Control Design – August 2026

MULTI-DISCIPLINE ENGINEERING 4-STEP VISION IMPLEMENTATION C-SUITE SYSTEM INTEGRATION AUGUST 2026

AVOID HIGH-SPEED NETWORK COLLISIONS Edge controllers can keep data collection out of the PLC’s deterministic lane

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Volume 30, No. 4

table of contents

13 cover story

Avoid high-speed network collisions Edge controllers can keep data collection out of the PLC’s deterministic lane Mike Bacidore, editor in chief

IMAGE BY BILL ANTKOWIAK, GENERATED WITH SHUTTERSTOCK AI

20

23

28

32

machine control

vision systems

system integration

product roundup

What’s a singlediscipline engineer to do?

A practical start guide for machine vision

From plant floor to top floor

Connections make the machine

Artificial intelligence, robotics and additive manufacturing converge into a single stack

4-part roadmap for implementing automated imaging systems

How Process and Data Automation (PDA) drives integration

Terminal blocks and I/O modules offer performance and functionality

Mike Bacidore, editor in chief

David L. Dechow, Arthur G. Russell

Tom Kelly, Automation Alley

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Volume 30, No. 4

table of contents

editorial team editor in chief

Mike Bacidore mbacidore@endeavorb2b.com digital editor

Madison Ratcliff mratcliff@endeavorb2b.com contributing editor

Rick Rice rcrice.us@gmail.com contributing editor

Joey Stubbs

7 editor’s page

12 component considerations

Welcome 3D sensing technologies

A terminal block is more than a junction

Mike Bacidore, editor in chief

Tobey Strauch, contributing editor

8 embedded intelligence

31 shake hands or throw hands?

Does the PLC-IPC debate still matter?

Can these components communicate?

Jeremy Pollard, CET

Mike Bacidore, editor in chief

Bill Antkowiak

9 technology trends

34 live wire

subscriptions

What is an operator interface?

Old sensors, new tricks

Rick Rice, contributing editor

Joey Stubbs, contributing editor

joey.stubbs@gmail contributing editor

Tobey Strauch tobeylstrauch@gmail.com columnist

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Jeremy Pollard jpollard@tsuonline.com

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editor’s page

Mike Bacidore editor in chief mbacidore@endeavorb2b.com

Welcome 3D sensing technologies THE AUTOMATE SHOW, hosted by the Association for Advanc-

ronments. By removing barriers while enhancing protection,

ing Automation, was filled with a variety of automation

it allows manufacturers to unlock the full potential of their

spanning machine control, motion and sensing. One inter-

collaborative robot investments, achieving higher productiv-

esting development was the number of technologies put to

ity, greater flexibility and improved safety simultaneously.”

use for sensing the presence of individuals in three-dimen-

ADAR One is already in series production and shipping on

sional (3D) zones. Two of those, Sonair’s ADAR One sensor

deployed industrial robots. Since the introduction of the beta

and AuraSensae’s Hexopus, drew particular attention.

version of ADAR one year ago, more than 80 robotics compa-

Sonair’s ADAR One sensor, which uses acoustic detection

nies have evaluated it through Sonair’s test program.

and ranging (ADAR) technology, is now suitable for SIL2 and

“ADAR One does not merely replace a sensor,” said Sand-

PL d applications and is certified to fulfil all requirements

ven. “It introduces a new safety layer for robotics, a certified

of the European machine directive as a sensor for the safe

3D perceptual foundation that sits beneath any camera, AI

detection of humans and objects.

stack or motion system.”

ADAR One is designed to deliver 180°-by-180° 3D spatial awareness, detecting people and obstacles at all heights. “The bottleneck to safe human-robot coexistence isn’t

The patented ADAR technology

The sensor attaches around the end of the robotic arm and creates a spherical detection zone.

uses ultra-compact 3D ultrasonic sensors to give autonomous robots full omnidirectional depth perception. The innovation lies in

intelligence or speed,” said Knut

the combination of wavelength-

Sandven, Sonair CEO. “It’s safe

matched ultrasonic transducers,

perception; knowing reliably under any condition, that a human is nearby.”

