Control Design – November 2025

HIGH-SPEED VISION CONTROLLER MIGRATION ENCLOSURES AND HMIs

Artificial intelligence, robotics and digital tech build the foundation for

machine autonomy NOVEMBER 2025

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Volume 29, No. 6

table of contents

16 DEREK CHAMBERLAIN / SHUTTERSTOCK AI

cover story

No humans allowed Artificial intelligence, robotics and digital tech build the foundation for machine autonomy Anna Townshend, contributing editor

28

36

40

controllers

hydraulics

product roundup

PLC logic, PID control automate distillation

Massive crane requires precision

Keep it secure with connectors and cables

How to apply industrial control to small-batch distillation: a case study in smart reflux automation

Engineers solve an hydraulic physics problem to reduce unloading times at an Australian port

Application connectivity configured for industrial machinery

Douglas Reneker

Ian Duncan, Motion Australia

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ControlDesign.com / November 2025 / 5

Volume 29, No. 6

table of contents

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COLUMNS 9 editor’s page

13 component considerations

How much is AI worth?

Why UPS is the last line of defense

Mike Bacidore, editor in chief

Tobey Strauch, contributing editor

VP Content Strategy Manufacturing & Engineering Group Robert Schoenberger Group Editorial Director Keith Larson

editorial team editor in chief

10 embedded intelligence Vision drives high-speed automation Jeremy Pollard, CET

14 automation basics HMI begins at the electrical cabinet Charles Palmer, contributing editor

Mike Bacidore mbacidore@endeavorb2b.com digital editor

Madison Ratcliff

11 technology trends

Rick Rice

When to rip and replace PLCs and I/O

rcrice.us@gmail.com

Rick Rice, contributing editor

mratcliff@endeavorb2b.com contributing editor

contributing editor

42 live wire Digital twins accelerate debugging Joey Stubbs, contributing editor

Joey Stubbs contributing editor

Tobey Strauch tobeylstrauch@gmail.com contributing editor

Charles Palmer charles101143@gmail.com columnist

Jeremy Pollard jpollard@tsuonline.com

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44-Turns in a 22 mm Package N≤v≤≤≤≤h≤≤k’≤≤≤Z≤≤ ≤≤≤≤≤≤≤≤≤≤≤l≤≤-≤≤≤≤≤ ≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤ ≤≤≤44-≤≤≤≤≤≤(≤≤,84≤≤)≤≤≤≤ ≤≤22≤≤≤≤≤≤≤≤≤≤≤≤≤h≤≤≤≤≤≤≤ ≤≤≤f≤≤≤≤≤≤≤≤≤v≤≤≤≤≤≤≤≤≤≤≤ ≤≤≤l≤≤≤≤≤≤≤≤≤≤B≤≤≤≤≤≤≤≤G≤≤≤≤≤ ≤≤≤≤≤≤≤-R≤≤≤≤≤≤≤≤≤≤≤≤≤h≤≤l≤≤y≤(G≤R),≤≤h≤≤≤Z≤≤ ≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤l≤≤≤v≤≤≤ wh≤≤≤≤≤w≤≤≤≤≤≤≤≤≤≤v≤≤≤≤Wh≤≤≤≤≤w≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤h≤≤ ≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤l≤≤≤≤≤≤h≤l≤≤≤≤≤≤≤≤≤≤≤≤≤ Key specifications: ≤≤44-≤≤≤≤≤≤(≤≤,84≤≤) ≤≤≤≤≤≤≤≤≤≤≤≤≤≤l≤≤≤≤≤≤≤y≤≤≤≤≤≤ ≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤≤

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Learn more at www.novotechnik.com/mz1

N≤v≤≤≤≤h≤≤k≤U≤S≤,≤≤≤≤≤ T≤l≤≤h≤≤≤:≤≤≤8-48≤-2244 E≤≤≤l:≤≤≤f≤@≤≤v≤≤≤≤h≤≤k≤≤≤≤

editor’s page

Mike Bacidore editor in chief mbacidore@endeavorb2b.com

How much is AI worth?

MERGERS AND ACQUISITIONS occur often in the automation

affordability and community, Qualcomm plans to super-

and technology space, especially among suppliers. Compa-

charge developer productivity across industries. SoftBank’s

nies develop ecosystems with partners, and soon multiple

next frontier is physical AI, and ABB has seen the advantages

organizations become one. Or sometimes a company has

of artificial intelligence in robotics applications, exemplified

grown so large that it must divest or spin off a division that’s

by its investment in LandingAI vision AI for the ABB Robotics

become too big.

software suite.

In a span of two months, three significant acquisitions took place that will reshift the automation landscape.

Mitsubishi Electric’s acquisition of Nozomi Networks and

Arduino will preserve its open approach and community spirit while unlocking a full‑stack platform for modern development, with Arduino Uno Q as the first step. The Uno

its cloud-service platform, as well as artificial intelligence

Q dual-brain platform interconnects a Linux Debian-capable

(AI) technology, in September could dramatically impact the

Qualcomm Dragonwing QRB2210 microprocessor (MPU) with

emphasis placed on OT security

a real-time STM32U585 microcon-

going forward.

troller (MCU).

In October, Qualcomm announced plans to acquire Arduino, maker of the little microcontroller that could. Qualcomm’s interest is

Following the acquisition, the

Notice that all three transactions include an AI component.

more than 33 million active users in the Arduino community will gain access to Qualcomm Tech-

in edge technologies. The Arduino

nologies’ technology stack and

acquisition builds on Qualcomm’s

global support of technologies

recent integrations of Edge Im-

through its partner ecosystem.

pulse, known for its AI platform, and Foundries.io, known for

Remember what happens in ecosystems. Arduino sold its 10

its Linux-based DevOps platform.

millionth Uno board in 2021 and entered into a System Inte-

Also in October, ABB revealed it had signed an agreement to divest its robotics division to SoftBank Group for $5.4

grator Partnership agreement with DMC in 2023.

In addition to maintaining compatibility with the Arduino

billion and not pursue its earlier intention to spin off the

integrated development environment (IDE) and Uno eco-

business as a separately listed company. In April, the ABB

system, the Uno Q is the first Arduino board to work with

board of directors said it believed listing ABB Robotics as a

Arduino App Lab, an IDE built to unify the Arduino devel-

separate company would optimize both companies’—ABB’s

opment journey across real-time OS, Linux, Python and AI

and ABB Robotics’—ability to create customer value, grow

flows. App Lab is an open-source platform.

and attract talent. But along came SoftBank with its capabilities in AI, robotics and next-generation computing.

Notice that all three transactions include an AI component that suppliers are determined to leverage.

“ABB and SoftBank share the same perspective that the world is entering a new era of AI-based robotics and believe that the division and SoftBank’s robotics offering can best shape this era together,” said ABB CEO Morten Wierod.

The acquisition of Nozomi Networks brings an AI-pow-

The world is changing fast. It seems like just yesterday

ered, cloud-first cybersecurity software business with scal-

we were “sheltering in place” as part of a global plan to end

ability to Mitsubishi Electric. By combining its processing,

a pandemic. And now we’re witnessing the dawn of the AI

graphics, computer vision and AI with Arduino’s simplicity,

wave that is sweeping through technology.

ControlDesign.com / November 2025 / 9

embedded intelligence

Jeremy Pollard jpollard@tsuonline.com

Vision drives high-speed automation SENSORS ARE OUR WORLD. Imagine having to determine if a

arm has fallen off a limit device, so this would not be a good

part is in place using what was available in the 1980s—me-

choice for a safety application. A safety rated non-contact

chanical switches. But the 1980s also brought us electronic

device which is securely positioned on/in the process would

sensing with photocells and proximity switches. This wasn’t

be the better choice.

new technology, but we didn’t have an interface system to

The application should determine the right presence

use them with like a programmable logic controller (PLC).

sensing device. Anything can be sensed. The advent of

Sensing encompasses the world. Any physical attribute

Ethernet and the PLC/PAC processors and associated I/O

can be measured and sensed. High-speed processes can be implemented because of the devices that are used to sense.

suggests that we have options to sense a part.

One application I had worked on a few years ago was

I’ve spoken about my first ap-

a bag stuffing, or poucher,

plication of a lumber sorter, and it bears to speak of it again.

I needed to monitor the speed of a chain carrying various lengths of lumber to be cut to

machine. The machine was sup-

Vision systems communicate with the PLC over Ethernet using a common protocol.

length. There was a large drive

remember how.

to integrate it into the system.

It was for a DNA test kit, so the swab had to be placed in a waiting pouch, and then the pouch

sprocket that controlled the chain, and it was a variable speed motor, although I can’t

plied by a third party, and I had

was sealed when the swab had been detected inside the pouch.

How is that accomplished with 1980s technology? It was

I used a 120 Vac proximity switch to detect the large teeth

nothing short of a miracle. Now, vision systems communi-

on the gear that mechanically drove the chain. If we assume

cate with the PLC over Ethernet using a common protocol

it had 24 teeth, then the leading and falling edge would hap-

called Ethernet/IP.

pen 48 times. At a certain lugs/minute setpoint, the saws

The level of intelligence this vision system had was as-

that cut the boards to length would need to operate—come

tounding. Once we trained the vision controller to see what

down, cut and retract—at a certain interval based on speed.

the part looked like, it searched the pouch on demand for

The system operated perfectly at 50 lugs/minute, but at 51

the outline. The orientation of the swab was immaterial—

it lost its way. Target speed was 72 lugs/minute. What was

the vision system found it and gave an all-clear signal to the

the problem?

control system that the pouch can be sealed and released.

The ac proximity sensing device was the problem. In

Throughput was a major consideration since DNA test kits

reading the spec for the device, the transition time between

were a hot item, and, to service all of the order requests, the

part present and part absent (leading/trailing edge) was 25

throughput approached 60 swabs/minute.

milliseconds. This is the part when I’m sure you are smirking, but remember it was the 1980s. A dc-powered sensor had a transition time of less than 2 milliseconds—10 times faster. Problem solved.

Sensing is taken for granted in lots of applications.

There was no other way to accommodate this requirement other than a high-speed vision system.

Proximity, photocell, light curtains and vision can all be used for part sensing. The PLC systems allow for high-speed sensors to be employed for high-speed systems. Relay pan-

Reaction time is important in all non-contact applications.

els cannot play in the same sandbox. In every application,

Mechanical switches are typically not used in anything high

everything is based on time and position.

speed and more for end-of-travel indication and safety.

Nothing is more consequential than a missed signal in a

JEREMY POLLARD, CET, has been writing about technology and

safety system. Whether the sensors are mechanical or non-

software issues for many years. Pollard has been involved in

contact, they can’t fail. It is very difficult to detect that an

control system programming and training for more than 25 years.

