinet itself. There is a gasket there to

body of the enclosure and the extend-

tend to wear out more quickly when

ostensibly keep moisture and dust out,

ed flange, then it is minimal and has

working with stainless, so extra cost

but it also creates a catch point where

an opportunity to move away better.

considerations are part of the decision

those elements will sit for long periods.

process, as well. While the general construction

Another way that helps with liquid

Liquid and debris, of course, will

removal is to slope the top of the en-

mix over time and create a substance

closure. While this usually means that

of an enclosure has remained the

that is difficult to clean. It can also

the inner panel will not be as big as the

same over the years, some recent

work on the gasket over time and

back surface of the enclosure, it does

improvements have tweaked the

break down the base material. Vendors

improve the ability to shed water off

performance, as it were. For example,

have come up with some ways to deal

the top. The door itself may be sloped

enclosures in wet environments are

with this issue.

to match the slope of the enclosure to

built to NEMA 4 or 4X standards. The

One method is to change the design

further help with this feature.

primary element here is the use of

of the door to bring the flange of the

stainless steel for the cabinet.

cabinet out to the inner edges of the

removal of water is to extend the top of

One of the main concerns with

Yet another way to improve the

door profile. By doing this, the gasket

the enclosure over the top edge of the

enclosures in wet environments is that

is protected from prolonged exposure

door. Imagine the overhang on your

water or other liquid can lay in the

to the liquid and dust/product. If the

house to push water away from the

gap between the cabinet door and the

liquid lays in the crevice between the

front door before dropping off.

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technology trends

that is resistant to sunlight, ozone,

mates up with the inside surface of

greatly improves the ability to keep

A combination of all three methods

abrasion, cutting and tearing, so it is

the door. This double dam, as it were,

water off the enclosure and improves

more resilient than silicone. Neither

greatly improves the ability to keep

both the integrity of the seal and the

does well with exposure to gasoline

liquid and dust contaminants from

cleanliness of the top of the enclosure.

or oil products.

getting inside an enclosure.

Gaskets perform the important

Thermoplastic elastomers (TPEs)

It is a good idea to institute a peri-

function of providing a semi-rigid bar-

behave like beefed-up EPDM but are

odic inspection of all enclosures after

rier that takes up any gaps between

more costly to produce. Fluorosilicone

installation to confirm the integrity of

the door and the enclosure. Two com-

gaskets are an improvement over

the seal and any penetrations of the

mon materials from which gaskets are

silicone with the benefit of better

surface from normal application like

made is silicone and ethylene propyl-

resistance to oxidizing chemicals, as

conduits and operator buttons, opera-

ene diene monomer (EPDM).

well as gas and oil products.

tor control screens and signal lights.

Silicone is a synthetic elastomer

A more recent improvement is the

that stands up well to temperature

introduction of a dual seal. Both the

and has low reactivity with chemi-

door and the enclosure have a gasket

RICK RICE is a controls engineer at Crest

cals. They come in a variety of

installed. The door gasket mates up

Foods (www.crestfoods.com), a dry-foods

durometers, or hardness, and colors.

with the frame of the enclosure, when

manufacturing and packaging company

EPDM is also a synthetic polymer

closed, while the enclosure gasket

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1/19/24 10:33 AM

component considerations

Shawn Cox contributing editor brianshawncox@gmail.com

What is pulse-width modulation? PULSE-WIDTH MODULATION (PWM) is a technique for vary-

Applications of PWM offer numerous benefits across

ing the width of electrical pulses to control the amount of

various industries. Accurate control over motor speeds is

power delivered to a device. It allows for precise control, as

made possible by PWM, which improves performance and

well as efficient energy consumption. PWM is critical in a

efficiency in robotics and industrial machinery. PWM is a

wide range of applications. It enables energy-efficient motor

commonly used technique for dimming LED lights. It offers

speed control, precise light-emitting-diode (LED) dimming,

flicker-free, smooth brightness adjustments for a variety

audio amplification, solar power and battery charging.

of applications, including display technologies and archi-

Pulse-width modulation works by quickly switching a

tectural lighting. PWM charge controllers in solar power

signal with varying widths between two states, usually high

systems control battery charging to maximize efficiency

and low. The average voltage over

and extend battery life.

time determines the power delivered, allowing for precise control. The pulse width is adjusted to achieve the desired results. By varying the width, the average

PWM charging techniques are

PWM offers energy-efficiency and power-savings benefits by adjusting the width of the pulses.

voltage or current can be controlled, resulting in different mo-

employed in a variety of batterypowered devices to optimize charging rates and enhance battery performance. PWM implementation techniques can be broadly catego-

tor speeds, LED brightness levels, or audio volumes. A PWM

rized into hardware-based and software-based approaches.

waveform consists of a series of pulses. The pulse width

Hardware-based PWM utilizes dedicated hardware mod-

represents the “on” time, whereas the period represents the

ules or specialized microcontrollers with built-in PWM

total length of each cycle. The duty cycle is defined as the

capabilities. This approach provides precise and efficient

pulse width-to-period ratio.

PWM generation, making it suitable for applications with

Energy efficiency and power savings: PWM offers energy-

stringent timing requirements, such as motor control and

efficiency and power-savings benefits by adjusting the

power electronics. Software-based PWM, on the other hand,

width of the pulses to regulate the power delivered. This

utilizes general-purpose microcontrollers or digital signal

technique eliminates the need for energy-wasting resistors

processors to generate PWM signals through software

and provides on-demand power delivery, reducing energy

algorithms. While it offers flexibility and ease of implemen-

consumption and costs.

tation, software-based PWM may not achieve the same level

Precise control and flexibility in various applications: PWM provides precise control and flexibility in various

of accuracy and timing control as hardware-based solutions. When considering PWM controllers and industrial con-

applications by adjusting the duty cycle of the pulses. This

trollers (ICs) available on the market, factors such as resolu-

allows for customization and adaptability, enabling fine-

tion, frequency range, input/output compatibility and cost

tuning of parameters, optimal performance optimization

should be considered. Different manufacturers offer a range

and accommodation of diverse requirements. From motor

of options, allowing designers to choose the most suitable

speed control to LED brightness adjustment, PWM offers

solution based on their specific requirements.

versatile control options for achieving desired results with accuracy and ease. Reduction of noise and electromagnetic interference

The choice between hardware-and software-based PWM and the selection of controllers depends on the application’s needs, performance requirements and cost.

(EMI): PWM helps reduce noise and EMI by minimizing abrupt changes in power levels, resulting in cleaner and

Shawn Cox is a licensed master electrician/PLC programmer.

more reliable signals for improved performance and sig-

He was co-owner/operator of Bobby Cox Electric for 15 years

nal integrity.

and is currently employed by BMW Manufacturing as an ESA.

16 / January/February 2024 / ControlDesign.com

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automation basics

Charles Palmer contributing editor

Motion control relies on feedback sensors IN ANY MOTION-CONTROL SYSTEM, a set of interconnected

ac motors, such as induction and synchronous motors, and

components is necessary. Two types of control are common-

stepper motors. Motors generate rotational or linear motion

ly used—open-loop control and closed-loop control. Each

based on the applied electrical signals. They provide the

has its own system dynamics and its own pros and cons.

mechanical force needed to move loads in the system.

Each hardware item has a specific role to play in the overall

The controller normally has a pre-set speed, which in

system concept. The components’ roles, types and functions

control terms, is known as the setpoint or set value (SV). The

comprise the system.

operator selects this as the required speed. The motion sen-

Feedback sensors, also known as position or motion

sor sends a signal to a comparator block within the control-

sensors, provide real-time information about the actual

ler. This signal is then compared to that value chosen by the

position, speed and sometimes

operator and the difference, or

torque of the motor or the system being controlled. Common types of feedback sensors include encoders, resolvers, potentiometers and Hall effect sensors. Feedback

error, is then used to either slow

Feedback sensors, also known as position or motion sensors, provide real-time information.

sensors continuously monitor

or speed up the motor until the two signals are the same, which is how feedback control works. The controller sends signals to the drive based on the

the actual motion and provide

desired motion profile. The drive

feedback to the controller. This feedback is crucial for the

modulates the power supplied to the motor according to the

controller to adjust and maintain the desired motion, ensur-

control signals. And the motor converts electrical power into

ing accuracy and reliability.

mechanical motion, moving the load.

The drive is an electronic device responsible for control-

Feedback sensors continuously monitor the actual motion

ling the electrical power supplied to the motor. Drives can

and provide feedback to the controller, which uses the feed-

be categorized as variable-frequency drives (VFDs), servo

back information to adjust the control signals, ensuring that

drives and stepper-motor drives. Drives take the control sig-

the system maintains the desired motion characteristics.

nals from the controller and modulate the power supplied to

In an open-loop system, there is no speed sensor and

the motor, adjusting factors like voltage and frequency. The

hence no feedback. In an example of a closed-loop speed-

drive ensures that the motor operates at the desired speed,

control system, the tachometer, or speed sensor, might

torque or position based on the control inputs.

provide actual speed sensing, with the data transmitted

The controller is the brain of the motion-control system,

back to the comparator block, in negative polarity = nega-

responsible for processing commands, receiving feedback

tive feedback. The use of feedback sensors in a closed-loop

and generating control signals for the drive. Controllers can

system allows for real-time correction and compensation

be programmable logic controllers (PLCs), microcontrollers,

of errors, improving accuracy and stability. Closed-loop

digital signal processors (DSPs) or dedicated motion control-

systems are also more robust and can handle disturbances

lers. The controller receives input commands—setpoints—

or variations in the load.

specifying the desired motion profile. It compares these set-

When considering the design and setup of an efficient

points with the feedback from the sensors, calculates any

speed-control system, one should be aware of the old adage,

necessary adjustments and generates control signals sent to

“A chain is only as strong as its weakest link.”

the drive. The controller ensures that the system follows the desired trajectory or achieves the specified motion goals. The motor is the primary actuator responsible for con-

Charles Palmer is a process control specialist

verting electrical energy into mechanical motion. Common

and lecturer at Charles Palmer Consulting (CPC).

types of motors used in motion control include dc motors,

Contact him at charles101143@gmail.com.

18 / January/February 2024 / ControlDesign.com

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OPC UA continues to expand its reach Security, interoperability and speed change industrial networks by Mike Bacidore, editor in chief

SEVEN INDUSTRIAL-AUTOMATION veterans shared their

Jay Hughes, field engineering supervisor, Omron Automation:

thoughts on open platform communications unified archi-

Authentication and encryption. By requiring

tecture (OPC UA), programmable logic controllers (PLCs), the edge and cloud-based computing. Tobey Strauch is an independent principal industrial controls engineer in Fremont, California. Karthik Gopalakrishnan is a technical consultant at Yokogawa.

credentials, OPC-UA can be an important asset in addressing cyber vulnerabilities before bad actors can deploy techniques such as “man in the middle.” This is even more significant when you add in the power of high-resolution data and the cost of cyber attacks becoming cyberphysical. With a 9% compound annual growth rate of

Deane Horn is director, marketing, at Softing.

OPC-UA Foundation membership over the past five years,

Prashant Adkoli is product manager of MindConnect at

it’s clear that users of this technology agree. This is a huge

Siemens Digital Industries Software. Jay Hughes is field engineering supervisor and Thomas

testament to both the technological ethos and the advancements which have fueled both adoption and utility.