AuraSensae is an Italian company specializing in ad-

software-based beamforming technology and object recognition algorithms that emit and detect sound waves to capture 3D spatial information.

vanced safety for industry. “We develop innovative capaci-

AuraSensae’s Hexopus capacitive sensor enables fence-

tive sensors and intelligent algorithms that can precisely de-

free and flexible production layouts by transforming proxim-

tect human presence in real time,” said Javier del Rio Martin,

ity sensing into deployable industrial safety to enable closer,

operations and business developer at AuraSensae. “These

safer human-machine interaction.

technologies are designed to create reactive and adaptive

The sensor attaches around the end of the robotic arm

systems that enhance safety and facilitate more natural,

and creates a spherical detection zone that can be extended

seamless human-machine collaboration. Our mission cen-

up to 2 m. To be sold as safety devices in the European

ters on transforming industrial safety by enabling respon-

market, AuraSensae capacitive sensors are required to have

sive, flexible and smart human-machine interactions.”

a Notified Body certificate, which is issued by a government-

Hexopus, which uses capacitive sensing, is AuraSensae’s

designated organization. “We’re now pursuing certification

answer for human-robot collaboration. “It is a smart safety

targeting PLd, Cat. 3, with respect to ISO 13849-1, and SIL 2,

device that transforms robots into human-aware systems,

with respect to IEC 61508,” explained del Rio Martin. “Com-

detecting workers in real time and creating an invisible, lo-

mercialization of safety devices requires an EC examination

calized, dynamic safety zone,” said del Rio Martin. “Hexopus

from a notified body, in our case, with respect to Machinery

is an enabling technology for robotics and collaborative envi-

Directive 2006/42/EC, Annex IX, Module B.”

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embedded intelligence

Jeremy Pollard jpollard@tsuonline.com

Does the PLC-IPC debate still matter?

HARDWARE INDEPENDENCE IS what PC-based control prom-

meant getting the drawings out and having a meter in hand.

ised back in the 1990s. You can run any software on any

Relay logic created great troubleshooting methodologies and

hardware you choose. Sound familiar?

approaches to getting to the root cause.

Comparing industrial computers to programmable logic

When the PLC and software arrived, we all thought every-

controllers (PLCs) is an unwinnable argument, in my view.

thing would be easier to troubleshoot. While basically true,

The number of proponents of standardized programming,

the same approach still needs to be employed. If the power-

which can run on any hardware, is wild and free. Part of the

on light is off, it probably isn’t a limit switch.

argument is that you can choose the hardware to run on, and, if you need to change, the software goes with it.

Regardless of whether the control system is a PLC or an IPC, the software inside monitors the system. Both would

That hardware platform has a large surface area and can

control a fault light prompting the operator or maintenance

include commercially available single-board computers like

person to investigate the HMI to determine what the fault is.

Raspberry Pi and Arduino. Suppliers have built solutions around these platforms and can run IEC software.

For me, when a control system is in place, regardless of the platform, it becomes a single-source solution.

Having said, that we don’t care if that data came from the control system using Windows or Pi; we just care that the data is there. We just need to know how the data got there, should we need to dive deeper into the communication.

The big area of support comes

Using an IPC delivers a dif-

from training so that the main-

ferent subset of what could be

tenance staff can troubleshoot and get processes back up and running. It’s that darn 3 am trouble call that dictates how

Using an IPC delivers a different subset of what could be wrong than a PLC does.

you handle the outcome.

What the PLC has done for

wrong than a PLC does. With the continuing advancement and integration of commercially available technologies, our skill set needs to keep pace.

Newer PLCs can support

automated control systems has been well-documented.

multi-CPU core architectures, where one of these cores

IPC systems, while not new, don’t get the kudos they

can support a Windows installation. This can bridge a

deserve in some arenas.

gap between a PLC and an IPC.