10 / November 2025 / ControlDesign.com

technology trends

Rick Rice contributing editor rcrice.us@gmail.com

When to rip and replace PLCs and I/O RECENTLY, I HAD THE OPPORTUNITY to make a career change

upgrade is based on the ability of the machine or process

that gives me a fresh perspective on control design and an

to do the job it was designed to do and what risk do we en-

opportunity to work completely remotely. I have shifted

counter if that function is lost due to failure of the controls.

from consumer goods packaging into material handling

As it turns out, the real driving force behind the decision

systems. The first thing I encountered in my new position

to upgrade is component obsolescence. Minor components

is that the past 15 years I spent guiding the upgrade of

like relays and contactors can usually be replaced with

controls systems has followed me from the in-plant office

modern versions that perform the same function, usually in

to the home office. In my previous job we executed many

a small form factor that improves panel space. However, it is

upgrades to “smart relay” controllers to make them all the

the major components that force bigger decisions. The big-

same brand and model, but it was

gest of them all, of course, is the

the bigger systems that provided

processor that drives all those

the greater challenge, and the end results were very rewarding.

Upgrades can take various

There are plenty of chances to make mistakes when moving the wires.

components. The processor is the heartbeat of the control system. Everything that happens,

paths, depending on the age of

whether locally, in the main

the equipment and how well it

panel, or remotely, in sub-panels

was taken care of. Most of you have likely just had some vivid memories come to life, both good and bad.

or on the machine itself, emanates from or passes through the main processor chassis.

For most vintage systems, the main chassis also pro-

We’ve all probably opened a control panel only to see

vides a gateway for any networked devices. It is also not

missing wireway covers and wires just hanging down or

uncommon to find more than one network protocol pres-

strewn across the expanse of the enclosure. Often, there is

ent in these older designs. For example, with my previous

a real risk of shock or short from power and control wires

employment, we primarily worked with Allen-Bradley SLC

intermixed and wound around each other. Perhaps the in-

500-based systems. Those systems used a lot of Remote

sulation on the conductors has aged to the point where they

IO, Data Highway (DH), Data Highway Plus (DH+), Data

have lost the physical characteristics that make them insu-

Highway 485 (DH-485) and DeviceNet protocols, many

lators. Others may appear to be intact until they are touched

of which were on the same machine or process. A few

or moved around, and then chunks of insulation drop off

systems involved EtherNet/IP as that was still an evolving

the wires, making them even more unsafe. The devices on

technology at the time this equipment was purchased,

the panel may have suffered from age, as well. Components

from 1980 to 2000.

perhaps not on the DIN rail any more are so degraded with

In my new position, I have run into an old friend—the

age that they barely resemble the devices they once were.

1771-based PLC-5 again from Rockwell Automation Allen-

Other times, we might have opened an enclosure only to

Bradley. I cut my teeth on the PLC-5 and its predecessor,

discover, to our delight, that great care has been exercised,

the PLC-2 in automotive and cereal plants very early in my

and the results look like they just came out of the panel

career. This processor isn’t an old piece of equipment sitting

shop that built it. All the wires are tucked into the proper

in a boneyard—I did run into one in my previous job on an

places and routing. Components appear to be fresh and

old cartoner that we purchased at auction—but in daily

mounted in their original locations.

operation in a distribution warehouse.

When deciding whether to perform an upgrade, the

One might ask, “How could the user still have something

examples give us some of the information needed to make

that old in operation?” I look upon such encounters with

an informed decision, but they are only part of the decision

reverence as that system was likely installed in the late

process. Ultimately, the decision to go down the path of an

1980s or early 1990s and has been faithfully serving ever

ControlDesign.com / November 2025 / 11

technology trends

since. This speaks volumes to the robust design and quality

and then each I/O point must be transferred from the old

of components that went into this 40-year-old program-

module to the new one.

mable controller and associated I/O components.

The above examples, the modular SLC-500 and the chas-

There are plenty of chances to make mistakes when moving the wires, and, if old enough, the moving and bending of

sis-based PLC-5, can be found with many other hardware

wires might result in breaking off the insulation or ending

brands as the good ones seem to last forever. At some point,

up with a wire that is too short to re-purpose.

however, the specter of obsolescence raises its ugly head,

Luckily, there is an alternative for this very involved task.

and we are faced with a decision on how to move forward.

The manufacturer provides a migration kit that converts the

For me, the SLC-500 upgrade was split into two paths. If

1771 chassis-based I/O into the current 1756 chassis-based

the panel was clean and the wires and insulation were in

I/O system. A transition kit starts with a mounting plate

good condition, we would plot a path to directly replace the

that matches the dimensions of the original I/O chassis and

SLC-500 with the newer 1769-based, now 5069-based, Com-

even uses the same mounting holes.

pactLogix product line. If the original control panel had

The technician starts by removing the wiring arms off the

lots of obsolete components and the wiring was a mess,

original I/O modules and leaves them hanging down in the

then a completely new control panel with the new technol-

panel. The original I/O chassis is removed, and the new transi-

ogy was the way to go.

tion plate is mounted in place of it. Once in place, the original

The SLC and the CompactLogix share the same ap-

wiring arms are plugged into the base of the new transition

proximate footprint, so a processor swap out is straight-

plate and then a cover plate mounts to the transition plate

forward and involves very little in the way of work, other

with holes that match the mounting holes for the new chassis.

than pulling the connectors off the original processor and

The new chassis mounts directly to the plate, and then

modules and then manually moving the wires from old

pre-molded interface cables are added to connect the older

assembly to the new one.

wiring arm, on the base transition plate, to the new I/O

In this situation, the older processor likely used Remote

modules in the new chassis. The great thing about this pro-

IO for additional I/O chassis, and this can be directly re-

cess is individual wires do not need to be de-termed from

placed with EtherNet/IP communication modules in the new

the old module and then re-termed to the new module.

system. The I/O on the machine doesn’t care how it gets to talk to the PLC, just as long as it can.

All this sounds like a win-win situation, but care must be taken when it comes to the legacy network protocols

This process of moving wires from old to new can be

that might be present on the original control system. Most

expedited if the originals were wired to terminals. The

newer logic controllers utilize the Ethernet/IP protocol, or

panel technician could use coded cable to pre-wire the

an equivalent, as a standard method of communication, and

new I/O modules at the comfort of a work bench and then

that simplifies the migration process. However, depend-

simply connect the other end to the terminal blocks in the

ing on the size of the legacy system, the project might be a

control cabinet. My technician liked to use an 18-conductor

multi-phase event to step through the process and still be

machine cable for this purpose so that the numbers simply

able to run the existing system for operations if it can’t be

went in order from 1 to 16 for the I/O points, and the re-

down for long periods of time.

maining wires provided power and common to the module.

Migrating vintage controllers over to current technology

When physically working with Rockwell Automation’s

might not be such a feared task if it is well-planned and ex-

older Allen-Bradley PLC-2 or PLC-5 system on the 1771-series

ecuted. The clear benefit is to eliminate obsolete equipment,

chassis, the situation is more complicated. The 1771 series

and the result is a control system with a faster controller,

has a much larger footprint than the replacement 1756 se-

more memory and greater flexibility when it comes to con-

ries: ControlLogix. Both are chassis-based, but that is where

necting to the incredible technology that’s available.

the similarities stop.

The process of pulling all the I/O module connectors off

RICK RICE is a controls engineer at Crest Foods

and then completely removing the old chassis is quite time-

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

consuming. The new chassis needs new mounting holes,

and packaging company in Ashton, Illinois.

12 / November 2025 / ControlDesign.com

component considerations

Tobey Strauch contributing editor tobeylstrauch@gmail.com

Why UPS is the last line of defense AN UNINTERRUPTIBLE POWER SUPPLY (UPS) is primarily

added or how UPS systems may be daisy-chained to allow

used in automation to provide continuous power in emer-

for additional loads.

gencies or disruptions.

Other protections include power quality components and

Most automation systems will have a UPS available for

surge protectors and line filters. These devices are used to

protecting the control room but also to supply power to mo-

ensure equipment is protected and reduce the possibility of

tor control centers (MCCs) or process control rooms for the

damage to costly electronics. This is also key for data-center

purpose of protecting control cabinets and variable-speed

type applications because one way to cause problems is to

drives and ensuring that data has time to be saved. Because

break the power of a system as a cybersecurity threat. Data

automation systems have become extremely data-depen-

is either stored or in motion.

dent, the servers used in automa-

Privacy of data is put into

tion systems are also an asset in

jeopardy when attackers can

need of protection.

Uninterruptible power supplies are used to provide battery or generator power during a power

Remember that electrical components have a verified shelf life.

gain network access. One way of gaining network access is by physically faulting a system and intercepting on recovery.

flicker or a brief outage to allow

Like many things, UPS

that safety critical systems may

systems may be networked.

be cut over to backups or shut down in a safe manner.

The key benefit of a UPS is to provide power continuity, so devices do not short from surges. Other benefits are to

Providing a power solution may help prevent cybersecurity attacks, but you also must protect the UPS from attack using SNMP/HTTP security agent tactics.

ensure data integrity, improve safety and give a window to

Failures of power systems in general are related to con-

switch to generator support. Once on generator power, then

trol-system fault, battery degradation, lack of maintenance,

the system may be controlled or fueled with a maintenance

capacitor issue, overloading and environmental factors such

cycle. This means manning the equipment to make sure

as high temperatures, humidity and dust.

fuel is provided to keep systems running. Think data centers. Think safety systems.

Things to consider when choosing a UPS are sizing, high

Remember that electrical components have a verified shelf life, but, when they are not traded out, maintained or tried, then they may fail unexpectedly. This is the reason that bat-

in-rush devices, matching the application, expandability

tery banks, UPS systems and generator tests are performed

and integration with other protection. For ratings, the com-

in a periodic maintenance cycle. If these maintenance cycles

mon recommendation is to use a unit that is 1.2 times the

are neglected, then the UPS could fail when you need it most.

total load. Yup, math is involved to calculate full load Amps.

Uninterruptible power supplies may last five to eight

High in-rush current surge can occur from devices like

years, but this is dependent on operating conditions. This is

motor starters or high torque devices that require a boost

also dependent on battery quality and battery maintenance.

of power on startup and then level out. This depends on

Batteries should be replaced every three to five years. Other

the application, which may need to consider three types of

components that may fail in a typical UPS are the capacitors

interfaces: standby, line interactive and double conversion.

and the fan module.

Double conversion systems offer the highest level of protec-

It’s important to test your UPS system a minimum of once

tion by continuously running the load through the inverter.

per year. Once conditions of the UPS come to a variable state

No system is an island to itself; thus, even if you

of uncertainty, then the UPS should be replaced.

calculate loads and set up the UPS for a specific application, you may need to expand in the future. Thus, when

Tobey Strauch is an independent principal industrial

choosing a UPS, look at how more battery packs can be

controls engineer.