Kuckhoff is product manager—controllers and industrial PCs—at Omron Automation. Steve Ward is the EMEA director of application engi-

Karthik Gopalakrishnan, technical consultant, Yokogawa: The

most significant change we have seen is the

neering, Controls & Software at Discrete Automation, Em-

adoption of the technology more than the

erson. In his role, Steve leads the pre-sales support team

technology itself. If we had asked anyone to use OPC UA five

for machine automation in the Europe, Middle East and

years ago, there would have been a big pause due to

Africe (EMEA) region. In addition, he serves as a pre-sales

uncertainty. Today, however, it is a requirement over the

application engineer and solution architect. Steve has

OPC Classic technologies. We see almost all vendors

nearly 40 years of experience in the industrial automation

adopting OPC UA as a standard among all the technologies.

industry and earned his master of scienece (MSc) degree in information systems management.

Thomas Kuckhoff, product manager—controllers and industrial

What have been the most significant advancements/changes in technology that have affected OPC UA acceptance/implementation in the past five years?

ment in technology around OPC UA is in the foresight

PCs, Omron Automation: The most significant advance-

of OPC UA developers to create connectivity for sharing information between industrial devices with zero code. There is support for tag-based access and extensive security options. When there has been such great adoption over the past

Tobey Strauch, independent principal industrial controls

five years, hindsight bias is all too ready to become an alibi

engineer: Inductive Automation made the push for

for cognitive dissonance. This may mask the fact that the

an open supervisory-control-and-data-acquisition

most significant advancement is empowering so many man-

(SCADA) software and showed how easy OPC tag distribu-

ufacturers to leverage the foresight of OPC UA developers to

tion could be. Fortunately, since they came on the scene,

help so many facilities start moving data without intruding

more people have come up with ways to decrease network

on the performance of native architectures.

congestion—using user profiles, domain profiles, putting tags and parameters in scan time phases. It’s also possible

Deane Horn, director, marketing, Softing: Over the past five

to limit tags at a global level and then establish tag updates

years, several significant advancements and

based on changes or timing.

changes in technology have positively influenced

ControlDesign.com / January/February 2024 / 19

machine input

the acceptance and implementation of open platform communications unified architecture. Historically, a lot of events have fallen into place: • OPC first launched as an easy-to-use Ethernet and vendorneutral connectivity protocol. That set the stage.

automation and healthcare, thanks to its versatility, robustness and security • development of companion specifications to tailor OPC UA to specific applications—for example, strip out security for embedding OPC UA in field devices.

• OPC UA, also vendor-neutral, added encryption and security, along with a lot of other capability, but the next item would never happen without security. • Industrial plants began to implement digital-transfor-

Steve Ward, EMEA director of application engineering,

Controls & Software at Discrete Automation, Emerson:

While OPC UA continues to mature, the underly-

mation strategies that strategically integrated OT and IT,

ing OPC UA technology has been suitable for a wide variety

that is, integrated the factory-floor PLCs to business IT

of applications for many years now. Adoption of OPC UA is

networks and server to monitor performance, efficiency,

driven by several factors, one of the most important being

quality and a host of other process improvements like

cybersecurity. The ability for OPC UA messages to be signed

track and trace or downloading recipes (Figure 1). Without

and encrypted with passwords and certificates means that

encryption and security, IT departments would shut this

OPC UA is easy to secure, and the security may be extended

connection down.

to cover the most stringent requirements. As cyber-attacks increase, and as legacy systems are replaced, users are

Here are some other key developments:

looking for the most secure technology available, and OPC

• i ncreased focus on Industry 4.0 and Internet of Things (IoT)

UA meets that requirement. OPC UA also performs well in

• advancements in encryption and security

applications that need a combination of current, historian

•c loud computing and edge computing—OPC UA’s scalability

and alarm data, since it is one of the only protocols that

and support for complex data structures align well with

combines all three types of data into a single protocol.

these requirements, facilitating seamless cloud integration

Support for structures is also useful because, instead of

• i ntegration of machine learning (ML) and artificial intel-

offering data as a set of unconnected variables, a structure

ligence (AI)—OPC UA’s ability to handle extensive and

can combine related data pertaining to a single device. For

complex data models makes it well-suited for AI-driven

example, a motor structure can include status, start/stop

applications

commands, alarms and motor current, all in a single place.

• expansion in different industries—originally more focused on automation and manufacturing, OPC UA may expand into various other sectors like energy, building

What’s the most innovative or efficient OPC UA application you have ever seen or been involved with? Karthik Gopalakrishnan, technical consultant, Yokogawa:

One of the most innovative applications using OPC UA is as a core for Open Process Automation (OPA). OPA uses OPC UA to enable L2 systems such as I/O cards to directly communicate with servers using the same technology. OPA indeed levels the playing field and makes the entire system open and interoperable. Tobey Strauch, independent principal industrial controls

engineer: OPC lets us bring together different Figure 1: Industrial plants began to implement digital-transformation strategies that strategically integrated OT and IT, that is, integrated the factory-floor PLCs to business IT networks and server to monitor performance, efficiency, quality and a host of other process improvements.

20 / January/February 2024 / ControlDesign.com

original equipment manufacturers (OEMs) from the field to a server level or cloud in a short amount of configuration/programming time. This means data can be acquired remotely, either for diagnostics or for control.

machine input

Thus, maybe we are on the verge of work/life balance or blackout plant operations.

back is integrating into current machines without requiring additional equipment on the plant floor. OPC UA connectivity does exactly this. Perhaps that makes OPC UA a bit of an

Jay Hughes, field engineering supervisor, Omron Automation:

unsung hero. Without database connectivity, data playback

Our application engineering team just finished a

this efficient may not have been possible without connectiv-

project using OPC-UA recently at an automotive

ity as standard in Omron controllers.

facility. In this application, it was critical to get process data to operators, engineers and maintenance teams as quickly as possible, especially when the process data, trended over the course of a shift, was able to alert teams to a production issue. Latency in the flow of data increases downtime, and

How has OPC UA benefitted from the proliferation of components from multiple suppliers in machinery?

in the hyper-competitive automotive markets this down-

Thomas Kuckhoff, product manager—controllers and industrial

time adds up quickly.

PCs, Omron Automation: The foresight to develop

To create this efficiency the Omron application engineer-

database connectivity this open while creating con-

ing team supported an architecture to pull data from an

nectivity for sharing information between industrial devices

embedded OPC-UA server right to an Andon board. This

with zero code has been the rising tide to lift so many

Andon board not only was displayed right on the produc-

data-harvesting-capable devices on the plant floor. By

tion line but was mirrored on team member’s smart phones,

making the connectivity open, the OPC Foundation has

allowing the entire plant to be notified when a production

reduced inertia for adoptions which in turn has been the real

issue arose.

catalyst for all users to benefit from the OPC Foundation network effect. As we look to the future, this openness to

Steve Ward, EMEA director of application engineering,

foster collaboration within the industrial-automation

Controls & Software at Discrete Automation, Emerson: One

community could become a recipe for others to follow.

of our system integrators implemented a datalogging solution collecting 20,000 I/O tags every second. This

Prashant Adkoli, product manager, MindConnect, Siemens

is an extremely high throughput and an indication of the

Digital Industries Software: Not one supplier can supply

performance possible using OPC UA.

an entire set of components needed in an industry. A successful installation requires parts to be sourced from

Thomas Kuckhoff, product manager—controllers and industrial

different makers. This is not a problem when it comes to OPC

PCs, Omron Automation: Flexibility is rooted in the

UA since the specification governs connectivity as well as

entropy we have generated surviving up to this

data format. This is possible with its growing recognition as

point and debt we have accumulated as a result of our past

an interoperability standard in machinery.

technical decisions. The most innovative deployment of OPC UA is the deployment of connectivity to cut through the

Deane Horn, director, marketing, Softing : I see this has

complexity and make an efficient path for data to get to a

suppliers and end users benefiting. Suppliers have

central database. An example that comes to the forefront in

benefited because they can apply their expertise

the development around the Automation Playback function,

on products and be “in the game” simply by having an open

the advanced standard feature in the all-in-control platform

communications protocol. Customers benefit because they

technology. The Automation Playback is the convergence of

can select best-in-class solutions and not be forced into a

data, video, program structure and ladder logic in the same

proprietary ecosystem by one vendor.

development environment where programs are designed and commissioned through 3D simulation. All playback is time-synced and event-triggered to allow local and remote team members to quickly and accurately

Tobey Strauch, independent principal industrial controls

engineer: It’s in the definition of “unified architec-

ture.” This allows everyone with obsolete equipment

diagnose issues without interrupting production. Of course,

to talk across new networks and develop improvements

the only way to efficiently achieve this scale of data play-

without having to do it all at once. If you can get the data, you

ControlDesign.com / January/February 2024 / 21

machine input

have eyes to control it. I think we need more training and

with poor security is not a good solution. Going forward,

more understanding on the plant-floor level because we are

we expect OPC UA to play a key role in ensuring that a

losing some people when the software layers get added.

manufacturing facility can meet digital-transformation and Industry-4.0 goals through interoperability with a

Steve Ward, EMEA director of application engineering,

high level of security.

Controls & Software at Discrete Automation, Emerson: OPC

UA is open and adopted by many vendors, allowing interoperability of equipment, which is a major benefit for users. As users look to replace legacy equipment,

Thomas Kuckhoff, product manager—controllers and

industrial PCs, Omron Automation : The methods to

visualize data and take action are numerous.

open protocols that are easy to use and that are secure are

Regardless of using off-the-shelf third-party software or

replacing legacy protocols that are restricted to one or a few

proprietary programs, facilities need a common method to

vendors and that do not offer any security.

safely transport the data. OPC UA is a huge part of this, not only because of the inherent design of the communication,

Jay Hughes, field engineering supervisor, Omron Automation:

but also because of the ability to leverage OPC UA while

So much of the power of OPC-UA is the ability to

preserving the robustness of the control architecture.

allow supervisory control and data acquisition (SCADA) software communication to not require a path along

Prashant Adkoli, product manager, MindConnect, Siemens

a proprietary protocol to connect to a programmable logic

Digital Industries Software : A manufacturing system

controller (PLC). OPC-UA has benefitted from the prolifera-

consists of different sources and sinks. It

tion of components from multiple suppliers in machinery as

involves supervisory control and data acquisition

OPC-UA allows users to take complexity out of the architec-

(SCADA), machine data on one side and a manufacturing

ture—complexity that can often be attributed to having a

execution system (MES) and/or enterprise resource

multitude of proprietary protocols on the shop floor.

planning (ERP) on the other end. Each of the systems can

By making the connectivity open, the OPC UA Foundation

further contain disparate data sources and thus own data

has reduced inertia for adoptions which in turn has been

formats. In such a large and critical system, OPC UA plays

the real catalyst for all users to benefit from the OPC-UA

a very important role with its inbuilt nature such as

technology. As we look to the future, this openness to foster

reliability and interoperability with uncompromised

collaboration within the industrial-automation community

security. MES with standardized OPC UA has already

could become a recipe for others to follow.

proven its value in the manufacturing industry by establishing a very reliable connection between the

Karthik Gopalakrishnan, technical consultant, Yokogawa:

extreme ends of the large system.

The biggest value of OPC UA is moving away from OPC Classic vulnerabilities. OPC UA makes communication more secure and structured. Especially with so many vendors wanting to access data, it is impera-

Steve Ward, EMEA director of application engineering,

Controls & Software at Discrete Automation, Emerson :

Industry 4.0 and the Industrial Internet of Things

tive that we consider cybersecurity as the core for all

(IIoT) have driven adoption of OPC UA. There is a realiza-

connectivity. OPC UA takes the security to the next level by

tion throughout industry that plant-floor devices contain

encrypting the data at its source.

an incredible amount of useful data. That data can be collected and turned into information that can reduce

Can you explain how Industry 4.0 initiatives or the Industrial Internet of Things has impacted the use of OPC UA in manufacturing?

downtime, reduce scrap, reduce operating costs and increase efficiency. The technology itself is becoming easier to use, and the growth of similar technology in the consumer and commercial world is raising awareness;

Karthik Gopalakrishnan, technical consultant, Yokogawa :

however, there remains a skills gap in the automation

Interoperability is a core characteristic of

industry. The growth of sustainability efforts is also

Industry 4.0. However, an interoperable network

driving adoption of new technologies.