Windows 95 really changed the trajectory of personal

With blurred lines between IPCs and PLCs, the task selec-

computing in the industry. People became programmers,

tion criteria becomes more about software and what it runs

which was witnessed by the injection of computer lan-

on. What is common however is the fact that IEC-61131

guages into industrial control systems. Python and C++ are

software is becoming more prevalent in current process

prevalent, as well as Visual Studio (C#).

solutions. Many vendors have used the main premise of IEC

But, hang on a minute, a modern-day PLC has so much capability over and above ladder logic. Supporting IEC-61131 languages, as well as loadable libraries compiled and writ-

and created their own flavor of control software. The advent of virtual PLCs is creating another future challenge.

The typical automation infrastructure is being redefined

ten in the aforementioned languages, kind of makes them

using the hardware-independent virtualization of a PLC.

more like an IPC, but with the ability of providing a normal

This provides advantages over current solutions by deploy-

approach to troubleshooting the process when it fails.

ing a PLC onto a server multiple times and having access to

The training and tools needed to troubleshoot

each one of them from anywhere.

current systems that employ various languages and libraries are continuing to develop. Augmented reality

JEREMY POLLARD, CET, has been writing about technology and

is a methodology with promise.

software issues for many years. Pollard has been involved in

Back in the good old days, troubleshooting a system

control system programming and training for more than 25 years.

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technology trends

Rick Rice contributing editor rcrice.us@gmail.com

What is an operator interface?

OPERATOR INTERFACES ARE the bridge between people

For process control, operator interfaces allow users to

and machines. Whether on a factory f loor, inside a

start and stop equipment, change recipes, adjust process

packaging line or controlling heavy equipment, a well-

parameters, reset faults, initiate maintenance functions

designed operator interface (OI) enables users to monitor

and switch between automatic and manual operation.

processes, make adjustments, respond to alarms and

Access to these functions is often controlled through

maintain safe, efficient operations. A human-machine

password-protected user levels.

interface (HMI) is the hardware and software through

A well-designed alarm system improves response time

which an operator interacts with a machine or industrial

and reduces downtime by providing visual alarm indicators,

process. It presents information about machine status

audible notifications, alarm history, time-stamped events and

and allows authorized users to issue commands, modify

recommended corrective actions. Operators can quickly deter-

settings, acknowledge alarms and view production data.

mine the cause of an issue and restore normal operation.

Operator interfaces are commonly found on manufac-

HMIs collect valuable production information, includ-

turing equipment, packaging machinery, CNC machines,

ing production counts, downtime events, cycle times,

material-handling systems, water and wastewater treat-

energy usage, equipment efficiency and quality metrics.

ment facilities, food and bever-

This information supports

age processing lines, pharmaceutical production equipment and energy and utility systems.

The primary goal is to simplify machine operation while

continuous improvement

The primary goal is to simplify machine operation while improving productivity, safety and reliability.

improving productivity, safety and reliability.

Early machine control relied on physical pushbuttons, selector switches, analog gauges and indicator lamps. While these systems were durable and straightforward, they of-

initiatives and predictive maintenance programs.

Human-machine interfaces use screen resolutions and colors that were sheer fantasy for earlier versions. This im-

provement in technology has made the HMI an essential tool for maintenance and troubleshooting.

Not too many years ago, a machine going down meant

fered limited flexibility and required extensive panel wiring.

calling a maintenance team to pore over the machine,

The introduction of programmable logic controllers (PLCs)

searching for the cause of the stoppage. If nothing obvi-

transformed industrial automation, and graphical operator

ous was found, the situation was elevated by bringing in

interfaces soon followed. Instead of rewiring control panels

a technician or engineer with a laptop to plug into the

for every process change, manufacturers could update

controller as a means of troubleshooting. Time waiting for

software screens to accommodate new products, operating

maintenance or engineering is time not producing and the

modes and production requirements.

sound of a clock ticking when production is down can be the

Operator interfaces combine industrial computers,

loudest thing in the room—even worse if the source of help

high-resolution touchscreens, networking capabilities and

isn’t right there in the building. The expense of flying in an

powerful visualization software to provide operators with

outside resource was astronomical but, sadly, commonplace

comprehensive control over increasingly complex systems.

and an accepted cost of business. The operator interface has

Interfaces perform several functions that improve machine operation. Operators can instantly view machine

become ground zero in the war against downtime.