ControlDesign.com / November 2025 / 13

automation basics

Charles Palmer contributing editor

HMI begins at the electrical cabinet INDUSTRIAL ENCLOSURES AND human-machine interfaces

HMI layouts for unique automation solutions, boosting

(HMIs) represent a pivotal advancement in automation and

market differentiation.

control. These integrated systems enable seamless interaction between operators and complex machinery, offering

Design considerations

robust protection for sensitive electronics and user-friendly

When specifying an industrial enclosure with an HMI, sev-

access to real-time data. As factories evolve, the need for

eral factors must be evaluated for optimal system integra-

such enclosures grows, delivering durability, reliability and

tion. These comprise material selection, ingress protec-

efficiency across diverse applications.

tion, thermal management, mounting and access, custom

An industrial enclosure with an HMI is a protective cas-

cutouts and accessories and electromagnetic compliance.

ing, typically made from metals

Choose enclosures made from

like stainless steel or aluminum

stainless steel, polycarbonate or

or reinforced thermoplastics, equipped with electronic components, including an HMI screen or control panel. HMIs act as the

The intuitive interfaces of touchscreen HMIs provide user-friendly graphics.

“window” between operators and

coated metals for resistance to corrosion, chemicals and impact.

Higher ratings such as IP66 or NEMA 4X are essential for washdown or outdoor environ-

automated systems, allowing in-

ments. Include ventilation, heat

tuitive command input, process monitoring and diagnostics.

exchangers or cooling fans if electronic components gener-

Features include, environmental protection, rated for

ate significant heat. Consider whether the enclosure will be

dust, moisture, chemicals and impact, often to NEMA/

wall-, pedestal- or arm-mounted for ergonomic access and

IP standards; mounting flexibility, available as pedestal-

space efficiency. Design for cable glands, emergency stops,

mounted, pendant, panel or standalone cabinets to suit any

locks and viewing windows as required by application. En-

facility layout; customizability of sizes, depths and cutouts

sure designs meet electromagnetic compatibility standards

tailored for specific devices or processes; operator Ergonom-

to avoid interference with sensitive electronics.

ics designed for comfortable use with adjustable heights, angles and sometimes integral handles.

Applications include: • assembly and packaging lines where operators initiate

Operator safety Industrial enclosures with integrated HMIs play a crucial role in safeguarding operators in industrial environments.

cycles, adjust setpoints and monitor production metrics

They achieve this through several mechanisms:

via protected HMI panels

• For physical protection, the enclosure shields users from

• r obotics and automation cells where touchscreen HMIs

direct contact with high-voltage electrical components

on modular cabinets guide robotic arms or control con-

and moving machinery parts, significantly reducing the

veyor systems • process industries, such as chemical, food and phar-

risk of accidental shocks and injuries.

• For environmental isolation, robust, sealed enclosures

maceutical plants utilizing sealed enclosures for both

prevent exposure to dust, liquids, oils and chemical con-

hygiene and robust data entry

taminants, maintaining a safe workspace and protecting

• energy and utilities, such as power plants and substations, where enclosures main-tain HMI integrity against electromagnetic interference and severe environmental factors • c ustom machinery, where original equipment manufacturers (OEMs) integrate en-closures with tailored

14 / November 2025 / ControlDesign.com

sensitive electronics from potentially hazardous industrial conditions.

• For controlled access, many enclosures feature locking mechanisms or access restrictions, minimizing unauthorized interaction with control systems and limiting safety risks from improper use.

automation basics

Integrated HMIs often include emergency stop buttons

NEMA ratings

and safety interlocks, offering rapid shutdown in case of

The National Electrical Manufacturers Association (NEMA)

dangerous situations. Enclosures also are designed to meet

issues standards that cover aspects such as safety, environ-

stringent industry standards like NEMA or IP ratings, ensur-

mental sustainability and interoperability. A NEMA rating

ing that systems are built and maintained according to best

classifies an enclosure’s level of protection from water, cor-

safety practices.

rosion, dust and other environmental hazards.

Industrial enclosures and HMIs streamline workflows and

NEMA 4: Provides protection against windblown dust,

boost productivity through multiple features. Centralized

rain, sleet, splashing water and hose-directed water. Suit-

control allows operators to monitor processes, trouble-

able for applications with occasional washdowns and ma-

shoot issues and adjust parameters directly from a single,

chine tool coolant exposure. Offers protection outdoors and

protected interface without traveling to multiple locations,

indoors with moderate environmental risks.

reducing downtime and errors.

NEMA 4X: Extends NEMA 4’s protection by adding corro-

The HMI display delivers real-time feedback in the form

sion resistance. This rating is preferred in harsh and corro-

of immediate process data, alarms and diagnostics, allow-

sive environments such as food processing, chemical plants

ing swift decision-making and minimizing the response

and coastal sites where salts and acids are present. NEMA

time to anomalies.

4X enclosures ensure lasting performance by preventing in-

The intuitive interfaces of touchscreen HMIs provide user-friendly graphics, clear status indications and guided

gress of dust and moisture along with corrosion protection.

NEMA 3 and 3R: Suitable for outdoor use, these provide

workflows, making command input and data retrieval faster

protection against falling dirt, rain, sleet and external ice

and reducing training requirements for new staff.

formation. NEMA 3R is generally for enclosures in protected

For ergonomics and accessibility, enclosures are often designed with adjustable mounting options and optimal

structures but lacks dust-tight sealing, while NEMA 3 offers dust-tight sealing, as well, but is heavier and more rigid.

screen placement, enhancing operator comfort, reducing

NEMA 13: Offers protection similar to NEMA 12 but adds

operator fatigue and facilitating more effective interaction

oil resistance, making it optimal for environments with oil

with machines.

mist or splashes such as machine shops.

Automation via the HMI reduces the need for manual

Using stainless steel enclosures rated NEMA 4X is widely

inspections or direct interaction with hazardous machinery,

considered the most effective choice for harsh environ-

lightening the operators’ workload and further reducing the

ments requiring durability, corrosion resistance and protec-

risk of human errors.

tion from water and dust ingress. For less corrosive but

Materials and NEMA ratings for protection vary, especial-

still challenging conditions, NEMA 4 with stainless steel or

ly in harsh industrial environments. Stainless steel is highly

coated aluminum is suitable. Polycarbonate covers provide

resistant to corrosion, chemicals and impact, making it ideal

lightweight, UV-resistant protection, often used as HMI

for environments with corrosive substances, moisture and

screen covers. This combination of robust materials and

mechanical stress. Stainless steel helps maintain structural

appropriate NEMA ratings ensures functionality, safety and

integrity and seal performance critical to environmental

accessibility, despite harsh environmental challenges.

protection ratings.

Cast aluminum or cast iron is used especially for heavy-

Industrial enclosures with integrated HMIs create a safer, more efficient work environment. By combining robust

duty enclosures rated for hazardous locations, such as

physical protection, intuitive controls and real-time feed-

NEMA 9, due to their robustness and durability, though they

back within a single unit, they allow operators to interact

tend to be heavier and more expensive.

confidently with complex machinery while minimizing

Non-metallic materials, such as polycarbonate and

risks and maximizing productivity.

reinforced thermoplastics, offer resistance to corrosion, UV exposure and impact, while also being lighter than met-

Charles Palmer is a process control specialist

als. These materials are often used to protect against dust,

and lecturer at Charles Palmer Consulting (CPC).

water and damage from ultraviolet light.

Contact him at charles101143@gmail.com.

ControlDesign.com / November 2025 / 15

cover story

16 / November 2025 / ControlDesign.com

cover story

by Anna Townshend, contributing editor

I

n a factory with no humans,

mously. Autonomous mobile robots

advanced technologies take their

(AMRs) utilize advanced sensors and

place. Even a fully autonomous,

navigation algorithms to transport

lights-out operation may still need hu-

materials within manufacturing

man oversight in some form, in case

facilities, optimizing internal logistics

of equipment failure or security risk.

and conveyance,” says Tim Guelde,

Maybe our future factories will run

application engineering manager at

completely by artificial intelligence

Wauseon Machine.

(AI)-enabled robots and systems. How-

The increased adoption of mobile

ever, with industry’s current tech-

and collaborative robotics over the

nology, experts foresee autonomous

past five years has allowed Comau

machines and systems but within

to reach new industries, such as

some constraints.

aerospace and renewable energy.

The adoption of robotics on the

“Automation has evolved over the past

factory floor is ever increasing, but the

five-plus years from largely fixed pro-

technology has some current limita-

duction lines to flexible, AI and vision-

tions. As with many technologies, in-

enhanced systems capable of handling

vention may overcome those challeng-

complex, unstructured tasks,” says

es eventually, but an interdependence

Alessandro Piscioneri, head of prod-

among the many technologies will

ucts and solutions management of Co-

need to coalesce as they advance for

mau. “These advancements highlight

autonomy to become a reality. Some of

a broader trend of automation moving

the advanced technologies include ro-

beyond large-scale industrial settings

botics, artificial intelligence, machine

into applications that require adapt-

vision, digital twins, edge computing

ability, intelligence and precision.”

and advanced motion control.

Autonomous mobile robots, like

DEREK CHAMBERLAIN / SHUTTERSTOCK AI

their more fixed and routed robot

Industrial robotics will connect machines and systems, moving and handling material

siblings, automated guided vehicles

Modern industrial robots can perform

proven reliable for moving work-in-

complex tasks with high precision,

progress production from workstation

and higher precision has opened

to workstation. “In many material-

the door to more applications. “By

handling operations, fully autono-

processing and analyzing visual data

mous operations are possible within a

in real time, machine vision systems

given size envelope for the containers/

(AGVs); they can use AI to learn routes and avoid obstacles; and they’ve

enable robots to identify defects, guide

pallets. AMRs can extend the capabili-

precise assembly operations and navi-

ties of these installations, reducing or

gate complex environments autono-

eliminating the need for fork trucks

ControlDesign.com / November 2025 / 17

cover story

Autonomy challenges ahead For every new technology at hand to aid autonomous facilities, there are many challenges to the lights-out factory or plant scenario. The history of manufacturing in this country is a challenge itself, as older facilities remain among the new shiny stars, and the challenges are many: infrastructure costs, hardware and software compatibility, cybersecurity practices and operator training.

Wide acceptance of artificial intelligence (AI) for processes like quality control will take some culture change in some organizations, and standardization of industrial protocols will help advance these solutions faster, says Borczak. He also echoes the security concerns.

“Cybersecurity also remains a massive concern.

Autonomous systems require hyper-connected infrastructure, which can increase vulnerability to cyber threats,” he adds.