22 / January/February 2024 / ControlDesign.com

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machine input

Deane Horn, director, marketing, Softing : Historically,

to take complexity out of their designs to become more

PLCs and the plant floor were protected from

flexible, as this flexibility allows facilities to adopt future

business systems and software by firewalls.

innovations more quickly.

Industry 4.0 and IIoT have created a need to more tightly connect OT to IT, but this is dangerous without the right

Steve Ward, EMEA director of application engineering,

security. OPC UA can meet the security requirements,

Controls & Software at Discrete Automation, Emerson: OPC

which becomes an enabler for Industry 4.0 and IIoT.

UA is useful in both small embedded systems and for larger cloud-based applications. In small applications,

Tobey Strauch, independent principal industrial controls

the ability to browse data means that a system can be

engineer: I think industrial applications probably

configured very quickly without having to understand a

influence the Industrial Internet of Things more,

complex data structure. In larger applications, the ability to

based on the need for having easy communications across

send enormous amounts of data securely is often key. OPC

platforms. Also, hardware is allowing us to do this based on

UA also includes context about the data that can make it

Ethernet capacity. Now that Ethernet is going to single pair

more useful than protocols like message queuing telemetry

with power and communications, the sky is the limit.

transport (MQTT) that do not attempt to define the data, although efforts like Sparkplug mean that MQTT may also

Jay Hughes, field engineering supervisor, Omron Automation:

be used more easily in larger applications.

When distilling down the challenges in facilities when implementing an Industry 4.0 campaign, it is important to keep in mind that facilities need to get the data from centralized control without compromising

Tobey Strauch, independent principal industrial controls

engineer: I find OPC to be convenient in either case.

Two things you must ask:

process performance, securely send data to central

• Where is your device located?

locations and efficiently visualize the data.

• Where do you want that device data?

Embedding an OPC-UA server within the machine auto-

We are no longer limited by field, demarcation, IT-OT

mation controller (MAC) is at the very heart of addressing

convergence or a motor control center (MCC). What the

all three of these challenges. Industry 4.0 has definitely

question becomes is: Do I have a switch in the vicinity?

aided the adoption of the OPC-UA through its efficiency and

I can have a vibration sensor on an oil rig in the Gulf of

security. Industry 4.0 has also been a real driver for Omron

Mexico register a 14.6 mA value; a supervisory-control-and-

to embed an OPC-UA server right in our flagship MACs,

data-acquisition (SCADA) system in Texas show an alarm;

which of course aids greater adoption.

and a reliability engineer in Norway, say, “What are we going to do about it?” within an hour or less.

Do you find OPC UA more useful in small embedded systems of larger cloud-based applications?

Take it to the next level: automatically generate a maintenance ticket, and a computer dispatches a tech to verify/validate/fix what the computer saw. This is what OPC UA gives us. However, OPC UA/data access (DA) is not good for trans-

Jay Hughes, field engineering supervisor, Omron Automation:

fer over networks, so OPC UA/DA must be converted either

Regardless of scale, we find OPC-UA more useful

on the OT side or the IT side, or proper tunneling must be

in systems or applications where new data-trans-

used. ABB uses Cogent DataHub. Thus, use of OPC adds a

mission solutions must integrate into existing architec-

complication for the data. Hardware guys may complain

tures, specifically applications with a host of proprietary

about speed if you have two-way control.

protocols. While adding an additional computer to the shop floor loaded with middleware may appear simple, we also

Karthik Gopalakrishnan, technical consultant, Yokogawa :

know the answer—which is obvious, simple and logical—

Scalability is a strong OPC UA benefit. Using the

very well is, more often than not, wrong.

OPC UA broker as the data source will ensure

OPC-UA is more useful at facilities that have accumu-

that a solution can be scaled all the way from a small

lated a large amount of technical debt and need to start

on-premises system to a large-scale cloud application.

24 / January/February 2024 / ControlDesign.com

machine input

Today, more vendors are adopting the cloud and moving toward a software-as-a-service (SaaS) model. OPC UA enables the robust, secure connectivity and ease of connection in a SaaS solution.

• Security: OPC UA provides robust security features, which are essential for cloud-based applications dealing with sensitive data and requiring secure communication. • Complex system integration: Large applications often involve complex system integrations. OPC UA’s comprehen-

Prashant Adkoli, product manager, MindConnect, Siemens

sive feature set supports complex data models and commu-

Digital Industries Software: It is seen that the OPC UA

nications, making it well-suited for these environments.

server can be scaled down to 15 kB RAM and 10 kB

In summary, while OPC UA can be more resource-

ROM. This allows small embedded systems to house the OPC

intensive than some protocols traditionally used in small

UA severs in them. Also, small embedded systems need to be

embedded systems, its scalability, security and interoper-

efficient when exchanging data with an external system.

ability features make it highly beneficial in larger, complex,

OPC UA addresses such use cases nicely in its specification.

cloud-based applications. However, for smaller systems

For example, Part 14 of the OPC UA is entirely dedicated to

with limited resources and real-time requirements, a sim-

efficient pub/sub service. By adhering to OPC UA pub/sub,

pler protocol might be more appropriate unless scalability

they can efficiently exchange data with larger cloud systems.

and future integration with larger systems are anticipated.

Deane Horn, director, marketing, Softing : One answer is it

is most useful in the middle. Small embedded systems like sensors and devices are normally

How have the security and scalability of OPC UA made it more user-friendly?

connected to PLCs and distributed control systems (DCSs),

Deane Horn, director, marketing, Softing : Regarding

so OPC UA is not normally needed here. Then PLCs and

security, encryption and authentication have

DCSs have the challenge of connecting to business systems

enabled OT to cross into IT more easily. In fact,

and cloud applications. This middle connection, PLC-to-

this will challenge the entire Purdue Model since the

software/cloud is where OPC UA is most useful.

historical layers of protection will not be required.

The second answer is OPC UA is more useful in cloud-

For scalability, I’m not sure. Although I know that OPC UA

based applications.

being an untraditional protocol with tons of flexibility has

In small embedded systems:

enabled some interesting OPC UA solutions that solve chal-

•R esource constraints: Embedded systems often have lim-

lenges of managing and maintain five to 10 or even hun-

ited processing power, memory and storage. OPC UA, be-

dreds of OPC UA sources and destinations without needing

ing a robust and feature-rich protocol, might require more

to manage each on it its own. For example, how do you

resources than some embedded systems can provide.

manage this? OPC UA allows for solutions to be developed

•R eal-time requirements: Many embedded systems require

to manage this and keep this secure.

real-time performance. While OPC UA supports real-time operations, the complexity of the protocol could intro-

Steve Ward, EMEA director of application engineering,

duce latency, which might be a critical factor for certain

Controls & Software at Discrete Automation, Emerson:

embedded applications.

Scalability in terms of OPC UA means that users

•S calability and flexibility: For small-scale applications,

can start with small applications and grow them without

the comprehensive features of OPC UA might be under-

worrying about hitting a performance or capacity limit at a

utilized, yet they offer scalability if the system needs to

later date. This is of great benefit for many users. Larger

expand or integrate with larger networks in the future.

systems can implement OPC UA browsers and discovery

Larger cloud-based applications:

servers to make it easier to find data on the corporate

• I nteroperability: OPC UA excels in environments where

network. Security and ease of use are often opposed, but

interoperability between different systems and devices is

the growth of tools like Emerson’s PAC Security Centre

crucial. In large cloud-based applications, this interoper-

allows non-technical users to implement security more

ability facilitates seamless integration and data exchange

easily. Most vendors need to do more to make security

across diverse platforms.

easier to use, though.

26 / January/February 2024 / ControlDesign.com

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Karthik Gopalakrishnan, technical

consultant, Yokogawa: As

mentioned, scalability is a key driver for OPC UA. Scalability can be driven by more secure systems, which adopt technologies such as OPC UA. Tobey Strauch, independent

principal industrial controls engineer: This is yet to be

seen, I think. It’s so individually driven based on company policies. OPC UA means that the networks need to be tighter, so to speak, as far as security. We must isolate operations and data collection and then whitelist users via firewalls and network isolation based on machines, based on users, based on functionality. I think we have huge gaps, in that there is not a push for making strong demarcation points and then allowing operations networks to shut off the information technology connec-

Figure 2: OPC UA can provide high-performance bidirectional contextual data transfer from the factory floor to the cloud in a secure, structured and streamlined manner.

tion if there is a breach. Also, there are not standards being applied, unless it’s demanded by the industry,

OPC UA addresses scalability. Also,

capabilities, such publish-subscribe

based on safety or applications like

the small footprint of OPC UA servers

(PubSub), will simplify interdevice

chemicals or nuclear.

has enabled its scalability.

communications (Figure 2). Currently this often needs an additional device

Prashant Adkoli, product manager,

MindConnect, Siemens Digital Industries Software : The

layered security model of OPC UA and

What future innovations will impact the use of OPC UA in manufacturing operations?

such as an industrial PC with human-machine interface (HMI)/ supervisory control and data acquisition (SCADA) software and associated

its scalability makes it a favorite for

Steve Ward, EMEA director of

configuration or scripting. But overall I

industrial automation. X.509-based

application engineering, Controls

think the biggest innovation will be

authentication secures the data

& Software at Discrete Automa-

the continued increase in computing

through encryption and message

tion, Emerson: Well-defined data

power along with reductions in cost.

signing. The standardized authentica-

structures make it much easier for

These will allow more devices to

tion reduces the learning curve

users to work with data. Special

become intelligent and able to support

during the onboarding process of the

interest groups can also consider

protocols such as OPC UA natively

OPC UA data servers. This authentica-

defining their own structures specific

without needing expensive gateways

tion is central in popular systems

for their industries and applications.

and without requiring external

where the OPC UA servers can

The addition of the Engineering Units

tools—for example, an intelligent

securely exchange the data with a

specification will add further context

device can be configured using a

wide range of support for applications

to data. The growth of peer-to-peer

built-in web server.

28 / January/February 2024 / ControlDesign.com

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It’s going to alternate and cause motion of that rotor as the magnets in the stator and the windings of the rotor align. And then as we start to rotate the commutation voltage changes from one winding to the next. We get continuous motion that way. With a brushless motor, we have to come up with a way to control the current that’s going through the windings. Instead of the windings being energized on the rotor, we now have the magnets within the rotor, and then the stator is energized. By varying the current, we have three different phases in there. We energize them a little bit out of phase. By varying the frequency of that signal or the voltage level, we can increase the torque and change the speed of the motor. With a stepper, we’re running that using a direct current to generate our magnetic field and then toggling off and on between two different wings called the A phase and B phase to generate that magnetic field to generate motion. With a servo, we have three different phases of voltage. That’s ac voltage that we’re sending through those windings to generate motion because we have to make sure that we have alignment between the phases and those voltages that we’re putting through the windings of the servo. Q: What are the advantages of decentralized vs. centralized motion control? A: At AMCI, we like to centralize everything through the PLC through a network interface. The operator can push a button, and it affects everything on the machine, but that’s not always necessary, and sometimes it’s not always practical or possible.