Good design also impacts productivity and performance.

status, including operating mode, production rates, motor

Simplicity: Screens should present only the informa-

speeds, temperatures, pressures, tank levels and system

tion needed for the current task. Excessive graphics, un-

diagnostics. Real-time visualization helps operators quickly

necessary animations or cluttered layouts can distract

identify abnormal conditions before they become problems.

operators during critical situations.

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technology trends

Consistency: Colors, symbols, buttons and navigation

press on a particular part of the screen to access a more

should remain consistent throughout the application. Oper-

detailed screen, then the application is significantly dimin-

ators should immediately understand how to move between

ished as an effective tool. The use of navigation buttons to

screens and locate important information.

quickly jump to main focal points is essential and provides

Readability: Text should be large enough to read from

a means for less experienced operators to get to the heart of

normal operating distances. Im-

the matter in fewer touches.

portant values should stand out clearly, and color should never be the sole method of communicating critical information.

Industrial touchscreens have

Operator interfaces are no longer isolated devices.

become the preferred interface for most machine builders due to their flexibility and ease of use.

Situational awareness: Opera-

Common touchscreen tech-

tors should be able to determine

nologies include resistive touch,

the overall health of the machine within seconds.

capacitive touch, projected capacitive and infrared touch.

Dashboards should highlight abnormal conditions while

Industrial environments often require screens that function

allowing users to drill down into detailed diagnostics

while wearing gloves, resist water and chemicals and with-

when necessary.

stand vibration, dust and temperature extremes.

Intuitive: Often overlooked in the design of an operator

Operator interfaces are no longer isolated devices. They

interface is the ability of the end user to get to the desired

frequently communicate with PLCs, SCADA systems, indus-

information or control point in an efficient manner. A purely

trial networks, manufacturing execution systems, warehouse

graphical interface, for example, might show the process

management systems, ERP software and cloud platforms.

flow, but, if the operator doesn’t know that they have to

This connectivity enables remote monitoring, centralized

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technology trends

reporting, predictive maintenance and

gesture control and wearable devices

taining consistent functionality and

improved production analytics.

are also being explored for specialized

centralized management.

Operators and maintenance personnel can often access machine informa-

industrial applications.

Meanwhile, web-based HMIs are

RICK RICE is a controls engineer at

tion from tablets, laptops or secure

making it easier to deploy interfaces

Trew Automation, a material handling

mobile devices without standing di-

across multiple devices while main-

manufacturer based in West Chester, Ohio.

rectly at the equipment. The proliferation of smart phones and tablets has made its way into industrial automation as effective ways to provide handheld operator interfaces for personnel on the production floor.

A maintenance technician, for example, can use a personal device to make a VPN connection to the operator interface on the machine. This is a huge advantage for technicians in that they can access data about the operation of the machine without being at the main control station.

Imagine trying to set the timing on a glue station and being able to make that adjustment on your smart phone while standing right in front of the glue nozzles instead of having to walk back and forth to the HMI to adjust.

As industrial systems become more connected, cybersecurity has become an essential component of operator interface design.

Best practices include user authenti-

The Next Phase in Power Management.

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ized access and minimizes the risk of production disruptions.

Several emerging technologies are shaping the next generation of operator interfaces. Artificial intelligence is beginning to assist operators by identifying abnormal operating conditions before alarms occur.