1

3

Challenge: Building new machines for old factories, equipment and systems The challenge with new technologies can be ensuring they are compatible with legacy equipment. “This can be challenging, often requiring significant modifications or replacements. Implementing new autonomous technologies requires substantial upfront costs for training, purchasing, setting up and integrating new systems,” says Tim Guelde, application engineering manager at Wauseon Machine.

The explosion of cloud and advanced computing technology has changed the face of manufacturing infrastructure.

Software is surely replacing hardware in newer applications, but industrywide change will take many years. “The challenge is machine builders will have to integrate software-driven intelligence into traditionally hardware-centric designs.

Compatibility, cybersecurity risks and retraining engineering teams are major hurdles,” Andrew Borczak, industry marketing manager, Omron, says.

2

Challenge: Cybersecurity practices for connected, autonomous systems Cybersecurity will be another challenge, where interconnected autonomous systems need to be fully protected in a changing security landscape. “Ensuring the security of interconnected autonomous systems is vital to protect against potential threats,” Guelde says.

18 / November 2025 / ControlDesign.com

Challenge: Production line changeover and increased product customization still largely rely on operators Fully autonomous operations are rare in the manufacturing environment, as operators still solve issues like material jams or monitoring faults. Customized products and packaging, which is a growing trend for many manufacturers, requires more intervention for production line changeover.

“The requirement for changeovers due to mass customization makes a completely unattended manufacturing line more complicated,” says Pal Roach, senior principal industry consultant for oil and gas at Rockwell Automation. “Automatic changeover is still relatively unreliable, so a person sometimes needs to verify that the machine is set for the new product correctly.”

4

Challenge: When operators are needed in the event of a failure, how do facilities train when systems otherwise run autonomously?

Even as we move toward autonomous operations, Sohail Nazari, global vice president and head of automation and digitalization for Andritz feed and biofuel division, says it’s important to remember that autonomy does not mean no humans.

“Operations still need humans to take control when everything fails. And the question is: If the plant runs 99.9% of the time automatically, how are operators trained to take control?” he asks.

As an example, he points to the airline industry, where planes take off, cruise and land automatically. Pilots are only there to monitor and take over in the rare event of a failure. “So how do pilots practice landing a plane on water when they never get to do it in real life? They use flight simulators,” Nazari says.

Process industries can do that same thing in the face of a similar challenge as industries move toward autonomy. To keep operators alert and ready to intervene when needed and capable of understanding the systems, Andritz built an operator training simulator specifically for the feed and pet food processing industry. “It’s a fully dynamic model of the plant—a complete digital twin—allowing operators to practice handling abnormal conditions when everything else fails,” he adds.

5

Challenge: All the new advanced technologies required for autonomous operations are costly Upgrading plants and factories to the next level of automation will not come cheap.

In addition to a premium price tag on many advanced technologies, these products can also require facility changes and other equipment upgrades. As with many new innovations, its price will come down in time as the market expands, and robotics is still finding its sure footing in the industrial market.

“I think that the biggest challenge with robotics at present is the cost. The hardware cost, it’s hard to justify single-shift ROI on a piece of equipment,” says Greg Berguig, president of PAC Machinery. As the cost for robotics comes down, it will open the market for more manufacturers. Berguig says Asia is leading that robotics market and will likely eventually help lower the cost of a typical industrial setup from, on average, $15,000 to closer to $2,000. “Once we get there, then I think many more industries will be doing some really cool automation,” he adds.

cover story

and other manual handling applica-

and generate return on investment

human oversight. The right technolo-

tions,” says Pal Roach, senior principal

(ROI). The focus has shifted from ‘Can

gies are in place to advance autonomy

industry consultant for oil and gas at

we automate?’ to ‘How do we make

as operations begin to connect all the

Rockwell Automation.

automation smarter?’” he adds.

machines and robots into an intelli-

AMRs have shown significant

Artificial intelligence can make au-

impact across various industries,

tomation smarter in combination with

such as flexible factories, logistics and

these many other technologies, and

warehousing says Eric Kraus, director

manufacturers will move from auto-

Machine builders move toward autonomy

of sales and automation, Doig. “AMRs

mating repetitive tasks and quality

Industry continues to push the auto-

are particularly effective in flexible

inspections with basic vision systems

mation envelope, and technologies

factories where floorplans may change

to autonomous material handling,

like artificial intelligence, machine

frequently. They are used for tasks

predictive maintenance and real-time

vision and robotics are pushing the

such as material handling, inventory

process optimization.

boundaries further. Machine build-

tracking and mobile manipulation.

“In the past five years, manufactur-

gent system.

ers Andritz, Doig and Comau provide

They are also applied in light assem-

ing customers have increasingly fo-

three examples of innovative uses of

bly, packaging, logistics and ware-

cused on automating processes using

automation that are moving opera-

housing,” he adds.

advanced technologies like Industrial

tions toward autonomy.

Internet of Things (IIoT), digital twins

Someday we will have fully autono-

Artificial intelligence will lead autonomy, with help from other technologies

and machine vision. These innova-

mous, what some have referred to

tions enable real-time data collection,

as lights-out, manufacturing or dark

predictive maintenance and improved

factories, but for now operators still

Dr. André Scholz, head of innovation

decision-making. The adoption of

rule the factory floor, and they will in

department: autonomous factory, at

cobots has also grown, allowing for

some capacity for a long time.

Siemens, says the main driver for the

safer and more efficient human-robot

In some industries, automation is

adoption of autonomous operations

collaboration,” says Cliff Ortmeyer,

second nature, and they’re much fur-

is artificial intelligence. “The usage of

head of solutions at Newark.

ther on the journey to autonomous

camera data is another key enabler to

“Cobots are revolutionizing as-

operations, but many industries are

gather information about the current

sembly lines by enhancing precision

still adopting automation machine

situation. With deep learning, rein-

and adaptability. The integration of

by machine.

forcement learning and vision-lan-

machine vision with deep learning is

guage models, new ways to use robots

transforming quality-control pro-

are being discovered,” Scholz says.

cesses, allowing for real-time defect

Andrew Borczak, industry market-

detection,” says Anjesh Shekhar, prod-

Andritz optimizes dryer control for better product and lower power consumption

ing manager, Omron, says a number of

uct marketing manager of networking

Manufacturers have adopted ma-

other technologies make autonomous

at Balluff. “In logistics and material

chines to automate their processes

robotics possible, including edge com-

handling, AMRs and AI-based systems

in probably every industry, espe-

puting, machine vision, digital twins

enhance efficiency by dynamically

cially discrete manufacturing. “The

and advanced motion control, as

optimizing routes and workflows.”

challenge now lies in continuous

Many industries have automated

processes and how to integrate all

well as artificial intelligence. “Today, autonomous operations aren’t just

parts of a production process with

of the automated machines together

about machines replacing humans. It’s

robots operating workcells or packag-

to create a truly autonomous opera-

about systems making decisions. They

ing the final product for distribution or

tion,” says Sohail Nazari, global vice

adjust parameters in real time, self-

AMRs transporting material between

president and head of automation and

correct errors and even orchestrate

workcells and to packaging. However,

digitalization for Andritz feed and bio-

workflows without human interven-

end-to-end autonomous operations

fuel, part of the company’s environ-

tion to improve efficiency, reduce risk

are rare, and most still require some

ment and energy group. The company

ControlDesign.com / November 2025 / 19

cover story

has set 2027 as a goal for autonomous operations for its feed and biofuel

constant human intervention?”

Nazari uses the example of working

ability in the moisture output—due to disturbances in the heating system,

customers. Nazari has worked in

with dryers in the pet food and feed

inlet moisture levels, raw material

Andritz’s pulp and paper and mining

industries. “For many years, we’ve

differences or environmental fac-

and mineral processing divisions, to

used programmable logic controllers

tors. This means that, even with PLC

enable more autonomous operations

(PLCs) to manage the drying process,

control, operations often suffer from

in those industries and will apply the

taking samples from the output to

inefficiencies,” Nazari says. Even with

lessons learned to an industry with

measure moisture and pellet durabil-

inline analyzers to measure moisture,

automation opportunity.

ity index (PDI).” Early on, he says, this

they still see high variability because

level of technology use was consid-

the dryer operation is too complex for

ered autonomous.

the control algorithm.

“Automating a machine when everything is going well is not a particularly difficult task. The issue arises

“However, it’s not sufficient to

Andritz has taken autonomous

when inputs or conditions deviate

handle process changes. The real-

control one step further with its

from the norm,” says Nazari. “How

ity is that when a recipe changes or

technology called model predictive

can we automatically make decisions

unexpected conditions arise, opera-

control (MPC), which has been used in

that tolerate these conditions without

tors have to step in. Even when they

oil and gas and pulp and paper plants

disrupting the process or requiring

don’t, there’s still a high level of vari-

for more than 20 years, Nazari says.

Until recently, this technology wasn’t affordable to the feed and biofuel industries, but MPC is now helping to reduce moisture variability in the drying process, cut power consumption and increase moisture levels in the final product.

“MPC is a fundamentally different type of controller. It first builds a model of the dryer’s behavior, a digital twin of the dryer, and then uses that model to predict and optimize performance in real time, even under uncertain or changing conditions,” Nazari says. Specifically for feed and pet food manufacturers, Andritz Dryer advanced control expert (ACE) will automate the drying process and can dramatically improve product quality.

Andritz’s results show a moisture variability reduction of up to 60% and increased moisture levels in the final product by up to 2% on average, says Nazari. Dryers can use up to 50% of a plant’s energy, and the

Figure 1: Doig’s cobot palletizing setup, Pallet EZ, handles and stacks goods on pallets.

system reduces power consumption by 15%, and operators no longer need to monitor product quality or content, says Nazari.

20 / November 2025 / ControlDesign.com

cover story

Doig uses robots and AMRs to automate palletizing operation Collaborative robots (cobots) are stepping in to do logistics and warehousing work in many operations, moving or stacking material or pick-and-place packing applications. Automation distributor and manufacturer Doig offers a cobot palletizing setup, Pallet EZ, using a collaborative robot to handle and stack goods on pallets (Figure 1).

It uses OnRobot’s D:PLOY applicationbased software, a no-code platform that automates programming and adapts to various pallet patterns and product sizes.

With a cobot palletizing system, end users can begin with a single rapid-deployment palletizing station and expand as demand grows, adding

Figure 2: Comau built the MR4Weld mobile robot to autonomously weld up to 170 m of steel in a single shift.

more palletizing units, then scaling upstream by integrating automated case packing and carton forming with additional cobots or industrial robots.

“Downstream, autonomous mobile robots can be incorporated for pallet handling, seamlessly transporting finished pallets between stations or to shipping zones,” says Doig’s Kraus.

“This modular approach, driven by technologies including simplified, intuitive software systems, cobots and AMRs, has surged in adoption recently, offering an accessible entry point into automation, particularly in smaller businesses where automation has been hard to adopt due to expertise or capital constraints.”