ONE PACKAGE

The drive and control can be put in the motor and mounted on the machine. Sometimes I just don’t have enough cabinet space to have everything in one enclosure, so I have to put something out separately on the machine. Or maybe I have a piece of equipment that comes in different stages, and maybe function B is only needed 40% of the time. I can remove that stage from the system and push A and C together. If everything is centralized, removing that B portion can sometimes be a little bit more difficult. I can always have part of that decentralization with a network protocol like an IO-Link or an Ethernet-type network that allows me communication back to the PLC for some sort of information-sharing. Q: Are you seeing customers looking for components that are IP67 or IP69 and can come out of the cabinet?

A: It’s a big part of what we do here at AMCI every day. We started talking 15 years ago about the classic motion system—drive, motor and control—and putting everything in one package. We can now take the drive and the control out of the cabinet and put it in the motor, which now mounts out on the machine. We can reduce cabinet space and heating by taking the drive out of the cabinet. Air-handling can be different within the cabinet, and, instead of running encoder cables and motor cables, I can run one power cord—say, 24 Vdc or 48 Vdc—and a network cable, and that’s all I have to do. With the dual-port networking that we offer, I only run one network cable and can daisy-chain several motion axes together. For more information, visit www.amci.com.

ControlDesign.com / January/February 2024 / 31

cover story

Through a global pandemic, supply-chain strains and a surge in automation demand, the integrated circuit stands ready by Anna Townshend, managing editor

32 / January/February 2024 / ControlDesign.com IMAGE GENERATED BY SHUTTERSTOCK AI / SHUTTERSTOCK.COM

cover story

he worst of the supply

leaner. As a result, it became normal

chain woes brought on by

for components to be overnighted or

companies to redesign electric circuit

the pandemic are largely

This led many industrial automation

even flown directly to plants to keep

boards to consolidate the number of

in industrial automation’s rear-

lines running, given, it was argued,

components used as much as possible.

view mirror, but microelectronics

that the inventory savings far out-

“Additionally, system-on-a-chip (SoC)

remains a sore spot. The supply and

weighed the cost of expediting.”

designs that could support EtherNet/IP

demand imbalance for electrical com-

When COVID-19 shut down this

and other leading industrial automation

ponents was reaching another critical

complex global supply chain, it

networks reduced the need for automa-

point earlier this year, but industry

drove widespread product short-

tion vendors to stock multiple chips for

largely redesigned its way out of the

ages, hampered by worker shortages,

different networks,” Fales adds.

crunch. The U.S. government contin-

delivery-equipment breakdowns and

ues to support domestic semiconduc-

border challenges. “The aftermath of

tor manufacturing for those all-impor-

the pandemic led many companies to

The dependence on microelectronics

tant microchips, but those efforts will

question continued use of outsourc-

Pepperl+Fuchs, which works in nearly

take time to produce real results. Many

ing since global wage differences were

every industry, didn’t see one that

vendors have highlighted their success

lessening and supply chain localiza-

wasn’t affected by global supply-chain

stories from making it through the

tion opened up the possibilities for

issues following the pandemic, says

supply-chain shutdown, bolstered by

flexibility, enhanced sustainability

Perry Hudson, market manager, packag-

strong relationships and new part-

and higher delivery certainty,” says

ing at Pepperl+Fuchs. The fundamen-

nerships. Many continue to innovate

Fales. “Additionally, greater reliance

tal issues of COVID-19 compounded

and update their businesses with a

on industrial automation kicked into

supply-chain issues because states

renewed sense of agility and value.

high gear to help reduce the pandemic-

had different policies across different

related impacts of a lack of available

industries, combined with policies from

workers across industries.”

companies and countries around the

How the supply chain broke With the economy humming and the

Fortunately, demand for industrial

world. “The result was that the produc-

global supply chain in sync, many

automation products increased during

tion of materials and most importantly

manufacturers had moved toward

the pandemic, but unfortunately this

electronic components came to a stand-

just-in-time and lean-manufacturing

further strained the industrial sup-

still,” says Hudson. “Countries closed

practices in lieu of more traditional

ply chain. “Not only were companies

their doors, shipping came to a halt, and

statistical methods for inventory

heavily relying on existing automa-

nothing moved from A to B.”

control. The development and success

tion, driving spare device orders, but

Food and essential-goods manu-

of the global supply chain allowed

also the scarcity of employees made

facturers were affected first during

companies to keep fewer products on-

adding more automation very desir-

the pandemic, and Hudson says many

site, which had its benefits.

able for end users,” Fales says.

factors culminated in creating the

“These new approaches reduced

Across all industries, the global

supply-chain crisis. With consumers

costly stockpiles of inventory and co-

demand for electronics to support

at home, working remotely and shop-

ordinated flows of components across

remote workers also increased demand

ping online, some panic led to product

multiple locations to meet demand as

substantially. Likewise, the semicon-

hoarding, and those manufacturers

close to the predicted time as neces-

ductor industry under strain, Fales says,

struggled to meet demand early on in

sary,” says Steve Fales, director of

began to focus on producing the most

the pandemic. Low interest rates and

marketing at ODVA. “At the same time,

complex, and most profitable, chips,

more mobility from remote work led

offshoring was kicking into high gear,

“leaving the supply of simple and low-

to people moving and increased new

making supply chains both longer and

cost microcontrollers lagging,” he adds.

home construction, which eventually

ControlDesign.com / January/February 2024 / 33

cover story

put a strain on construction materi-

placed with something else in current

force development. It also created a

als. At the same time, cryptocurrency

designs, so many industries that made

25% tax credit for capital investments

was increasing its use of electronics

automobiles, CAT scans, program-

in semiconductor manufacturing.

for mining; and gaming systems, new

mable logic controllers (PLCs), PS5s,

The Biden Administration says the

phone development and media tech-

missile controllers, blood analyzers

United States produces about 10% of

nology for remote workers all demand-

and more all needed FPGAs. Hudson

the world’s global supply of chips,

ed more and more microelectronics,

says the FPGA problem first came to

and none of the most advanced chips,

right when the pandemic slowed

light around April 2022, and by October

and it wants the CHIPS Act fund-

production. Eventually, the automotive

2022 the current supplies were taken.

ing to change that. One year after

industry suffered its own supply chain-

By the beginning of 2023, the situation

enactment, the administration says

crisis because it didn’t have enough

was critical, he says. Many plants that

that companies have announced

microelectronics to produce the cars

had shut down were back up and run-

more than $166 billion of private

consumers demanded.

ning, but production takes months to

investment in semiconductor and

restart and more to reach the needed

electronics manufacturing. At least

production levels.

50 community colleges in 19 states

“We live in a world today that is largely based on electronics,” says Hudson. “At the heart of all electron-

“Companies, once again looking

ics are microchips. If you shut down a

ahead, began to redesign their circuit

programming to develop the semi-

microchip plant due to a global pan-

boards,” says Hudson. “This single but

conductor industry workforce.

demic, you stop producing microchips.

monumental task helped lead the world

But the orders kept coming 200 times

out of the microprocessor crisis.”

have announced new or expanded

The first round of funding applications was launched in February 2023

faster than before because of panic

Demand also declined post-pan-

by the Department of Commerce at

and impulse-buying. It takes time to

demic, which has helped micropro-

$39 billion and focused on companies

get a chip factory up and running,

cessor supplies. Hudson says, for

already making large investments

and, as the order book grew, so did the

companies that took the necessary

in semiconductor facilities or larger

crisis. Over time, the demand for all

steps early on to secure multiple mi-

supply-chain projects. On September

things—precious metals, petroleum,

croprocessor suppliers so that they’re

29, 2023, the Commerce Department’s

plastics, wood—was affected.”

not dependent on one single source,

CHIPS for America program released

“the crisis is over.”

another funding opportunity, seeking struction, expansion or modernization

integrated circuits (ASICs) and field-

The CHIPS and Science Act progress

programmable gate arrays (FPGAs).

Microchip production has rebounded

ductor materials and manufacturing

“FPGAs are very popular because they

from the crisis, but it has yet to return

equipment with capital investments

are reprogrammable and can be con-

to pre-pandemic levels for many. The

less than $300 million.

figured to implement various digital

U.S. government has taken many ef-

In July 2023, the Department of

circuits and functions,” he says. “ASICs

forts in the past few years to shore up

Commerce and Department of De-

are custom-designed and have a fixed

domestic production for semiconduc-

fense also signed a memorandum of

function, so they are used for a specific

tor chips and support new production

agreement (MOA) to strengthen the

application. Both were in short supply

facilities for microelectronics.

U.S. semiconductor defense industrial

As an example of the microprocessor supply chain issues, Hudson points specifically at application-specific-

and had an incredible backlog because

applications for projects for the con-

In August 2022, the Creating Help-

of commercial facilities for semicon-

base and facilitate close coordination

they are used in all industries in all

ful Incentives to Produce Semicon-

on the CHIPS for America’s incen-

fields. This being said, FPGAs were

ductors (CHIPS) and Science Act was

tives programs. “Advancing U.S.

used by far more in most industries.”

enacted, which planned to make

national security is a top priority,”

This made FPGAs harder to find as

a nearly $53 billion investment in

says CHIPS Program Office Director

production slowed and demand in-

U.S. semiconductor manufacturing,

Michael Schmidt, who signed the

creased. FPGAs could not be easily re-

research and development, and work-

MOA on behalf of the Department of

34 / January/February 2024 / ControlDesign.com

cover story

Commerce. “Our departments must

priority focus areas. The 10 metrology

cal engineers and measurement sci-

work together and align on where and

focus areas include:

entists to expand both conventional

how we are making investments to

•a dvanced materials and devices

and advanced packaging capacity in

strengthen the U.S. industrial base.

•n anostructured materials

the United States.

This agreement will enable our teams

characterization

The Department of Commerce has

to coordinate the national secu-

•3 D structures and devices

received more than 550 statements of

rity review of applications, produce

•m aterials characterization for ad-

interest and almost 150 applications

semiconductor chips in America that our military relies on and bolster our domestic supply chain resiliency.” The CHIPS Act also includes $11 billion for semiconductor research

vanced packaging •v erification and validation of advanced models •a dvanced modeling for next-genera-

or concept plans for CHIPS incentives. One of the first preliminary agreements was announced December 11, 2023, with BAE Systems Electronic Systems.

tion manufacturing processes

The non-binding preliminary memo-

and development. This effort includes

•a dvanced measurement services

randum of terms will provide about $35

the development of the National

• i nteroperability standards for equip-

million in federal incentives under the

Semiconductor Technology Center (NSTC), a National Advanced Packaging Manufacturing Program (NAPMP)

ment and software • s tandards for automation, virtualization and security

CHIPS and Science Act to modernize the company’s Microelectronics Center, a mature-node production facility in

and up to three Manufacturing USA

• s upply chain trust and assurance.

Nashua, New Hampshire. The project

institutes to advance research and

Approximately $3 billion will

will replace aging tools and quadruple

commercialization of semiconductor

fund NAPMP, designed to drive U.S.

the production of chips necessary for

technologies. Research-and-devel-

leadership in advanced packaging.

critical defense programs including the

opment (R&D) efforts also include

In November 2023, the Department

F-35 fighter jet program.

the CHIPS R&D Metrology Program

of Commerce said an initial fund-

Pepperl+Fuchs’ Hudson notes that

to advance measurement science,

ing opportunity for this program is

the CHIPS Act has both economic and

standards, material characterization,

expected to be announced in 2024. At

political motives, as well. The CHIPS

instrumentation, testing and manu-

this time it also published The Vision

Act prohibits recipients from expanding

facturing capabilities, established by

for the National Advanced Packaging

production in China and in countries

the National Institute of Standards

Program, defining advanced pack-

that pose a threat to national security,

and Technology (NIST).

aging as a cutting-edge design and

“so it is both an economic incentive and

manufacturing method that places

a political countermeasure.”