Augmented reality is providing maintenance personnel with interactive repair instructions overlaid on physical equipment. Voice interaction,

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component considerations

Tobey Strauch contributing editor tobeylstrauch@gmail.com

A terminal block is more than a junction WHAT IS A TERMINAL BLOCK? A terminal block is a place to

mounted and have thin housing for low-voltage connec-

connect a wire to another wire and create a junction point.

tions. Fused blocks may be used for protection of input

Picture a terminal block as an intersection on a two way or

cards or for enhancing troubleshooting. Green lights mean

four-way highway.

good. Red light or no light means bad. Fused blocks may also

Terminals may be required because the wire got short,

isolate other circuits from being affected. For instance, sole-

the wire needs to have a condition or there is protection

noids are notorious for shorts. How does a controls engineer

required. Automation uses and machine building uses ter-

protect the PLC cards from a solenoid short? Bring them in

minal blocks for signal and power distribution, as well as

fused terminal blocks with a normally open status.

grounding. Terminal blocks may be integrated with a fuse

What if all the fancy stuff is not necessary and a 24-V dry

for isolation. Terminal blocks may have integrated relays.

contact is needed for a starter circuit. Basically, if the contact

Terminal blocks may have multiple levels or withstand

is turned on by the PLC output, then send 120 Vac to start

high currents. Terminal blocks may be push-pull, plug in,

a motor. This is not a problem. But what if the wire breaks?

screw types or clamps.

Having the panel configured with terminal blocks between

The possibilities are endless when it comes to terminal blocks.

Push-in blocks may allow toolfree insertion and faster wiring, but high-vibration environments might work better with a spring

the PLC and the field allows for a

Some newer versions of terminal blocks are fused and have indicator lights.

clamp block. Screw terminal

segmented wiring approach for signaling and protection for the PLC cards. PLCs are more expensive than terminal blocks.

With the onset of more functional safety in machines, moni-

blocks may come undone with

toring wire breaks is important.

vibration or get over-torqued. Choosing what types of termi-

This is not a new concept. It’s a review of Ohm’s Law and

nals may be dependent on the application. Typical automa-

applied electronics. IO-Link has made it more common for

tion panels will have ground, power distribution, fuse, PLC

terminal block aptitudes. However, the IO-Link block is not

I/O, relay or disconnect/test terminal blocks.

a typical terminal block, but it still meets the idea of an

The terminal blocks may use colors to denote signal types. For instance, green blocks may be used for grounding;

input with a transition point and an output.

For hydraulic monitoring of pressure or pneumatic

white for commons; and blue for 24 Vdc. Field connection

feedback via a hub, IO-Link can provide data, power and

boxes may have feed-through blocks, though most remote

diagnostics to a master block. It also allows drop-in replace-

inputs or outputs may be installed so that signals may re-

ments of devices. If the device breaks, then the IO-Link

main local before going to the main PLC chassis.

network can download the parameters to the new device

What is the best approach for describing terminal blocks

when the M12 is plugged in to the new one. Short circuits

in the field? If one takes the view of the electrician doing the

and cycle logs are not an issue for components on IO-Link.

terminations, then it’s literally a three-column table with

IO-Link is a communications technology with protocols.

the to cable number, the terminal block number and the

Smart terminal blocks are hardware. What makes an awe-

from cable number may suffice. This would allow the tech-

some duo is a smart terminal block on an IO-Link system.

nician to print the wire labels for the cables being installed,

Is IO-Link necessary with smart terminals? No. All these

as well as have a reference sheet for terminations in the

design options are dependent on the application and the

field. Small drawings showing terminal block screws are not

customer needs.

practical in industrial environments.

Some newer versions of terminal blocks are fused and have indicator lights. The blocks are normally DIN-rail

Tobey Strauch is an independent principal industrial controls engineer.

12 / August 2026 / ControlDesign.com

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cover story

AVOID HIGH-SPEED NETWORK COLLISIONS Edge controllers can keep data collection out of the PLC’s deterministic lane

by Mike Bacidore, editor in chief

Industrial manufacturing is shifting. Yes, it’s always shift-

ficial intelligence inferences and maintains secure, encrypted

ing, but this time is different. It’s shifting to the edge.

streams of data to cloud-hosted analytics platforms.