Comau manufactures mobile welding robots and temporary factories for solar farm assembly Comau is working with customers in manufacturing and beyond to automate traditional and more

Figure 3: Comau’s Hyperflex is a temporary factory for solar farm assembly.

complex emerging processes, increas-

ControlDesign.com / November 2025 / 21

cover story

Figure 4: The mobile factory can be tailored to handle different types and sizes of solar blades or even for other types of large-scale, outdoor assembly projects.

ingly deploying robotics and artificial

Fincanieri, a shipbuilder. “MR4Weld

intelligence for more autonomy, says

is essentially a mobile robot that can

and photovoltaic (PV) module in a sin-

Comau’s Piscioneri. Automation has

autonomously weld up to 170 m of

gle, streamlined operation,” he adds.

evolved, he says, from fixed produc-

steel in a single shift, while work-

Hyperflex was designed originally to

tion lines to flexible systems that

ing side-by-side with operators in

work with EDP Renewables, an energy

handle complex, unstructured tasks.

complete safety,” Piscioneri says. With

provider based in Madrid, Spain, with

“The adoption of mobile and collab-

a flexible design, MR4Weld can be

a portfolio of solar projects. The sys-

orative robotics has increased over

adapted to a variety of applications,

tem can be tailored to handle different

the past five years, which has allowed

such as the production of large steel

types and sizes of solar blades or even

us to reach new industries such as

infrastructure projects, continuous

for other types of large-scale, outdoor

aerospace, shipbuilding and renew-

structures for suspension bridges and

assembly projects (Figure 4).

able energy,” Piscioneri says. “Comau

large hoisting systems.

is increasingly deploying advanced

Comau also developed Hyperflex

of the torque tube, transversal beam

7 industry trends

automation within manufacturing

(Figure 3), a temporary factory for

Few industries haven’t been touched

environments but also outside the

solar farm assembly. It reduces mul-

by automation, but there are leaders

traditional factory setting.”

tiple steps into a highly automated

and laggards. For many industries,

workflow. “The Comau-designed rover

like many decisions, the implementa-

2), an outdoor automation prod-

autonomously manages the manufac-

tion of automation comes down to

uct, designed in collaboration with

turing, transportation and installation

cost. “Like many other technologies,

One example is MR4Weld (Figure

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cover story

began to adopt it,” says Andritz’s Naz-

The automotive sector has accelerated automation with the rise of EV production.

ari. “The adoption rate has also been

ing processes, which is why we are

influenced by the underlying need

increasingly deploying solutions that

electronics manufacturing: “Indus-

to automate—whether due to safety,

leverage robotics, artificial intelligence

tries such as automotive, electronics,

profitability, lack of human resources

and digitalization to improve efficien-

pharmaceuticals and food and bever-

or the desire to increase plant avail-

cy, flexibility and autonomous opera-

age have led the way in automation,

ability. In the past five years, the pace

tions. While welding, machining and

driven by the need for high precision,

of adopting more advanced digital

assembly remain key areas, industrial

efficiency and regulatory compliance.

technologies—and making them af-

automation has now expanded into

The automotive sector has acceler-

fordable enough for widespread use—

logistics, precision manufacturing and

ated automation with the rise of EV

has accelerated significantly.”

renewable energy production,” says

production, while electronics manu-

Comau’s Piscioneri.

facturing relies on AI-driven optimiza-

automation has followed a natural progression: as it became more affordable, more sectors and industries

We have the foundation technologies in place for autonomous opera-

2. Logistics, especially handling

4. Electric vehicle production and

tion for high-volume production. In-

tions, but it will take some time to

and transportation tasks: “For our

dustries like textiles, construction and

adapt to each industry. Nazari says oil

manufacturing customers, there has

agriculture have been slower to adopt

and gas, pulp and paper, and mining

been a significant focus on the auto-

automation due to high upfront costs,

have been among the early adopters of

mation of handling and transportation

workforce skill gaps, and product

advanced digital technologies, and all

tasks over the last five years. As far as

variability challenges,” says Newark’s

process industries are moving toward

industries that are more focused on

Ortmeyer.

more automation and autonomy.

automation, the logistics industry has

5. Material handling and pro-

“Today, there is no process or unit

invested heavily in automation since

cess automation, beyond repetitive

of operation that cannot be automat-

2023. Due to a lack of skilled workers,

tasks: “Manufacturers once looked

ed. But simply automating a process is

robotics solutions are more in demand

to automate repetitive tasks, such as

no longer enough. What’s needed now

for manufacturing and logistics,” says

using robotics for pick-and-place and

is automation that can optimize and

Siemens’ Scholz.

palletizing, as well as automating

adapt to both predictable and unpre-

3. Asset-intensive operations

quality inspection with basic vision

dictable changes, and support manag-

without a lot of variability: “Indus-

systems. Today, the same companies

ers in pushing for higher availability

tries with asset-intensive operations

are looking for autonomous material

and efficiency,” says Nazari.

have been at the forefront of having

handling, predictive maintenance

If adaptable, efficient operations are

interests in autonomous technologies.

and real-time process optimization,”

the end game, many technologies will

For instance, areas like manufactur-

says Omron’s Borczak.

get us there. Some industries are more

ing, energy and transportation have

Traceability continues to be of im-

advanced than others, and automa-

integrated autonomous operations to

portance, especially in light of Section

tion is gaining speed in different areas

enhance efficiency and operational

204(d) of the Food Safety Moderniza-

of manufacturing. Here, seven more

uptime,” says Wauseon Machine’s

tion Act (FSMA), a records require-

experts discuss the leaders and lag-

Guelde. “Industries that have com-

ment from the Food and Drug Ad-

gards for automation that will lead to

plex, variable tasks have been slower

ministration. “The food and beverage

autonomy.

to adopt automation. Areas such as

sector, for instance, is doubling down

1. From traditional welding and

agriculture, construction and certain

on track-and-trace systems to comply

machining to logistics and renewable

service industries face challenges due

with FSMA 204(d),” says Borczak.

energy: “Our manufacturing custom-

to the variability of tasks and the need

“And automotive manufacturers are

ers look for automation to enhance

for human judgment, making automa-

integrating AI-driven quality control

both traditional and complex emerg-

tion more complicated to apply.”

to minimize recalls.”

24 / November 2025 / ControlDesign.com

cover story

Who’s close to autonomy?

is still necessary. “Industries such as

quality assurance for automotive and

Industry is making strides toward ful-

automotive manufacturing are closest

electronics industries: “The automo-

ly autonomous operations, but gener-

to achieving full autonomy, leveraging

tive and electronics sectors are at the

ally in most sectors human oversight

robotics, software-based quality con-

6. Assembly, material handling and

forefront of this trend, utilizing robotics, vision systems and IIoT-enabled devices to improve assembly, material handling and quality assurance processes. Conversely, sectors like food and beverage and textiles have

Protec Enclosure Air Conditioners ssssssssssssssssssssssssssssssss

been slower to embrace automation, primarily due to intricate material handling requirements and significant product and packaging variability.

Nevertheless, innovations in intelligent sensors and collaborative robotics make automation more feasible and accessible for these industries,” says Balluff’s Shekhar.

7. Beyond loading and sorting, highvolume industries have resources to scale: “Over the past five years, small to medium manufacturing businesses, especially in food and packaging, paper converting and general manufacturing, have faced a shrinking labor pool, pushing them to automate simple tasks like loading, sorting or basic machining since they can’t rely on more workers. But it’s tough; their custom applications make automation costly, and they struggle to justify the capital investment. They’ve lost in-house technical talent due to labor shortages, and they’re restricted by the need to grow faster than manual labor can handle. Meanwhile, high-volume

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industries like consumer goods and medical and pharmaceutical are leading autonomous operations. They’ve

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got the resources and scale to drive efficiency and precision. The laggards are those same small to medium manufacturing businesses, held back by capital challenges and growth pressure,” says Doig’s Kraus.

Seifert Systems, Inc. info.us@seifertsystems.com 401-294-6960 www.seifertinc.com

cover story

trol and high level of standardization,” says Comau’s Piscioneri.

Logistics and warehousing are another big growth area, but the

Facilities need process flexibility to allow production to be done in different ways.

product variability presents additional complexity. “Challenges remain in

Full autonomy has two prerequi-

robotic inspections, drone-based

flexible decision-making, adaptability

sites before industry can fully realize

monitoring and AI-powered predic-

to unpredictable scenarios and com-

a factory with no humans, Scholz

tive maintenance, aimed at improv-

plex assembly tasks,” Piscioneri adds.

says. Facilities need process flexibility

ing safety, efficiency and productiv-

“Future advancements in AI-driven

to allow production to be done in dif-

ity,” Roach says.

process optimization, advanced

ferent ways, such as a robot handling

machine vision systems, cybersecu-

product, instead of a fixed machine.

rity and real-time sensor fusion will

The other necessity is intelligence.

Joe Biondo, strategic marketing manager for OEMs and machine builders at Rockwell Automation,

be key to making fully autonomous

“An intelligent system that can un-

says those autonomous operations

manufacturing a reality.”

derstand the current situation—for

are the low-hanging fruit for the

example, an error in one part of the

energy industry. “The next tier of

with software company Intrinsic to

production system—and find alterna-

opportunities is significantly more

develop and make scalable operations

tive ways to reach the goal of produc-

challenging, such as oil and gas

easier with pre-configured application

tion—for example, usage of other

exploration, oil and gas production,

templates. The AI-backed software

parts or other station—is essential

and petroleum refining,” Biondo says.

will power intelligent decision-making

to make this a reality,” says Scholz.

“This will involve integrated sensing,

and help deploy this kind of advanced

“Some matrix production lines in

measurement, control and optimiza-

technology at a faster pace.

automotive are quite close in aspects

tion, all informed by the underlying

“The software platform, equipped

of flexibility and intelligence.” Again,

physics and chemical engineering of

with a low-code graphical interface,

individual processes or even produc-

the processes being controlled.”

enhances robotics adoption and cost-

tion lines are an autonomous reality,

effectiveness by helping companies in

but entire operations, factories or

and oil and gas technology provider

various industries access modern au-

plants operating in sync requires not

Schlumberger (SLB) formed Sensia,

tomation solutions. It simplifies robot

only more intelligent systems, but

an automation provider for oil and

programming, making it intuitive for

also better-connected machine data

gas, to build autonomous opera-

non-experts, particularly in industries

to power that intelligence.

tions for various types of facilities.