In September 2022, NIST published a report: Strategic Opportunities for

multiple chips with a variety of func-

U.S. Semiconductor Manufacturing,

tions in a densely interconnected

which identified seven challenges that

two- or three-dimensional “package.”

“The success of the program is that

need critical attention from a metrol-

According to the report, this design

more than 600,000 jobs have been cre-

ogy perspective, including 32 elements

paradigm can help the sector achieve

ated since 2021, and construction has

for the path forward. In October 2022,

the ever-denser, smaller dimensions

increased by 116%,” says Hudson. “To

the CHIPS R&D Metrology Program

that the most advanced semiconduc-

date, companies have invested $166 bil-

consolidated the 32 elements into 20

tors require. Advanced packaging

lion in manufacturing, so they are doing

programmatic focus areas, and by

brings together chip designers, mate-

what they are supposed to do. The

November 2022, had narrowed the

rials scientists, process and mechani-

problem is that building plants takes

He says the main beneficiaries are the semiconductor manufacturers.

time, so we won’t see the actual results

Microchip production has rebounded from the crisis, but it has yet to return to pre-pandemic levels for many. The U.S. government has taken many efforts in the past few years to shore up production.

36 / January/February 2024 / ControlDesign.com

of these investments until 2024.” He thinks the investment efforts could reduce costs, but long-term supply issues for all microelectronics might persist beyond these initial efforts.

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cover story

Multi-source strategy and partnerships

Max Bänziger, chief operating officer

reduced the availability of special

at EAO. “In some areas, we built up

components and in many cases result-

The biggest challenge for human-

second sources or changed suppliers.”

ed in last-time buys, when a supplier

machine interface (HMI) manufactur-

The company examined its standard

stops producing a certain part or com-

ers were extended lead times from

practices looking for more flexibility,

ponent, which have largely subsided.

their suppliers, particularly for plastic

including a group-wide review and

Long-term, Bänziger forecasts lowered

compounds. They also experienced

supplier audits.

volatility for microchips from Asia

the supply crunch from electronics

“The positive result of these issues

production coming to the west. The

and surface-mount devices (SMDs).

is that it has transformed our supply-

company has also seen a recovery in

Increased expenses and lowered profit

chain management to become a more

supply for the plastics industry.

margins would eventually lead to ma-

robust and dynamic organization. As

Pepperl+Fuchs is still experiencing a

jor revenue losses, so HMI manufac-

a company, we are better prepared to

backlog for electric motors, but on the

turer EAO sought additional sources

handle shortages and disruptions in

whole, the crisis is over. “As already

and a multi-sponsor strategy for the

our supply chain,” Bänziger says.

mentioned, no industry and no manu-

most critical materials. “EAO built up inventories, which

Microchip production has increased

facturer was immune to component

and supply demands have eased in

issues during this crisis. To make mat-

is not ideal, but this works well for

2023, but lead times still remain lon-

ters worse, it was impossible to rely on

the short-term for small companies

ger than pre-pandemic, says Bänziger.

information about when manufactur-

with little purchasing power,” says

Increased inventories across industry

ers would receive components. The manufacturers who were honest and in constant communication with their customers survived best. Communicating delivery times in years rather than weeks was a situation that everyone got used to,” Hudson says. Gray Solutions, a system integrator,

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mostly felt the supply-chain crunch

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on PLC components and variable-frequency drive (VFD) shortages, notably for motion control. “This led to long lead times, which caused long project delays and forced us to choose the lesser of two evils— delays vs. re-design—both of which are costly and time-consuming,” says Jeremy Reed, instrumentation manager at Gray Solutions. The system integrator also saw supply-chain issues with Ethernet modules, analog cards, IO-Link modules and PLC safety mod-

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ules, but, overall, supply-chain issues have largely been eased this year. During the pandemic, the integrator saw many manufacturers shift

www.hammondmfg.com

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1/16/24 10:42 AM

cover story

lieu of what was available. “In many

thanks to the proactive measures and

people daily. New technologies

cases, customers found that some of

decisions we have taken in the past

like single-pair Ethernet, 5G wire-

the lesser-known suppliers were just

24 months. There are also many new

less, and data models that enable

as good as the big-name competitors,

companies that we are working with

edge and cloud infrastructures to

which eventually caused a shortage

as a customer, thanks to the same

optimize production with the help

for those brands, as well,” Reed says.

forward-thinking decisions made by

of artificial intelligence are set to

“It was beneficial for some of the

our management team,” says Hudson

further accelerate the value that in-

manufacturers, as they were able to

of Pepperl+Fuchs. “The lessons we

dustrial automation provides to both

sell to new customers and foster new

have learned and the investments and

industry and the world. While my

relationships.”

changes we have made have resulted

forecasting days are behind me, I’ve

in a more agile company that is ready

found that the foundational statis-

to face the future.”

tics are just as relevant today as they

As with many crises, the best rise to the top. Strong companies find agility fast when faced with no other choice. Like Gray Solutions, many companies

are driving the advances in artificial 3. Industrial automation became even more

intelligence that are set to enhance

came out of the other end of tragedy

foundational to the global economy.

worker productivity through coding

with some powerful insights into how

“Industrial automation has be-

acceleration, content development

to build stronger supply chains and

come an even more critical piece

for emails, meeting notes and re-

production processes. Here are three

of the global economy that houses,

ports, and production-loop optimiza-

more lessons learned from industrial

feeds and transports billions of

tion,” says Fales of ODVA.

automation supply-chain woes. 1. Supply chain management is more robust. “The positive result of these issues is that it has transformed our supplychain management to become a more robust and dynamic organization. As a company, we are better prepared to

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handle shortages and disruptions in our supply chain. This assures consistent supply to our customers which further strengthens our position as a global partner, combining both added value and increased dependability to our customers,” says Bänziger of EAO. 2. C risis led to forging new long-term relationships, partners and customers. “If you offer technology, there is no way you’ve made it through the supply-chain crisis without entering into new relationships or partnerships. If you haven’t, you most likely still have supply-chain issues. This goes both ways. There are many new companies that we are working with as a supplier,

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The Leaders in Automation program recognizes innovation, leadership and excellence among suppliers of automation software, technology and products.

40 / January/February 2024

Advanced Micro Controls/AMCI

Altech Corporation

B&R Industrial Automation

Contemporary Controls

DigiKey Electronics

Encoder Products Company

Endress+Hauser

EZ Automation

Hammond Mfg. Co.

Misumi

Mitsubishi Electric Automation

Motion

Moxa Americas

Novotechnik

Pepperl+Fuchs

RS Americas

SMC Corporation of America

Strongarm

VEGA Americas

ControlDesign.com / January/February 2024 / 41

ADVANCED MICRO CONTROLS INC. (AMCI)

A CONTINUOUS COMMITMENT TO INNOVATION AND SOLUTIONS Advanced Micro Controls Inc. (AMCI) is committed to taking automation technology to the next level, producing quality product along with quality service and support. We pride ourselves on providing the best PLC integration available in the market today. Advanced Micro Controls Inc (AMCI) is a U.S. based industrial technology company with a global presence. Our automation controls are sold all over the world, improving the performance of today’s factories and industrial systems. AMCI products help factories run more efficiently, make product manufacturing smarter, and automation environments more productive. Our Specialty I/O Modules, Position Sensing Technology, and Motion Control Solutions can be found in a variety of industrial, manufacturing, and military applications. Founded in 1985, Advanced Micro Controls Inc commitment to the industrial marketplace can be found in all areas of the company; Research and Development, Sales, Distribution, and Product Support. Our many years of PLC experience give us the unique opportunity to engineer products that directly talk to your PLC, providing the best PLC integration available in the market today. We started by giving customers a direct, easy and reliable way to get absolute position data quickly into the PLC. We want to take automation technology to the next level while continuing to provide reliable solutions to the most demanding industries. Our mission has, and will continue to be, to deliver a quality product backed by exceptional service and support. We take pride in knowing that every purchase will provide a reliable solution for many years to come.

Advanced Micro Controls Inc. (AMCI) 20 Gear Dr, Terryville, CT 06786

(860) 585-1254

42 / January/February 2024 / ControlDesign.com

hzimbouski@amci.com

https://www.amci.com/

ALTECH CORPORATION

For 40 years, Altech has been a leading supplier of Industrial Automation Components. As an advanced supplier of disconnect switches, miniature circuit breakers, terminal blocks and enclosures, Altech has been in the forefront of product advancements. Products such as its Manual Motor Controllers, which provide users with panel safety at a less expensive price. Altech is also a quality supplier of DC UPS system, sensor, safety devices and many other quality product lines. All products meet UL requirements and international standards, and are ROHS and Reach compliant. Altech is has n ISO 9001 certification. One of the benefits that Altech provides is the ability to successfully perform a multitude of services for customers. This starts with its employees where Product Managers provide technical support and partner with customers in design assistance, ensuring the best solution for the application. Next, an efficient Customer Service Department ensures that customers are informed with complete order information. Depending on the product, the versatile Assembly Department provides manufacturing, value added or customization services to expedite delivery. Altech’s Marketing Department has been highly recognized for its catalogs, advertising and Web site designs, while the Sales Department motivates over 20 manufacturer representative companies throughout North America, ensuring product information is current and complete. The Altech product line includes miniature circuit breakers, busbars, DC-UPS devices, digital panel meters, DIN rail terminal blocks, printed circuit board terminal blocks, contactors, industrial relays, motor discon¬nect switches, pin & sleeve devices, receptacles, foot switches, relay modules, safety relays, slimline relays, solid state relays, push buttons & pilot lights. As well as metal detection systems, ferrules, marking & engraving systems, fuses, power distribution blocks, corrugated tubes, liquid tight strain reliefs, programmable relays, digital multi-timer, test & measurement devices, LED panel lights, mechanical thermostats, panel filters, tower lights & wire ducts

The Altech Procase shows the large range of products offered.

are also available. Altech’s products meet UL and many international standards and all are RoHS compliant.

Altech Corporation

35 Royal Road, Flemington, NJ 08822 908-806-9400

info@altechcorp.com

www.altechcorp.com

ControlDesign.com / January/February 2024 / 43

B&R INDUSTRIAL AUTOMATION

Together with ABB, we are the only company to offer a complete portfolio of robotics, automation and software. As part of ABB, we continue to be guided by the same values: Creating more productive and sustainable manufacturing solutions with our customers. We share our automation expertise through training and collaboration. B&R is an innovative automation company with headquarters in Austria and offices all around the world. On July 6, 2017, B&R became a business unit of the ABB Group. As a global leader in industrial automation, B&R combines state-of-the-art technology with advanced engineering to provide customers in virtually every industry with complete solutions for machine and factory automation, motion control, HMI and integrated safety technology. With Industrial IoT communication standards like OPC UA, POWERLINK and openSAFETY as well as the powerful Automation Studio software development environment, B&R is constantly redefining the future of automation engineering. The innovative spirit that keeps B&R at the forefront of industrial automation is driven by a commitment to simplifying processes and exceeding customer expectations.