For decades, the boundary between operation technology

This technological intersection has initiated the shift

(OT) and information technology (IT) in the enterprise suite

in control hardware. PLCs, built primarily for sequen-

was absolute. Air-gapped networks, proprietary protocols and

tial ladder logic and other IEC 61131 language execu-

programmable logic controllers (PLCs) defined the factory

tion, lack the computational resources and software

floor, prioritizing deterministic reliability above all else.

environments required to handle IT-type workloads.

But that boundary is dissolving. Or moving. Or vacillating.

The industrial edge controller is a hybrid platform engi-

The production floor generates high volumes of sensor data,

neered to run real-time machine control and advanced

executes real-time vision tracking, performs on-machine arti-

data processing simultaneously.

IMAGE BY BILL ANTKOWIAK, GENERATED WITH SHUTTERSTOCK AI

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cover story

The mechanics of determinism The primary engineering challenge of an edge controller is resource partitioning. Machine control relies on strict, microsecond-level execution where jitter or delayed scan cycle can result in mechanical failure, damaged

“Modern edge controllers must balance two very different workloads: deterministic machine control and flexible software environments used for analytics, visualization and system integration.”

— Ryan Budke, product manager for industrial IoT and edge platforms, Advantech

tooling or safety hazards.

“Modern edge controllers must balance two very different work-

ministic control environment, while

paradigm. “Most of the time the real-

loads: deterministic machine control

higher-level workloads run within

time portion gets a dedicated core

and flexible software environments

a Linux-based environment,” Budke

to avoid interrupts and other things

used for analytics, visualization and

notes. “Many platforms support

that normal PCs are affected by,” he

system integration,” explains Ryan

isolating CPU cores, memory and net-

states. “Furthermore, these systems

Budke, product manager for industri-

work resources so that control loops

often split responsibilities between

al IoT and edge platforms at Advan-

maintain deterministic performance

machine control and edge computing,

tech. To achieve this balance without

even while analytics or containerized

with the two complementing each

allowing high-level software to

applications run alongside them.”

other. The PLC is still part of the sys-

interfere with real-time operations,

Hardware segregation allows

tem responsible for fast, dependable

platforms have all but abandoned the

manufacturers to maximize their

control tasks, while the edge environ-

single-processor architecture.

investment without putting control

ment is better suited for things like

loops at risk. Justin Garski, Americas

data collection, analytics, visualiza-

these responsibilities by allow-

OEM segment manager for packag-

tion and application hosting.”

ing real-time control tasks, such as

ing, converting, print, and web at

motion coordination or machine se-

Rockwell Automation, highlights that

turers (OEMs), evaluating an edge

quencing, to operate within a deter-

this separation is a deliberate design

platform requires focusing on how

“A common architecture separates

For original equipment manufac-

these environments interact. “The key Figure 1: Not every manufacturer is ready to embrace a completely open environment.

question is not whether the edge side can replace the programmable logic controller, but whether the system is using each part for what it does best.

For OEMs, that approach enables them to make the best use of data and technology, without compromising the control layer that keeps their systems reliable and consistent.”

IMAGE COURTESY OF INTEG PROCESS GROUP

Real-time operating systems Under the hood, the determinism of these platforms relies on a real-time operating systems (RTOS) or modified Linux kernels. Where proprietary realtime operating systems are not used, open-source alternatives with realtime modifications have filled the gap.

“Debian or Ubuntu operating systems

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with real-time patches are common for

connected distributed remote I/O, not

it comes to safety systems,” Dahlen

edge control applications,” notes Noah

specifically identified as safety-rated.

emphasizes. “The design, as well as the

Greene, automation product market-

An example is a central PLC in a distri-

continued maintenance of this reflexive

ing specialist at Phoenix Contact USA.

bution center that coordinates the

safety network, falls squarely on the

“Specifically, the PREEMPT_RT patch

movement of objects on a conveyor. A

shoulders of the machine designers,

for Ubuntu allows higher priority tasks

network failure disables the machine

including the PLC programmer. This is

to execute immediately, preempting

but does not make it unsafe for the

operational technology (OT) territory.

lower priority kernel tasks.”

operator, when viewed through a SIL/

Each hazard must be identified and ap-

Developers are increasingly leveraging embedded build systems to strip

PL lens,” Dahlen continues.