To that end, Comau is collaborating

approaching automation for the first

A joint venture between Rockwell

“Implementations available today

Autonomous exploration, production and refining is next for the energy industry

include artificial lift oil production

Rockwell Automation’s Roach says

technology, computer performance,

the energy industry has invested

connectivity, AI and wider adoption

Considering automation in the scope

heavily in industrial automation for

of open standards will accelerate

of an individual production line, some

more than 50 years. The industry is

the development of more solutions,”

industries are close to fully automatic

capital-intensive, with dangerous

Biondo says.

production with no humans, says

processes and harsh environments,

Siemens’ Scholz. “Industry is far away

and recently, Roach says, those cus-

from fully autonomous operations if

tomers have accelerated automation

Semiconductor fabs lead the autonomous journey

we include service, maintenance and

projects. “Autonomous operations in

The facilities that build our most

new product introduction into the

the energy industry today encom-

advanced digital technologies, which

operations of a factory,” he says.

pass various applications, including

power all our electronics, are also

time,” Piscioneri says.

How to turn machine automation into plant- or factory-wide autonomy

26 / November 2025 / ControlDesign.com

and digital well pad operations. Continued advancements in information

cover story

highly advanced manufacturing pro-

It’s about getting that item into the

es after they are filled, but complete

cesses and largely autonomous.

package when you have variability.”

autonomy in building products and

“We’re still a ways from total lights-

The packaging industry has largely

packaging them remains the chal-

out factories where machines run

automated what we do with packag-

lenge and the next steps.

entirely unsupervised, at least for most industries,” says Omron’s Borczak. “The closest may be semiconductor fabs, where ultra-precise, highly automated environments require minimal human intervention with real-time monitoring and autonomous process control.”

While the industry has made significant advancements, fully autonomous operations remain a distant goal due to challenges in adaptability, decision-making and real-time optimization, says Newark’s Ortmeyer. “The semiconductor industry is currently the closest to achieving autonomy, with highly controlled fabrication environments enabling limited self-correction and optimization,” he says. “Automotive assembly follows, driven by heavy investments in connected systems and predictive analytics.”

Product variability and infrastructure flexibility are the current hangups to autonomy Continuous automation is easier for consistent products like feeding systems and scales, says Greg Berguig, president of PAC Machinery, but more challenging for varied products like e-commerce packaging. “It’s just about getting faster and more flexible. Where I think the opportunity lies is in processes that have a lot of variability of product,” he adds.

He points to the kitting process or e-commerce and packaging operations. “Once you get the item into the package, that’s super easy to automate from a packaging standpoint.

Build what you need and get access to: • 3D Drawings • 2D Drawings • Dimensional Dawings • Technical Data Sheets • Quote Request

controllers

PLC logic, PID control automate distillation How to apply industrial control to small-batch distillation: a case study in smart reflux automation

by Douglas Reneker

CREATING DISTILLED SPIRITS for

images of a pot still, but these are too

separation, hence their universal

beverage use is often more art than

inefficient for industrial applications.

industrial use.

science. Concentrating alcohol content

A far better approach—following in-

Hobbyist-scale stills are less com-

without losing distinctive flavors from

dustrial principles—uses a distillation

plex than industrial installations, but

the fermented mash calls for careful

column with trays or packing, where

it is possible to apply the same reflux

measurement and control of distillation

some condensation produces reflux

concepts. Our small team wanted to

principles to get a desired result. Tradi-

(Figure 1). Reflux is a technique where

try applying big-industry techniques

tional “moonshine” production conjures

the mixture is heated to produce va-

to operate a small-scale pilot still for

por, some of which is then condensed

beverage ethanol production, using

back into liquid, falling back into the

a cost-effective yet capable program-

column where it is reheated and re-

able logic controller (PLC), human-ma-

vaporized at a higher concentration.

chine interface (HMI), motor control

Consequently, a distillation column allows a higher degree of controllable

Figure 1: A distillation column with trays or packing provides greater performance separating alcohol from water than simple boiling methods. This sample is far fancierlooking than a typical industrial unit.

28 / November 2025 / ControlDesign.com

devices, instrumentation and other automation elements.

Figure 2: The differences between boiling and vapor temperature for alcohol and water makes separation by distillation possible.

(IMAGE COURTESY OF DOUG RENEKER)

controllers

Batch distillation basics Separation of alcohol and water using distillation is practical because they have different boiling points. Indeed, the boiling point of a mixture depends upon the relative proportions of the two (Figure 2). What’s more, vapor boiled off has a higher alcohol content than the liquid in the boiler producing it, concentrating alcohol as a result.

Creating pure alcohol via distillation works to a high limit of approximately 96%. For beverage purposes, this isn’t necessarily desirable, unless producing vodka, as much of the mash’s flavor profile is lost. Fortunately, the concentration can be easily regulated by controlling vapor temperature.

Creating beverage-grade alcohol usually involves two distillation steps.

First, fermented mash with about 10% alcohol content goes through a “stripping run” using a pot still, to raise proof to between 30% and 40%. This is distilled a second time in a “spirit run,” often using a distillation column, to raise proof to a level more suitable for aging and bottling.

As a quick review of distillation column operation, vapor driven up the column from the boiler interacts with reflux liquid coming down from cooler areas at the top (Figure 3). This

Figure 3: The actual still has the dephlegmator near the column top, just above the black coupling.

This installation has a twostage condenser, with an air-cooled section before a water-jacketed final stage.

(IMAGE COURTESY OF DOUG RENEKER)

allows for higher-efficiency separation via repeated condensation and

the column top provides final vapor

In this type of batch operation,

re-vaporization. The ultimate objec-

temperature control. Condensation

alcohol concentration in the boiler is

tive is controlling the vapor tem-

from the dephlegmator falls back

highest at the start, therefore the boil-

perature, which in turn indicates the

into the column as reflux. Vapor tem-

ing temperature is lowest. As alcohol

alcohol concentration, by varying the

perature, measured just above the

cooks off, boiler temperature increas-

amount of cooling.

dephlegmator, is controlled by me-

es, and the proportion of alcohol to

tering the flow of cool water through

water leaving the boiler drops. There-

the dephlegmator.

fore, the amount of cooling necessary

Adding a dephlegmator—a small shell-and-tube heat exchanger—at

ControlDesign.com / November 2025 / 29

controllers

to maintain the same vapor temperature at the column top constantly increases, creating more reflux and reducing the ultimate output. Matching cooling flow to alcohol reduction is the essential challenge. Eventually as boiler alcohol nears zero, cooling water flow is highest, either choking off vapor flow entirely, or saturating the pump, making it impossible to maintain the setpoint.

Control strategies Since cooling water flow control is relatively low—around 8 ml/min— and variable, approaches such as needle valves prove ineffective. A peristaltic pump is a more practical

Figure 5: The HMI provides clear visualization of all temperatures on a common trend, making it easy to see how they tend to change as a group.

(IMAGE COURTESY OF DOUG RENEKER)

approach, but manual control requires constant attention to compensate for temperature changes.

handled automatic control partially

trol. This PLC integrates easily with

but still demanded manual tweaking

the AutomationDirect C-more CM5

an Arduino-based controller, pro-

and did not provide data integration.

touch-panel HMI. By selecting a two-

grammed to drive the pump. This

A better integrated system using

slot controller model, we were able to

modern automation hardware offers

add a Node-Red controller in the sec-

critical advantages:

ond slot to enhance data connectivity.

• PLCs interface directly with tempera-

Two four-channel RTD modules allow

ture and other sensors, while provid-

connection to temperature sensors:

ing proportional-integral-derivative

• boiler

(PID) control with automatic tuning.

• column top

Our first automation attempt used

• H MIs provide clear visualization to consolidate setup, control and

• final condenser • dephlegmator cooling inlet and exit.

monitoring, with data logging.

Figure 4: The compact PLC and I/O, HMI, the stepper drive, the motor/pump and associated components are all mounted on a common backplate with thorough grounding to minimize noise in the temperature data.

(IMAGE COURTESY OF DOUG RENEKER)

30 / November 2025 / ControlDesign.com

• Stepper motor control via the Click

Top shelf program development

TTL module provides precise peri-

The PLC logic and HMI graphics needed

staltic pump operation.

to control and manage the system were

• D evices can be integrated

developed in parallel for this project.

via Ethernet.

While accurate PID-based pump con-

We chose AutomationDirect’s Click

trol would be essential, this would be a

Plus stackable micro modular family

data-driven project. All temperatures

of PLCs and I/O (Figure 4). It offers con-

and the pump output would be logged.

siderable processing speed, interfaces

Additional calculations and logic would

to a wide range of I/O signals, includ-

determine the amount of cooling in

ing resistive temperature detector

the dephlegmator, and a recording

(RTD) sensors and high-speed pulse

of which jar of product is produced

digital outputs for stepper motor con-

throughout the run.

controllers

Using the free Click and C-more programming software packages, it was straightforward to connect the RTDs into the PLC and map scaled values to the HMI. The first screen presents and trends these temperatures, using a standard chart object and a 15-second sampling interval (Figure 5).

Pump control was the next task.

The SureStep 4830 dc micro-stepping drive operates the pump motor. Conveniently, the Click Plus PLC includes a native motion control block with configurable maximum pulse rate, maximum acceleration and other parameters. An associated HMI screen was developed with a slider for set-

Figure 6: The Pump page indicates volumetric flow, as well as the actual cooling effect in Watts.

(IMAGE COURTESY OF DOUG RENEKER)

ting motor speed, plus an indicator for motor speed, making it simple to calibrate the pump.

Although the PLC and HMI are closely integrated, functions are divided.

The PLC handles all mathematics, logic and control processes, while the HMI provides user visibility and access to controls and information produced in the PLC. Together, they provide all controls and display all process information in engineering units. Advanced features and variables provided by the PLC improved HMI design.

Several HMI screens were produced: • startup, to set date and time • controls, providing operational inputs, such as the setpoint and manual pump speed • temperatures, displaying and track-

Figure 7: The Tuning page provides a detailed presentation of all control parameters.

(IMAGE COURTESY OF DOUG RENEKER)

ing various values in the system • pump, displaying speed and cooling

such as buttons to allow easy screen

bining this with the specific heat of

water flow to the dephlegmator

navigation, and buttons for selecting

water allows the cooling rate in Watts

manual or PID pump control.

to be calculated, with both displayed

• t uning for the PID loop parameters.

on the Pump page (Figure 6).

Because PID pump control based on

While the I/O signals provide im-

temperature input is a core function,

portant data, even more information

In addition to logging I/O signals

a temperature setpoint slider resides

can be derived. Because the peristal-

and calculated values, the configura-

on the Controls screen. Several HMI

tic pump is positive-displacement, its

tion allows users to manually enter

objects are accessible on all screens,

speed indicates coolant flow. Com-

externally generated information,

32 / November 2025 / ControlDesign.com

controllers

An additional goal of this project was to make the produced data readily accessible by external systems. For this we used the Node-Red module.