B&R Industrial Automation

1250 Northmeadow pkwy, Suite 100, Roswell, Ga 30076 770-772-0400

44 / January/February 2024 / ControlDesign.com

office.us@br-automation.com

https://www.br-automation.com

CONTEMPORARY CONTROL SYSTEMS

Providing innovative and reliable solutions to the industrial automation industry With more than 48 years of experience, Contemporary Controls is a leader in innovative solutions for industrial automation. Contemporary Controls’ customers are systems integrators, contractors and OEMs seeking simple, reliable networking and control products from a dependable source. Designed for unattended operation in environments not conducive to office-grade equipment, Contemporary Controls’ products provide convenient DIN-rail mounting in control panels, 24VAC/DC power, UL 508 and improved EMC compliance. Contemporary Controls’ Skorpion series of IP routers ease the integration of new machines into the existing network. Each machine consisting of multiple IP devices connects to the LAN-side while keeping the same IP settings for the devices and the application, lowering installation cost and eliminating troubleshooting. VPN models of the routers can provide secure remote access with the use of the RemoteVPN service from Contemporary Controls. Cellular routers with available data plans for hassle-free device activation provide quick and easy commissioning of the devices on the remote jobsite. A virtual private network (VPN) can provide secure access to remote job sites while giving systems integrators the flexibility to maintain systems from an offsite location. Contemporary Controls offers three VPN solutions to meet your remote access needs. Unmanaged switches provide a cost-effective method for expanding Ethernet networks. For troubleshooting, diagnostic switches allow a network sniffer to attach to an unused port on a switch and observe all traffic on the network. Contemporary Controls is headquartered in the US, with wholly owned operations in the UK, Germany and China, and self-manufacturing in the US and China. With over 48 years in business, four locations around the world serving the Americas, EMEA and APAC, and a reputation for service and technical support, Contemporary Controls is committed to making your automation projects successful.

Contemporary Control Systems 2431 Curtiss Street, Downers Grove, IL 60515, USA

+1 630 963 7070

info@ccontrols.com

www.ccontrols.com

ControlDesign.com / January/February 2024 / 45

DIGIKEY

Enabling the world’s ideas DigiKey is a global distributor of more than 15.3 million electronic and automation products from over 2,900 quality namebrand manufacturers. The company’s reputation extends worldwide as the original industry pioneer and provider of 1.9 million in-stock parts ready for immediate shipment. With products available in both design and production quantities, DigiKey is the best resource for designers and buyers alike. The key service differentiators that made DigiKey who they are today have laid the foundation for what DigiKey brings to the world of automation tomorrow. Through the use of digital tools, industry-leading supplier partnerships, and an unrivaled breadth of products, DigiKey paves the way as a one-stop shop to serve customers in a unique automation landscape. DigiKey is the preferred supplier for industrial automation, control and safety products, carrying a broad portfolio including advanced controls like PLCs, HMIs, motion, safety and robotics. DigiKey provides detailed technical resources and robust search functionality to help you find the exact parts you need, including a range of digital tools, on-demand multimedia library, comprehensive article library, community forums, and more. The company’s 2.2 million square foot Product Distribution Center expansion allows DigiKey to meet and exceed customers’ expectations more efficiently. From prototype to production, DigiKey has the resources and products to take your design to the next level! Learn more at www.digikey.com/automation.

DigiKey

701 Brooks Ave S., Thief River Falls, MN 56701 800/344-4539

46 / January/February 2024 / ControlDesign.com

sales@digikey.com

www.digikey.com

ENCODER PRODUCTS COMPANY

Encoder Products Company strives to be the world-wide leader in the manufacturing of motion control devices for automation. We focus on continually improving value by providing customers with high-quality products, fast delivery, excellent service, and expert technical support. We succeed with a consistent drive to reduce costs and improve efficiency.

CONVEYOR INSPECTION

Encoder Products Co. (EPC) is a leading global

MATERIAL HANDLING

manufacturer of incremental and absolute rotary encoders suitable for a wide range of industrial OEM and commercial applications. The company’s products are known for innovative designs, high-performance feedback, and robust housings. Established in 1969, EPC’s global headquarters is in Sagle, Idaho, with regional divisions in Asia and Europe. EPC offers a three-year warranty and is ISO 9001:2008 certified.

PICK AND PLACE

Encoder Products Company

464276 Highway 95 South P.O. Box 249 Sagle, Idaho 83860 USA 1-800-366-5412

sales@encoder.com

www.encoder.com

ControlDesign.com / January/February 2024 / 47

ENDRESS+HAUSER USA

We support our customers in improving their products and in manufacturing them even more efficiently. Endress+Hauser is a global leader in measurement instrumentation, services and solutions for industrial process engineering. They provide process solutions for flow, level, pressure, liquid analysis, gas analysis, temperature, recording and digital communications, optimizing processes in terms of economic efficiency, safety and environmental impact. The company serves a variety of industries, including chemical, oil & gas, food & beverage, water & wastewater, life sciences, power & energy, and primaries & metals. Endress+Hauser, a Switzerland-based company, was founded in 1953, and expanded operations to the U.S. in 1970. More than 80% of all Endress+Hauser instruments ordered and shipped within the U.S. are manufactured in the U.S. This means customers can rely on Endress+Hauser to deliver the products they need quickly. This strong manufacturing base is complimented by a complete network of sales partners and service locations to support its customers – wherever their instruments are installed. Premium services, customized solutions, project management and IIoT applications round out Endress+Hauser’s offering, helping customers gain efficiency, increase quality and maximize plant availability.

Endress+Hauser USA

2350 Endress Place, Greenwood, IN 46143, United States +1-317-535-7138

48 / January/February 2024 / ControlDesign.com

info.us@endress.com

www.us.endress.com

COMPANY NAME EZAUTOMATION

EZAutomation industrial automation products are Exceptionally Innovative, Made in America, Top Quality, and sold Factory Direct at Great Prices. At EZAutomation, no matter how big or small a customer is out of the tens of thousands we support from all industries, every customer is our top priority. EZAutomation, a division of the AVG Group, is a designer, manufacturer and direct on-line seller of innovative low cost automation products Made in America. The AVG Group has been in business serving the automation industry since 1968! EZAutomation, first launched in 2001 with its jaw dropping “two for one” concept HMI/Operator Interface, “EZTouch” now used by over 50,000 companies today. Over the past 23 years, EZAutomation has designed hundreds of industrial automation products, becoming a one stop shop, of affordable automation innovations, while proudly maintaining the “Made in America” status. EZ manufacturers HMI/Operator Interfaces, Programmable Logic Controllers (PLCs), Industrial IoT Gateways, SCADA systems, Din-Rail Mount Power Supplies, Industrial Panel PCs, Inductive Proximity Sensors, Rotary Shaft Encoders, all-in-one HMI-PLC combo units, Time Delay Relays, and much more. We are always at the fore-front of technology innovating new concepts based on industry needs while continuing to remain competitive against all our overseas competitors. At EZAutomation we focus on providing the best quality service that will put a smile on your face. Given that EZAutomation designs, manufacturers and directly sells its products right here in the Midwest, we flourish on customer feedback and new ideas based on application needs, so please do not hesitate to reach out anytime at applications@ezautomation.net.

EZAutomation

4140 Utica Ridge Road, Bettendorf, IA 52722 877-774-3279

sales@ezautomation.net

https://www.ezautomation.net/

ControlDesign.com / January/February 2024 / 49

HAMMOND MANUFACTURING CO. LTD.

Ham

475 Cayu Phone: 7 https://

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Hammond Manufacturing Co. Ltd. 475 Cayuga Rd, Ste 100. Cheektowaga NY 14225

716-630-7030

50 / January/February 2024 / ControlDesign.com

sales@hammfg.com

https://www.hammfg.com/

MISUMI USA

MISUMI is a manufacturer and distributor for configurable components and off-the-shelf products. With a vast selection of 80 sextillion standard and customized parts, MISUMI is an unmatched, one-stopshop to meet customer specifications. MISUMI is committed to empowering customers to do high-precision design work incredibly fast. With over 20 million products globally for automation, press die, and plastic mold applications, MISUMI is the most comprehensive, userfriendly engineering resource for a variety of industries including automotive, medical equipment, consumer packaging, semiconductor, and warehouse automation. MISUMI is one of the largest distributors of Japanese electronic components, and we also offer a wide selection of US/EU brands. Some of these top brands include Mitsubishi Electric, Fuji Electric, Patlite, IDEC, Murrelektronik, Nitto Kogyo, Takachi, Molex, and Eaton. We offer an extensive range of electrical, wiring, and control components at competitive pricing and fast shipping. Our product categories include electromechanical controls, power distribution, power supplies, enclosures, cordsets, connectors, and more. MISUMI simplifies the process for customers to find, configure, and order hard-to-find international and local electrical brands through our online and paper catalogs. We offer our customers valuable, timesaving services such as cut-to-length cabling, custom made cordsets (cable assemblies), and customizable hole cut-outs for enclosures. Discover the key features that sets MISUMI apart: • High-quality products

• Easy online ordering

• Competitive pricing

• Fast shipping

• Industry-leading brands

• Low or no minimum order quantities

MISUMI USA

1475 E Woodfield Rd Suite 1300 Schaumburg, IL 60173 800-681-7475

electrical@misumiusa.com

MISUMIUSA.COM

ControlDesign.com / January/February 2024 / 51

MITSUBISHI ELECTRIC AUTOMATION, INC.

At Mitsubishi Electric, we have built a tradition of technological leadership and innovation for more than 100 years. Our mission is to enrich everyday life through superior, technologically advanced automation products and solutions. And our people are the most critical component of delivering on that mission. Headquartered in Vernon Hills, Ill., Mitsubishi Electric Automation, Inc. is a U.S. affiliate company of Mitsubishi Electric Corporation. It offers a broad product portfolio, including programmable automation controllers (PAC), programmable logic controllers (PLC), human machine interfaces (HMI), variable frequency drives (VFD), servo amplifiers and motors, control software, computerized numerical controllers (CNC), motion controllers, robots, and low-voltage power distribution products. Additional information about Mitsubishi Electric Automation is available at us.MitsubishiElectric.com/fa/en.

Mitsubishi Electric Automation, Inc. 500 Corporate Woods Parkway, Vernon Hills, Illinois 60061

847-478-2100

52 / January/February 2024 / ControlDesign.com

mitsubishi-electric@meau.com

us.mitsubishielectric.com/fa/en/

MOTION AUTOMATION INTELLIGENCE (MOTION AI)

Motion Automation Intelligence (Motion Ai) is the leading high-tech solution provider for industrial automation across the United States. The expertise found in this group includes emerging automation technologies with focused solutions engineering for machine and motion control, pneumatics, robotics, machine vision, digital networking/ IIoT, industrial framing and custom mechatronic systems. Motion Ai’s engineering expertise and vast distribution network serve to implement automation solutions for a diverse set of end markets and applications. Many industries, including semiconductor, pharmaceutical, medical, logistics, automotive, aerospace and many more, benefit from Motion Ai applying best-in-class engineered systems, products, and services. Motion Ai serves various industries, including automotive, defense/military, agriculture, material handling, metals, textiles, food and beverage, construction, medical devices, pharmaceuticals, plastics, semiconductors and more. Whether it’s motion control, industrial networking or robotics, Motion Ai’s automation specialists provide product selection, sizing and configuration, technical support and application engineering services customized for specific automation needs. Other engineered solutions include motor controls, electric panels and machine-level controls that network to customers’ manufacturing controls. Motion Ai also supplies parts and entire assemblies, simplifying its customers’ supply chain. Motion Ai helps customers design and implement a trusted solution to decrease downtime and ultimately increase ROI.

Motion Automation Intelligence (Motion Ai) 1605 Alton Road, Birmingham, AL 35210

800-AUTOMATE

info@ai.motion.com

Ai.Motion.com

ControlDesign.com / January/February 2024 / 53

MOXA

Critical connectivity in automation is not just about having a fast connection; it is about making people’s lives better and more secure. Moxa’s connectivity technology helps to make your ideas real. We develop reliable network solutions that enable devices to connect, communicate, and collaborate with systems, processes, and people. Moxa is a leader in edge connectivity, industrial computing, and network infrastructure solutions for enabling connectivity for the Industrial Internet of Things. With over 36 years of industry experience, Moxa has connected more than 94 million devices worldwide and has a distribution and service network to serve customers in more than 87 countries. Moxa’s solutions cover a wide range of industrial applications, such as Energy Storage, Renewable Energy, Critical Power, Substation Automation, Rail, Intelligent Transportation, Oil & Gas, Marine, Manufacturing, Semiconductor, and more.