The buffered edge class of communica-

propriate SIL/PL mitigation implemented. The OT team typically manages the

away the overhead in commercial

tion is important but not deterministic,

deterministic interface. This could be

operating systems. “Yocto Project is

explains Dahlen. “This is where the

visualized as a set of ‘do upon network

an open-source toolset for embed-

horizontal factory floor interfaces with

failure’ settings for the distributed I/O.”

ded Linux that allows developers to

the vertical enterprise network,” he says.

tailor the OS to the hardware,” Greene

“Staying with the conveyor example, the

The art of containerization

observes. “Parts of a Linux distribu-

vertical computers provide ‘what goes

To execute software on the fac-

tion that are not important for an edge

where’ data. The PLC provides telemetry

tory floor without destabilizing the

controller, like a GUI or Office Suite,

data for the folks in the control room: job

real-time control system, developers

can be omitted, while things like cus-

status, speed, rejection and faults.”

have borrowed a proven concept from

Understanding the boundaries of

enterprise IT: containerization. By

To properly deploy these architec-

the buffered edge is what ultimately

isolating applications within light-

tures, engineers must carefully catego-

defines modern edge computing. “The

weight containers, analytics, database

rize the signals entering and leaving the

use of buffers differentiates between

engines and cloud gateways can be

controller. Mapping the edge requires

edge and deterministic control,”

deployed on the same physical piece

analyzing the exact type of resource

Dahlen asserts. “The deterministic

of silicon running the machine.

being monitored or manipulated,

signals live close to the PLC scan cycle,

“Users want simplicity when

Aaron Dahlen, an applications engi-

while edge devices are more tolerant

deploying edge applications,” notes

neer at DigiKey, suggests. “This is best

of network fluctuations. A network

Manish Sharma, global marketing and

answered by considering the type of re-

fault is tolerated and even expected.

business development leader, Emer-

source that will be controlled, including

However, this does not imply network

son Machine Automation Solutions.

a safe, deterministic or buffered edge,”

communication is inconsequential, as

“Containerization, such as Docker

he explains. “With regard to networks,

our example conveyor does not move

containers, is a powerful technology

machine control is classified as safe,

without external instructions.”

that is being used in many Linux-

tom drivers can be added.”

deterministic and buffered edge.”

Dahlen breaks down these three critical domains—safe, deterministic and

Responsibility for safety remains dis-

based systems. Not only does it help

tinctly with the machine builder. “There

users easily add, remove and upgrade

is zero room for negotiation when

specific applications, it also provides

buffered. “Safe includes safety PLCs, light curtains, e-stops and networks such as ProfiSafe. This is where we design for the safety integrity level (SIL) or performance level (PL) requirements. Any network failure will cause the machine to enter a fail-safe state,” says Dahlen.

“The deterministic category includes time-critical signals that a machine requires to operate. Ethernet-

“There is zero room for negotiation when it comes to safety systems. The design, as well as the continued maintenance of this reflexive safety network, falls squarely on the shoulders of the machine designers, including the PLC programmer.” ­—Aaron Dahlen, applications engineer, DigiKey

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security benefits by isolating each ap-

run efficiently in coordination with the

creating temporary storage systems

plication from the other ones.”

system, enabling lightweight operation.”

for volumes that do not need to retain

Phoenix Contact’s Greene tracks

the data between reboots,” says

these deployments across varying

Flash memory wear-out

Greene. “All the data is stored in RAM

levels of the factory architecture.