Node-Red is a powerful programming tool, based on the notion of passing messages from one processing node to another. Programs are graphical, with nodes selected from a menu, placed in a working area and connected together, linking one node’s output to another node’s input. Many libraries of nodes have been created for accessing data from over the web, formatting displays, processing audio and posting internet of things (IoT) data.

Nominally, Node-Red runs on a web page, and once a program flow is created, it produces code for use on a target system. For the AutomationDirect implementation, Node-Red flows can both read and write variables in the PLC (Figure 8). For our trial purpose we created a simple dashboard webpage

Figure 8: The module seamlessly reads and writes data in the PLC, making it easy to create web pages populated with live data and viewable on site or over the internet.

displaying key operating temperatures and parameters and kept this local to our own isolated and private network.

However, Node-Red provides an easy and secure way to extend data connectivity throughout a much larger operation, and even over the internet. In our case the goal was to produce data,

(IMAGE COURTESY OF DOUG RENEKER)

but Node-Red also makes it easy to consume externally sourced data, such as a weather report or energy market prices, so the automation system can perform more advanced functions.

such as alcohol concentration mea-

ed variable (CSV) file allows importing

The proof is in the product

surement and jar number, on the left

data into spreadsheets for analysis.

With programming substantially

side of the screen, providing a compre-

The PLC includes native PID auto-

complete, it was time for a test run. A

hensive process log. All data is logged

tuning functionality, accessed via the

spirit run takes a 6- or 7-gallon batch

to a microSD card slot in the PLC.

Tuning page, which displays this and

of liquid with around 40% alcohol

Configuration is simply performed by

allows setting the PID parameters

concentration and works to extract as

adding variables to a list with a speci-

while displaying the process variable

much alcohol as possible over about

fied output format. A comma separat-

and control output (Figure 7).

three hours.

ControlDesign.com / November 2025 / 33

controllers

Once basic functionality was

cools below the set point. Hysteresis

confirmed, the next hurdle was get-

was set ±1 C around the setpoint. The

ting the PID loop tuned correctly.

PLC repeats these steps two more

Conditions were manually adjusted

times and then calculates new coef-

to a relatively steady state, and the

ficients. It then returns to normal PID

auto-tuning process was initiated.

control using the new values.

First, the pump runs in manual to

Auto tuning was successful as the

get the process variable a degree or

PID loop effectively maintained the

so below the setpoint. Next, the PID

critical column top temperature at

loop launches using initial coef-

the desired setpoint, varying by only

ficients, followed by triggering the

fractions of a degree. The automa-

PLC auto-tune process. In this case,

tion did not seem to struggle until

it first stops the pump, allowing the

the very last part of the run when

dephlegmator to heat up above the

boiler alcohol content was nearing

setpoint. Next, it drives the pump to

zero. The system responded nicely to

full speed, until the dephlegmator

set point changes of a few degrees,

Figure 9: Measuring final distillate percentage uses a hydrometer in a “parrot” to maintain a continuous reading.

(IMAGE COURTESY OF DOUG RENEKER)

Figure 10: The project proved to be a straightforward development, with quick integration of the controller into the distillation apparatus.

(IMAGE COURTESY OF DOUG RENEKER)

settling to the new value in about 90 seconds with no overshoot or oscillation. Final alcohol percentage was verified using a hydrometer monitoring final output (Figure 9).

The run was completed in auto mode with the desired final alcohol percentage. All in all, the project proved to be a straightforward development, with quick integration of the controller into the distillation apparatus, proving that industrialgrade commercial off-the-shelf (COTS) automation devices like PLCs, HMIs and motor drives are accessible and cost-effective to create premium solutions even for small-scale processes and systems (Figure 10).

Doug Reneker is a retired electrical engineer and circuit designer who worked for Bell Labs, Recon/Optical and Arris. He has a BS and MS in electrical engineering from Iowa State University.

Contact him at reneker@ieee.org.

34 / November 2025 / ControlDesign.com

VISION, EXPERIENCE, ANSWERS FOR INDUSTRY, ENERGY, & INFRASTRUCTURE

hydraulics

Massive crane requires precision Engineers solve an hydraulic physics problem to reduce unloading times at an Australian port

by Ian Duncan, Motion Australia

EFFICIENT UNLOADING OF BULK materials like fertilizer, minerals and cement clinker directly affects the regional industry north of Sydney, Australia. Before a new 30-ton unloader was installed, ships waited days while their own

Figure 1: The full crane cycle needed to be completed in just 62 seconds to achieve the throughput required for the port’s operational goals.

small cranes laboriously emptied their holds. The new machine promised to slash unloading times.

Predicting trouble A global manufacturer of bulk material handling equipment for shipping ports won the contract to build a massive unloading machine for the port. It encountered challenges with the machine’s hydraulic system—think of it like hanging a fishing weight on the end of a nylon line. When the line moves, the weight begins to swing. Without precision motion control to dampen the swinging, the system becomes unstable and inefficient.

In need of expert consultation, Motion Australia, our specialized Australia-wide hydraulic motion control engineering company with representation and workshops in all states was called to design a solution.

The difficulties were particularly on the safety side. Part of reviewing the hydraulics was to assess the motion control performance they were expecting because not only is the machine large—able to pull up to 20-ton bites of material out of the ship—they also quoted quite a tight cycle time.

The full crane cycle needed to be completed in just 62 seconds to achieve the throughput required for the port’s

showed how the grab would swing wildly through plus or

operational goals (Figure 1). This process included dropping

minus 6 m, oscillating for nearly 40 seconds after crane

the grab into the ship and retrieving material, hoisting it up,

movement stopped.

traversing it to the hopper, releasing it and returning. With

If you don’t control the motion properly, the grab will

a potential travel distance of 30 m, the physics demanded

sway. The analysis showed that conventional program-

extremely fast and precise motion control.

mable logic controller (PLC) functions would not provide the

When our team analyzed the proposed design, they iden-

precision required. An advanced motion controller, such

tified serious issues with dynamic response. To illustrate

as the capabilities built into Delta’s RMC, were essential to

the problem, we created a desktop-scale simulation that

manage the systems dynamics and prevent the instability

36 / November 2025 / ControlDesign.com

hydraulics

Effectively, we had to produce a whole series of these intermediate motion profiles and then stitch them together.

Imagine you take all of these motion profiles and stick them in a pot, mix them together and get out a hybrid version.

That’s what allowed us to solve the variable speed and variable height problems.

Before risking implementation on the massive port crane, the team constructed a small test rig in the office, a simple motorized suitcase with a suspended weight (Figure 2).

Videos demonstrated the dramatic contrast. With standard control, the weight swung wildly. With anti-sway algorithms active, it remained nearly stationary through identical movements.

Deploying precision For implementation, our team selected Delta’s RMC75E moFigure 2: Before risking implementation on the massive port crane, the team constructed a small test rig in the office, a simple motorized suitcase with a suspended weight.

tion controller. This controller offered sufficient memory and processing capability for the sophisticated algorithm, along with Ethernet connectivity to interface with the machine’s existing PLC. We went to the customer and explained how this would

I predicted. When the crane was put into operation, reality

be a complex motion control solution. The PLC did not have

proved my warnings correct — the grab swung so violently

the mathematical capability or the response speed needed.

that the machine became unusable.

Delta’s RMC75E was the logical choice. We only needed to control one axis, and the software capability was certainly

Finding help in mathematics

sufficient to implement this algorithm.

Early in 2023, I received a panicked phone call. The sway

The integration leveraged Delta Motion’s RMCTools

had defied all attempts at mitigation, and the port was

software, which made the complex programming task

threatening drastic action.

substantially more manageable. RMCTools’ graphical in-

Hope for a solution existed in theoretical work by Peter

terface simplified the configuration and implementation of

Nachtwey, former president and chief software architect

the solution’s essential circular buffer architecture. Delta’s

at Delta Motion. His “input shaping” concept provided a

intuitive design environment allowed the team to focus on

mathematical basis for controlling pendulum motion in

programming the algorithm’s sophisticated mathematics,

cranes. However, this use case presented additional chal-

rather than wrestling with programming details.

lenges, notably that the operator needed joystick control

The cost of the controller hardware was small compared

for variable speeds, and the rope length changed constant-

to the engineering time and effort. Plus, RMCTools is in-

ly during operation.

cluded at no extra cost.

Our team at Motion Australia built on Nachtwey’s work.

Of course, there were significant challenges. Most Delta

They developed an algorithm that not only controlled sway,

controllers typically connect to servo valves that respond

but also adapted to changing conditions. The approach broke

within milliseconds with 0.1% accuracy. The port machine

the motion into carefully calculated segments with interme-

used a Swash-plate controlled pump that took up to 2.5

diate speeds and pauses that canceled pendulum forces.

seconds to respond with only 10% accuracy. This required

ControlDesign.com / November 2025 / 37

hydraulics

additional tuning and algorithm refinement beyond the

Beyond expectations

core anti-sway function.

During commissioning, our team made gradual refinements

Safety concerns also demanded attention. The hydrau-

to handle both automatic positioning and manual joystick

lic cylinder driving the luffing motion—moving the grab

control. The results were immediate. The grab that had pre-

horizontally—had minimal overtravel margin. If the piston

viously defied control now moved with precision, stopping

were to reach end-of-stroke at high speed, catastrophic

directly over target points with barely a wiggle.

structural failure could result.

To prevent this scenario, the team implemented additional safety logic monitoring velocity versus position. If motion exceeded acceptable parameters near endpoints, an emergency stop would instantly trigger.

The software implementation required a circular buffer architecture, essentially predicting up to 20 seconds of motion data in the controller and using that knowledge to modify the present as conditions changed. This allowed real-time adaptation to changing rope length and operator commands while maintaining sway control.

Figure 3: The crane can operate at full productivity, with luffing motions completing in about 22 seconds.

38 / November 2025 / ControlDesign.com

The improvement proved so dramatic that the port’s operations manager delivered probably the best, and definitely most colorful, customer testimonial we’ve ever had.

The solution eliminated minutes of waiting for sway to diminish after each movement. This allowed the crane to

hydraulics

operate at full productivity, with luffing motions completing

are designing a crane or some device with a suspended load,

in about 22 seconds (Figure 3).

you must consider load swaying when factoring in the design

Unlike alternative anti-sway systems that require sen-

of the machine. Firstly, it will affect the forces and therefore

sors to measure rope angles, the Delta-based solution works

the structure as well as the drive device. Secondly, if the sway

without additional costly hardware. It calculates optimal

is uncontrolled, it can result in significant damage, or at the

motion paths mathematically, compensating for both vari-

very least, significantly slower operation while you wait for

able speed and changing rope length simultaneously.

the sway to dissipate. But now we’ve shown how to mitigate these issues with motion controllers from Delta Motion.