Moxa

601 Valencia Ave Ste 100, Brea, CA 92823 1-888-MOXA-USA

54 / January/February 2024 / ControlDesign.com

usa@moxa.com

www.moxa.com

NOVOTECHNIK U.S, INC.

Novotechnik introduced the potentiometer into the general machine engineering sector in the 1950s. Since then, the company developed technology used in position transducers and rotary and linear potentiometers that set the standard with outstanding linearity and reliability over an extended operating life. Today, Novotechnik has developed new technologies that are raising the standard, bringing a new level of linearity and reliability to non-contacting applications. An international sensor and transducer manufacturing company, Novotechnik’s US operations are headquartered in Southborough, Massachusetts. Contelec and Novotechnik are divisions of the Siedle Group. The company develops and produces a wide variety of rotary, and linear position sensors using contacting and non-contacting technologies for a wide range of motion control applications in the automotive, machine engineering, plastics, medical equipment, hydraulic, pneumatic, medical products and control industries. Novotechnik is world wide certified as one of the first companies to achieve the ISO/TS 16949 certification. This complies with the requirements of the automobile industry - VDA 6.1, QS9000, EAQF, AVSQ - regarding quality management systems. ISO 9001 Certified.

Novotechnik U.S, Inc.

155 Northboro Road, Southborough, MA 01772 508-485-2244

info@novotechnik.com

www.novotechnik.com

ControlDesign.com / January/February 2024 / 55

PEPPERL+FUCHS, INC.

For decades, Pepperl+Fuchs has been developing and distributing industrial sensors and sensor systems with the highest quality standards for use in automation technology. Our diverse product portfolio provides sensors for standard applications as well as customized solutions, so our customers always receive the ideal sensor system for their specific requirements. Our product portfolio of industrial sensors for factory automation is characterized by a high degree of innovation. It consists of inductive, photoelectric, capacitive, magnetic, and ultrasonic sensors. Additionally, we offer powerful components such as rotary encoders, positioning and identification systems (RFID, Data Matrix, barcode), AS-Interface, as well as suitable accessories. Industrial vision systems and sensors—one of the key sensor technologies of the future—are also part of our portfolio. Our full range of IO-Link sensors rounds off the comprehensive product range and paves the way for Industry 4.0 technology. State-of-the-art technologies and a global sales and production network make Pepperl+Fuchs the ideal partner for a wide variety of global industries. These include markets such as automotive, material handling, packaging, print and paper, doors, gates, and elevator construction, process equipment, mobile equipment, and renewable energy. The extent of our portfolio is backed by the product quality we offer. Our worldwide manufacturing sites are certified to ISO 14001, ISO 80079-34, or ISO 9001 through third-party certification bodies. We continuously optimize our processes to supply you with state-of-the-art technology and high-end products you can count on. Pepperl+Fuchs started its business in 1945 and from then on has grown continuously. Now we offer global support in virtually every area of the world with more than 40 subsidiaries on 6 continents.

Pepperl+Fuchs, Inc.

1600 Enterprise Parkway Twinsburg, OH 44087 330-425-3555

56 / January/February 2024 / ControlDesign.com

sales@us.pepperl-fuchs.com

www.pepperl-fuchs.com

Collaborating with designers, builders, and maintainers of industrial equipment and operations, we aim to make amazing happen for a better world. Our unrivaled choice of industrial products and business solutions helps drive organizations forward through ingenuity and innovation. We find solutions to engineering challenges, today and into the future. RS Americas is a global provider of product and service solutions for designers, builders and maintainers of industrial equipment and operations. We are part of RS Group plc, an FTSE 100 global leader in the omni-channel distribution of products and services for industrial equipment and operations. We carry more automation and control brand names than any other distributor in North America, with thousands of products from 700+ trusted suppliers (and growing). Our solutions seamlessly integrate with our products, helping you drive efficiency and reduce costs through each stage of the industrial lifecycle — whether you design, build, maintain, or protect equipment and operations. We’re always publishing relevant, insightful industry articles, interviews, and podcasts in our Expert Advice series. Everything we craft places critical knowledge and expertise at your fingertips, helping you identify product and technology solutions as unique as your business. We also offer a comprehensive suite of services and tools, including the industry’s largest collection of 360° product images, an extensive range of 3D CAD models, more than 1.1 million up-to-date datasheets, and a highly experienced technical support team.

7151 Jack Newell Blvd. S., Fort Worth, TX 76118 866-433-5722

CustomerService@na.rsgroup.com

us.rs-online.com/

ControlDesign.com / January/February 2024 / 57

SMC CORPORATION OF AMERICA

Our mission is to contribute to automation and labor-saving operations in industries through delivering high quality and high-performance automation control equipment to customers in all kinds of industrial sectors throughout the world. SMC Corporation is the leading global pneumatics and industrial automation components manufacturer. We support processing and packaging customers with our vast catalog of over 12,000 standard products including over 700,000 variations. Air Preparation • Actuators • Chemical Handling • Connectors • Directional Control Valves • Electrical Products • Sensors & Switches • Static Control • Temperature Control • Vacuum. This automation technology, including NEW product releases such as cobot end effectors, a combo electric rotary table/electric gripper, and battery-less absolute end coder for electric actuators, serves as solutions to the shortage of unskilled labor while creating new opportunities for technical talent. SMC’s commitment to sustainable products are designed to reduce unnecessary air and electrical consumption while still hitting rigorous performance expectations that meet or exceed existing specifications. By adopting the latest SMC technologies, we will help you lower energy costs and boost efficiencies, resulting in both cost savings and labor savings. SMC has a comprehensive approach focused on consuming less raw materials in our manufacturing process by making our products smaller, lighter and by extending the operating life thus reducing CO2 footprint. Our technical development centers in Japan, U.S., Europe and China house over 1,600 engineers. There are 560 sales offices (30 in the U.S. and Canada) supported by a sales force of over 8,400 in 83 countries and regions worldwide with domestic engineering, manufacturing and inventory. With its goal of ever more advanced automation, and using its many achievements as a base, SMC is developing high quality, highly reliable products to contribute to automation in industry, as well as in familiar areas of everyday life. SMC is dedicated to effectively delivering first-class business solutions to our customers through superior products and top-notch customer service.

SMC Corporation of America 10100 SMC Boulevard, Noblesville, IN 46060

800-762-7621

58 / January/February 2024 / ControlDesign.com

sales@smcusa.com

www.smcusa.com

STRONGARM DESIGNS, INC.

Strongarm serves the frontline workforce by providing the ideal ergonomic, and environmentally protected operator interface solution.

Strongarm Designs, Inc provides high quality operator interface mountings and enclosures. Our products are used all over the world: they are used in hospitals to serve patients, nurses, and doctors; in biopharmaceutical plants to produce vaccines; in advanced manufacturing facilities putting rockets into to space and building the electric cars of the future; across the world serving our transportation and logistics infrastructures; and virtually every industry of front-line workers.

Our innovative solutions solve real-world problems. Strongarm has the expertise and experience to customize, design, and build the ideal operator interface to suit your application. Our extensive design resources enable us to engineer every feature you’ll need before in-house fabrication, assembly, finishing, testing, quality assurance, and on-time delivery.

Strongarm Designs, Inc. 425 Caredean Drive, Horsham PA 19044

800-778-7901

sales@strongarm.com

strongarm.com

ControlDesign.com / January/February 2024 / 59

VEGA AMERICAS, INC.

With innovative technologies and services, we develop solutions that inspire. Through our sense of simplicity and our focus on people, we are looking to the future with curiosity. Locally grounded and globally connected, together we give values – measurement values as well as human values – a home. VEGA is the HOME OF VALUES. For more than 60 years, VEGA Americas, Inc. has provided industry-leading products for the measurement of level and pressure. VEGA’s full product line of level and pressure measurement instrumentation allows us to provide one of the most complete ranges of measurement solutions in the industry. VEGA’s continued innovation in radar, pressure, differential pressure, and point level switches ensures food and beverage operations of all sizes can continue to improve their processes and keep up with ever-shifting market demands. VEGA believes the future of instrumentation lies in the ability to produce high-quality, innovative products that keep pace with technology, and provide service and value to our customers in today’s competitive environment. Our measurement solutions have helped make more batches, maintain inventory of raw ingredients, and save energy. Located in Cincinnati, Ohio, VEGA Americas combines manufacturing, distribution, and service for products that represent the most sophisticated process measurement technologies anywhere in the world. VEGA Americas is a wholly-owned subsidiary of VEGA Grieshaber KG in Schiltach, Baden-Württemberg, Germany. VEGA understands the benefit of investing in community and employees, because it’s people who make the difference in achieving success. This success fuels future innovation and transfers to the solutions we provide to customers.

VEGA Americas, Inc.

3877 Mason Research Parkway, Mason, OH 45036 +1 800 FOR LEVEL

60 / January/February 2024 / ControlDesign.com

americas@vega.com

www.vega.com

product roundup

Take control of your machine automation Easy installation and versatility spearhead a sea change Schneider Electric Modicon M221 PLC

with a RS-485 serial port, dual Ethernet ports, a USB-C port

Schneider Electric’s Modicon M221 programmable logic

for direct configuration connection and a CANopen com-

controllers are available in brick or book format, require

munication port to expand applications where more digital

minimal installation and are

I/O may be needed or connecting to other devices such as

designed to offer tremendous

sensors or J1939-enabled devices.

versatility. Users can optimize

Wago / www.wago.com

the size of wall-mounted and floor-standing control-system enclosures due to their compact

KEB America C6 Safety PLC

dimensions. The M221 and M221

KEB’s C6 Safety PLC is a Fail Safe over EtherCAT (FSoE) mas-

Book controllers have an embedded Ethernet port, meaning

ter that is used in tandem with the machine PLC to execute

they can be integrated in control-system architectures for

and monitor the safety functions of the machinery. The C6

remote control and maintenance of machines using appli-

Safety PLC connects with other FSoE slave modules like Safe

cations for smartphones, tablets, and PCs.

I/O and Servo Drives with Safe Motion functionality. Each FSoE slave device has four

DigiKey / www.digikey.com

safe inputs, two safe outputs, and four OSSD outputs. One

IDEC SmartAXIS

FSoE master can control up to

IDEC‘s SmartAXIS touch family with the FT2J Series com-

65,535 slave devices.

bined PLC+HMI is a compact all-in-one form factor that

KEB America / www.kebamerica.com

combines built-in full-function controller features and functions, both onboard and expandable

ABB AC500-eCo V3 PLC

I/O and an advanced technology

ABB’s AC500-eCo V3 compact PLC is designed to integrate

7-inch touchscreen display. The

seamlessly into the broader AC500 family. The AC500-eCo

PLC and HMI are internally con-

V3 is designed to allow for customized solutions to be

nected, require only one power

created by using S500 and S500-eCo I/O modules for small

supply and share the same network connection. The FT2J is

applications. Starting on the AC500

designed to be ready to use and communicate right out of

platform enables you to scale up

the box. Built-in I/O includes 14 points of dc discrete inputs,

when needs dictate it. The user pro-

five of them configurable as high-speed counters, and four

gram is downloaded via memory card

points of analog inputs, configurable as 0-10 Vdc or 4-20 mA

without the need for programming

IDEC / www.idec.com

tools. And, built with modularity, connectivity and scalability in mind, CPUs with integrated I/Os for small to

Wago compact controller

large applications are also available

Wago’s Compact Controller

in three performance classes—basic,

100 has a dual-core processor

advanced and pro. Onboard I/Os can

with a mix of 18 digital and

be extended using up to three option boards, adding either

analog onboard I/O channels.

more digital or analog channels or serial interfaces with or

Programmed with CoDeSys 3.5

without isolation.

software, it comes equipped

ABB / explore.abb.com

ControlDesign.com / January/February 2024 / 61

product roundup

Pepperl+Fuchs BPC3200 Box PC

the controller is designed for han-

The Box PC 3200 series is based on the seventh-generation

dling extremely complex automation

Intel Celeron and i5 (Kaby Lake) embedded processor. It

projects in one ruggedized controller

supports high-speed memory technology (M.2 NVMe 1.3)

measuring 132 x 202 x 76 mm. The

and extended RAM con-

Intel Core i7 and i9 processors used

figurations with

in the C6040 are installed in a hybrid

up to 16 GB DDR4.

architecture, meaning four additional

These indus-

efficiency cores are added to the Core

trial box PCs are

i7 and eight to the Core i9 processors.

designed to offer ap-

This combination allows applications to be implemented on

plication flexibility and can be used

a total of 12 or 16 processor cores.

as a stand-alone device, as a panel PC, when mounted on a

Beckhoff Automation / www.beckhoff.com

Pepperl+Fuchs display unit, or as an HMI system—panel PC installed in a Pepperl+Fuchs enclosure.