Beyond implementation

For the port, the transformation from swinging terror to

The port implementation offers crucial lessons for heavy

a predictable, precision machine, all derived from best-of-

equipment design (Figure 4). The wisdom here would be if you

breed motion control and mathematical algorithms, means more than operational efficiency. It represents millions saved in potential litigation, untold structural damage avoided and

Figure 4: The port implementation offers crucial lessons for heavy equipment design.

faster, more reliable materials delivery for the region’s industries.

Ian Duncan is chief engineer at Motion Australia. Contact him at ian.duncan@motionaus.com.

product roundup

Keep it secure with connectors and cables Application connectivity configured for industrial machinery Pepperl+Fuchs M8/M12 sensor-actuator cables

Murrelektronik mini cables

Pepperl+Fuchs’ sensor-actuator cables for machine and

Murrelektronik 7/8 inch –

plant operation are available in many variations and are

16 UN2 mini cables feature

designed to be an addition to its industrial sensors. The

a four-wire, four-pole

combination of different threading and wire types is de-

configuration that enables

signed to match any application. The sensor-actuator cables

the transmission of both

with optimized M8 and M12 connectors are designed to be

power and control signals

rugged with a maximum service life. In addition to M8 and

through a single connec-

M12, the range of sensor-actuator cables contains numer-

tor. These mini connector

ous other common threading types like ½-inch, 7/8-inch,

cables are equipped with established power connectors for

M9 or M23. Gas-proof and gold-plated crimp connections

I/O modules and field devices, and they are UL-listed for

are designed to increase vibration resistance and durabil-

industrial control and signal applications. Each connector is

ity. The portfolio of wire types ranges from PVC sheathings

100% tested during manufacturing, and they are available in multiple configurations, including standard axial, rightangle connectors, and connector-to-pigtail combinations.

A range of 7/8 in – 16 UN2 mini field wirable connectors, designed for cable diameters of 6–8 mm is also available.

and PUR sheathings to POC sheathings specifically built for

When properly connected, they achieve an IP67 rating for

welding areas. For outdoor applications, PUR-O sheathings

dust and water protection. With a four-pin layout, these

are available. Additional cable features cover steel nuts,

connectors are designed to support field assembly and pro-

LEDs as operating and function indicators, 360° shielding,

vide transmission of both signals and power.

cULus certifications and NAMUR suitability. IP67, IP68 and

AutomationDirect / www.automationdirect.com

IP69 protections are available.

Pepperl+Fuchs / www.pepperl-fuchs.com

Phoenix Contact RJ45 jacks with magnetics Phoenix Contact offers RJ45 jacks

Wieland RST Plug+Play for machine applications

with integrated magnetics. The

Wieland Electric’s RST Clas-

integrated magnetics within

sic round connector series,

the RJ45 jacks are designed

engineered to streamline

to improve electromag-

machine installations with

netic interference (EMI) noise

plug-and-play, are available in

shielding and ensure reliable

two- to seven-pole configura-

data connections in industrial environments. The magnet-

tions. These connectors are

ics are integrated to simplify the Ethernet design process

factory-tested and modular.

and reduce PCB complexity. The 90° and 180° single-port

Designed for demanding indus-

PCB connectors are suitable for wave soldering (THT)

trial environments, the RST Classic offers protection ratings

and reflow (THR) processing. The RJ45 jacks are designed

up to IP69. Optional barrier seals are designed to prevent

for data rates up to 1 Gbps. They feature optional shield

moisture propagation through cable systems. With features

springs and LEDs as a visual status indicator for the inter-

like mechanical coding and color options, the RST Classic is

face. The new additions complement Phoenix Contact’s

designed to simplify installation and enhances safety.

existing industrial and standard RJ45 jack portfolio.

Wieland / www.wieland-americas.com

Phoenix Contact / www.phoenixcontact.com

40 / November 2025 / ControlDesign.com

product roundup

Binder M12 L-and T-coded connectors

ing allows exposed runs up to

Binder’s M12 L- and T-coded connectors featuring stain-

6 ft without conduit. Category

less steel locking mechanisms, are designed to ensure the

6A performance is designed to

highest levels of reliability and durability in demanding in-

ensure high-speed data trans-

dustrial environments. The 813 (T-coded) and 823 (L-coded)

mission for Ethernet/IP, Profinet

series field attachable M12 connectors have a stainless steel

and CC-Link IE Field applications. The cable features dual

locking mechanism, have an IP67

foil and tinned copper braid shielding for EMI protection,

degree of protection and a me-

along with an oil-resistant, sunlight-resistant PVC jacket.

chanical service life of more

Lutze / www.lutze.com

than 100 mating cycles. The 813 series offers a pole count of 4, while the 823 series offers pole

Hilscher SPE Media Switch

counts of 4 and 4+FE. Both variants are designed for cable

Hilscher’s gateway is designed to integrate single-pair

diameters of 6-13 mm. Another advantage is their high

Ethernet (SPE) into industrial Ethernet networks. The new

temperature resistance: they are designed for an operating

SPE media switch, based on Hilscher’s multiprotocol-capable

range of -40 °C to +105 °C.

netX90 communication controller, is designed to provide

binder / www.binder-usa.com

connectivity for SPE applications with Profinet, Open Modbus/TCP and EtherNet/IP networks. The SPE Media Switch is designed for IP-based communication from sensors to the

Icotek AT-HA grommet

cloud, allowing devices to be connected over distances of up

With the AT-HA grommet, icotek is expanding its IMAS-

to 1,000 meters using the 10BASE-T1L standard. Hilscher sup-

CONNECT adapter system. The AT-HA is designed to enable

ports both the Single Pair Ethernet

the integration of 3A and 4A plug inserts directly into an

System Alliance (SPE SA) and the

adapter cable entry without the need for an additional

SPE Industrial Partner Network

cut-out. The AT-HA cable gland is based on

(SPE PN) SPE connector standards.

the icotek KT cable grommet large and

The SPE Media Switch is compat-

is equipped with a polyamide body.

ible with IEC 63171-2 (SPE SA) and

It is fully compatible with all icotek KT based cable entry systems and

IEC 63171-6 (SPE PN) connectors.

Hilscher / www.hilscher.com

is delivered ready for use with a pre-assembled locking element. In ing connector housings for M20 or M25 with cable glands,

Weidmuller M12 panel receptacles with Push In technology

it is designed to provide a compact, efficient and flexible

Weidmuller’s M12 panel receptacles with Push In technolo-

system for a wide range of industrial applications.

gy are designed to redefine device wiring. The tool-free con-

icotek / www.icotek.com

ductor connection is designed to

combination with the 3A and 4A insert sets and the match-

reduce installation time while boosting process reliability.

Lutze 104397 Cat6A industrial Ethernet cable

Available in A- and D-coding,

Lutze’s 104397 flexible Cat6A industrial Ethernet cable is de-

these compact connectors are

signed to meet the evolving demands of industrial automa-

designed to ensure secure signal

tion. This cable is designed to simplify installations, reduce

and data transmission in demanding industrial environ-

inventory complexity and deliver reliable connectivity for

ments. Designed for applications requiring high flexibility

Industry 4.0 applications with versatility, now including

and rugged performance, the M12 with Push In is designed

PLTC-ER and approvals for wet locations. The Cat6A cable

to deliver a future-proof connectivity solution right at the

with PLTC-ER rating combines PLTC-ER, wet locations, AWM

device interface.

600 V and CMG ratings in a single design. The PLTC-ER rat-

Weidmuller / www.weidmuller.com

ControlDesign.com / November 2025 / 41

live wire

Joey Stubbs joey.stubbs@gmail.com

Digital twins accelerate debugging DIGITAL-TWIN CAPABILITIES create a virtual replica of a ma-

unnecessary rework in the control code. All this leads to

chine in software that can be tested and refined before the

the first power-up being smoother, with fewer unknowns.

hardware even exists.

The traditional method of machine development has al-

The simple definition of a digital twin is a virtual replica

ways been some variation on this theme: wait for hardware,

of a physical machine or motion system, synchronized

go through long debug cycles and then expect surprises

with control logic. Unlike a basic simulation, the twin is

at the end requiring changes to hardware, programming,

connected to the actual control logic, exchanging I/O, sta-

and interface aspects. Now, because the virtual model can

tus signals and motion commands in real time. It doesn’t

be shared with the entire cross-discipline team, the model

just look like the machine; it behaves like it, using accurate

helps connect programmers, mechanical engineers and op-

kinematics, physics models and

erators to design, evaluate, test

live feedback loops. Because it mirrors the actual machine behavior, programmers can run the same PLC or motion code against the twin as they will on

and correct the model prior to

Changes to the hardware specifications can be made prior to the first purchase order.

the factory floor. It is useful for

the machine being finished.

Changes to the hardware specifications can be made prior to the first purchase order being written. With simulation

full virtual commissioning, test-

through a digital twin, early

ing safety configurations, debugging logic, operator and

code can be tested, reducing downtime and making com-

maintenance training and lifecycle support.

missioning much less stressful.

Think of the difference between a simulation and a

The same qualities that enable streamlined commission-

digital twin like aviation simulators. A basic simula-

ing of a new machine also translate into incremental or

tion is like a f light demo on a screen: you can see how

major improvements in the future, resulting in less risky

the plane should move through the sky, and you can

changes made to installed machines. Hardware changes

test scenarios visually, but your inputs don’t actually

due to supply chain disruptions, obsolescence or improved

drive the aircraft model in real time. A digital twin, on

device design can be made to the twin and evaluated with-

the other hand, is more like a true f light simulator that

out taking down running equipment. Similarly, validation

is wired to the same avionics software the real aircraft

tweaks, data logging, product traceability or late-stage im-

uses. Every control input you make—throttle, rudder or

provements can be tested off-line, again reducing downtime

f lap adjustment—is processed through the actual control

by proving changes virtually prior to bringing a machine or

logic and ref lected instantly in the simulated plane’s

line down to test a change or improvement.

behavior. One is a picture of motion; the other is a living replica you can virtually f ly.

Because the twin machine is virtual, the programmer

After the machine has been commissioned, the long-term use of the digital twin can continue as a training and support tool. The twin can provide realistic operator training

gets to enjoy risk-free testing to detect collisions, over-

without occupying production equipment, and it can also be

travel and logic errors without damaging any hardware.

useful for troubleshooting issues later by replicating prob-

As a matter of fact, code debugging can begin in parallel

lems in the twin before sending technicians to work on the

with the machine build, shortening commissioning time.

actual machine.

The larger development team also gets deeper insights into the dynamics the machine will experience. They will

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

be able to see how payloads, inertia or compliance affect

from the University of South Carolina, was a development

motion, speeds and latencies. Tuning and trajectories can

engineer in the fiber optics industry and is the former head

be optimized before hardware is even purchased, avoiding

of the EtherCAT Technology group in North America.

42 / November 2025 / ControlDesign.com