EZTouch EZ5 Series HMI

Pepperl+Fuchs / https://www.pepperl-fuchs.com/usa/en

EZAutomation’s EZ5 Series HMIs include an i.MX RT based processor. The EZ5 series supports two serial ports (RS-

AutomationDirect ProductivityOpen P1AM-200 CPU

232/RS-422/RS-485), a 10/100/1000 Base-T Ethernet port,

AutomationDirect’s P1AM-200 open-source CPU can be

two USB ports (types A and B) and a MicroSD Card slot

programmed in C++ using the Arduino IDE or in Circuit-

for datalogging. The HMIs are

Python using any text editor. CircuitPython is a derivative

programmed via an EZ5 Program-

of the Python programming language built specifically for

ming Editor suite that is de-

microcontrollers

signed to allow passing through

and uses a runtime

to other PLC manufacturers.

interpreter instead

Available sizes are 4-, 7-, 8-,

of a compiler for

10-, 12- and 15-inch.

more flexibility

EZAutomation / www.ezautomation.net

with code editors and code syntax. The P1AM-200 CPU

PLC touch panel

hardware features

Mitsubishi Electric Automation’s high-resolution color

up to 16 MB of flash

HMI devices are designed to monitor machine functions,

memory for code and file storage, a 120 MHz processor, a

featuring more than 65,000 colors and screen sizes up to 15

Crypto coprocessor for higher performance when using

inches. The GT27 model,

encryption libraries and a neo-pixel RGB LED for visual-

part of the GT2000 series,

ization of the CPU program status. The ProductivityOpen

provides support for SD

CPUs utilize Productivity1000 series I/O modules and most

memory cards and is

Arduino MKR form factor shields for easy connections to a

equipped with Ethernet,

wide variety of devices.

RS-232, RS-422/485 and

AutomationDirect / www.automationdirect.com

USB host/device ports. Screen operations are designed to not be slowed by heavy processing such as log-

Beckhoff C6040

ging, script execution, alarm output and device data trans-

With 12th-generation Intel Core processors, the C6040

fer. The series also supports video recording and playback,

ultra-compact industrial PC (IPC) is designed to add

video input and RGB I/O.

further scalability the C60xx series. With up to 16 cores,

MiSUMi / www.misumiusa.com

62 / January/February 2024 / ControlDesign.com

real answers

Blended languages for industrial control A CONTROL DESIGN reader writes: We have some new younger

network communications, where a more textual language

engineers on staff who are fluent in some of the newer

like structured text or a high-level language (HLL) would

programming languages, but our customers want machines

be more useful. For these situations, being able to blend

with more traditional programming languages like ladder

the various IEC and HLL programming tools allows for the

logic. Are we wrong to hang onto International Electrotech-

creation of truly powerful solutions (Figure 1). There are

nical Commission (IEC) 61131-3 languages? Upper manage-

a growing number of software platforms that allow this

ment is slow to evolve with changing technology or letting

blending of programming methods and hardware to run

the younger generation lead the way. Where are languages

these solutions, so it is good to have a discussion on the

like Python and C++ most useful in industrial settings? Can

pros and cons of various HLLs.

Python run fast enough for real-time control? Where is the ability of C++ to create data logs most useful?

Answers

The questioner asks specifically about Python and C++. These are good languages to discuss as they, along with C# and Node-Red, have been making a significant impact on automation. There are a couple of significant advantages to using these languages—talent pool and online support

IEC languages shine for real-time control

resources. There are a large number of programmers versed

I don’t see anything wrong with using—I don’t like the

in these languages, and universities graduate far more pro-

phrase “hanging onto”—IEC 61131-related languages as

grammers with these skills than they do IEC programmers.

part of an overall Swiss Army Knife-style-toolkit ap-

Both languages have a large online support community

proach to offering a solution to complex automation

with extensive open-source libraries and code snippets in

systems. Ladder, function-block-diagram and sequential-

Github that have been tested and proven by the masses

function-chart programming tools offer a meaningful

and are available for download and used to provide

graphical interface for troubleshooting for many tech-

shortcuts to development. One programmer that I know

nicians who come from a more electrical/technician

mentioned needing to create a simple HTTP server, and

background and not a programming background. And

doing it in IEC was extremely tedious, whereas he was

programmers/developers should always keep in mind

able to download some open-source C++ code and have it

who will be diagnosing problems that occur in the field.

working in just a few hours.

The problem is using these tools to program very

When considering if Python has the speed to run a

complex automation processes, such as databasing and

real-time application, the question that needs to be asked is: “How fast does the application need to run?” The real issue with Python’s speed is its garbage collector—the means by which it manages memory so that the programmer doesn’t have to, like in the days of Fortran and C. The garbage collector makes for a more compact program, but the memory needs to be looked after, and this can slow down processing. The garbage collector can be strategically disabled during the running of critical code so the processing speed can be played with. So while Python can be used for real-time control, the experienced programmers I have talked to do prefer C++ for real-time control. These programmers also acknowledge that real-time control is an area where IEC languages still shine. Where platforms allow it, they will use Python for

64 / January/February 2024 / ControlDesign.com

real answers

Figure 1: This installation model combines different equipment and software, for operations on the plant floor, for IT systems and in the cloud.

data handling and networking and IEC for real-time. There

are working, then there is little perceived incentive to

are also platforms that allow HLL code to be encapsulated

change and accept risk.

inside IEC code to leverage the power of both languages.

But by modernizing, and using more contemporary

The ability of C++ to create data logs helps with the

programming languages, industrial companies will dras-

convergence of IT and OT by being able to utilize the more

tically increase the pool of potential employees. There is

standard IT data pipelines rather than using the more

little educational emphasis on IEC 61131-3 languages, so

proprietary pipelines that have developed for OT databas-

the availability of pre-trained candidates is growing very

ing methods. There are libraries that speed up the imple-

slowly or perhaps dwindling, making it harder to find

mentation of data logs and allow more flexibility in crafting

good people. On the other hand, the educational system

the wording and content of these logs. Also, the growth of

is producing graduates with training in more modern

services like Datadog and Elastic, which can chart, monitor

languages like C++.

and analyze your data, are creating a demand for the type of datalogging that can be done with C++.

From a cybersecurity perspective, modern languages provide a better degree of built-in security capabilities. C++

TED THAYER

data logs are one example, which users can fit into their en-

principal product specialist for control systems / Phoenix Contact

vironment to provide better security. There is no portion of an industrial network exempt from cybersecurity consider-

Modern languages can provide better built-in security Change is a risk, so it is understandable why end users and their management teams can be slow to adopt evolving technologies. In many cases, if current practices

ations, because if malicious actors get a foothold anywhere, then they can inflict damage. STEVE RAWLINS, SR., CISSP lead product cybersecurity officer, controls and software business / Emerson Discrete Automation

ControlDesign.com / January/February 2024 / 65

live wire

Joey Stubbs joey.stubbs@gmail.com

3 types of proximity switches WALK INTO ANY FACTORY, and, if you look closely, you will

point, the internal circuitry enables the outputs. Materials

see an incredible number of proximity switches on nearly

that can be sensed include metals, fluids and non-metallic

every piece of equipment on every line. Proximity switches,

solids and semi-solids. The sensing range of a capacitive

or just “prox switches” for short, are a huge multi-billion

proximity switch is affected by the dielectric constant

dollar industry, and that’s not even including the associated

of the material being sensed, so most include some

cables and cord sets that connect them to the automation

mechanism for calibrating the sensing distance, such as

controller inputs.

a set screw in the body of the switch. As with inductive

Although presence sensing can be done by other types of

switches, capacitive prox switches are also susceptible

sensors, such as ultrasonic and photo-optic, or even with vi-

to electrical noise, poor grounding practices and some

sion systems, proximity switches

particulates in the air, but

are a great low-cost, low-complexity and high-reliability noncontact method of accomplishing this task. Within the category, there are three different types of

mostly immune from vibration

The most common type of prox/ presence sensor seen in industry are inductive proximity switches.

proximity switches for sensing different materials in different ways.

and shock. The typical capacitive prox switch housing is also washdown-compatible. Probably the simplest of the three types of presence sensors, magnetic prox switches

The most common type of prox/presence sensor seen in

are limited to detecting magnetic materials only, such as

industry are inductive proximity switches. Their big limita-

a permanent magnet. The most common type of magnetic

tion is that they are applicable to only sensing metallic

prox switch is a “magnetic reed switch,” which has two

objects. Developed in the 1950s, these sensors generate an

thin metallic plates, or reeds, enclosed in a glass bulb

alternating magnetic field through a coil in the tip of the

with inert gas inside. The reeds are connected to the out-

barrel of the switch, and changes to the field caused by a

put stage of the switch. In the presence of a magnet, the

metallic object in the field are detected by a trigger circuit in

reeds flex and contact each other, completing the circuit

the switch. The sensing range is typically determined by the

and closing the contacts. Because these are more or less

physical size of the proximity switch and the shape of the

mechanical devices, they are almost completely immune

magnetic field. These units are robust, vibration- and shock-

from issues arising from electrical noise, but they can be

resistant, and usually sealed and potted to be washdown-

susceptible to issues with vibration and shock, which can

capable. They can be subject to false triggers in the presence

cause the reeds to make contact intermittently, giving

of electrical noise, poor grounding practices or the presence

momentary false-positive indications.

of metallic filings or dusts, so care must be taken to ensure

Using proximity switches in an industrial application can

their implementation works in the environment needed.

be a cost-effective method to detect the presence of ware or

Although they may look similar to their inductive

materials. Regardless of which proximity switch you use as

counterparts, capacitive prox switches work on a different

a presence sensor, make sure it fits the application by ensur-

detection method. As the name implies, these work on

ing the switch is correct for the environment, the material

capacitance rather than inductance. This means they are

being sensed and the range of sensing required.

not limited to metallic objects, but can detect anything that changes the capacitance of the sensor circuit. They detect the changes in capacitance between the sensor

Joey Stubbs is a former Navy nuclear technician, holds a BSEE

and the object being detected with reference to a virtual

from the University of South Carolina, was a development

ground. The closer the material is to the sensing end, the

engineer in the fiber optics industry and is the former head

greater the capacitance, and, once it reaches a trigger

of the EtherCAT Technology group in North America.

66 / January/February 2024 / ControlDesign.com

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