While containerization solves applica-

instead of on the SD card, limiting the

“Docker, Kubernetes and Podman are

tion isolation, it introduces a severe

number of write cycles an SD card

container runtimes that I have seen

physical risk to industrial hardware:

would go through.”

used in the edge control space,” he re-

rapid storage degradation. Controllers

Yokogawa’s Sekulich notes the

marks. “I tend to see Docker and Pod-

often rely on solid-state flash mem-

engineering approach similarly de-

man at the hardware level, most likely

ory, such as SD cards or embedded

couples volatile execution data from

running on a PC close to the machine,

MultiMediaCards, to store operating

physical silicon cells: “To reduce wear

while Kubernetes tends to run in the

systems and configurations. However,

on SD/eMMC storage, persistent data

cloud-based environments.”

Linux enterprise applications and

can be clearly separated and man-

Rockwell’s Garski highlights how

container engines are notorious for

aged independently.”

this architecture preserves the integ-

continuously writing verbose log files

When designing an edge topology,

rity of the underlying asset. “Contain-

to disk. If left unmanaged, a high-fre-

engineers must map volumes with care

erization is being used in industrial

quency logger can exhaust the write

and don’t pinch pennies with cheap

edge hardware to support application

endurance of a standard flash memory

consumer media. “To retain the data

deployment alongside control sys-

cell in a matter of months, resulting in

between the container starts, different

tems. Some edge platforms are built

catastrophic controller failure.

techniques of mapping volumes on the

on Linux-based operating systems and

“The typical limit for write cycles is

support standard container runtimes

around 10,000 for standard SD cards,”

Sharma. “As rightfully noted, mod-

such as Docker. This type of architec-

warns Phoenix Contact’s Greene. “If

ern Linux applications can generate

ture allows multiple applications in-

no measures are implemented, this

significant use of the disc by writing

cluding third-party tools to run locally

can pass rather quickly. Adjusting

logs; however, container configuration

at the edge while remaining isolated

some settings in the OS and for the

options do support ways to limit the log

from core control functions.”

container engine/runtime can slow

size and the amount of data being logged

this.” Greene outlines two primary

in the first place. Certainly, it will result

lead for semiconductors at Yokogawa,

techniques for mitigating this risk—

in higher load on storage devices, hence

shares a similar philosophy regarding

adjusting kernel swappiness and

SD cards are not recommended and

container deployment, favoring alterna-

volatile temporary storage.

eMMC devices with sufficient size and

Mark Sekulich, business development

disc to container are being used,” says

tives designed for minimal resource

“Adjusting the threshold for when

friction. “The edge controller can use

the Linux kernel swaps RAM to disk

Podman, a Docker-compatible container

down from the default will decrease

Open standards

technology,” he notes. “To minimize the

the amount of time data needs to be

For decades, industrial automation

impact on control tasks, it is designed to

written to persistent memory, and/or

was dominated by closed, proprietary

write endurance should be selected.”

ecosystems that protected single-

“The edge controller can use Podman, a Docker-compatible container technology.

To minimize the impact on control tasks, it is designed to run efficiently in coordination with the system, enabling lightweight operation.”

—Mark Sekulich, business development lead for semiconductors, Yokogawa

vendor architectures. However, the landscape is changing.

“The obvious advantage of a closed edge environment is that the interoperability and performance of the applications from a single supplier is assured by the supplier,” states Luis Duran, expert in industry initiatives, standards, and market trends for indus-

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IMAGE COURTESY OF EMERSON MACHINE AUTOMATION SOLUTIONS

trial automation at ABB Automation.

“However, with the user drive toward interoperability, the need for an open edge environment is gaining momentum, as demonstrated by the emergence of Margo. It’ll be possible for users to have flexibility to choose specialized edge applications or deployment environments to fit their needs.”

This emerging drive for open indus-

Figure 2: Advanced systems can be enhanced with specialized physical AI capabilities without increasing power consumption and temperature.

trial platforms stems from a fundamental reassessment of what a control

plify deployment initially, but they

creates greater freedom and flexibility

node actually represents. DigiKey’s

may restrict the ability to integrate

for users, while simplifying integration

Dahlen suggests the industry must

new analytics tools, communication

across their systems,” he emphasizes.

first clear up semantic misunderstand-

protocols or third-party applications.

“In closed environments, users can be

ings. “There is confusion about the

In contrast, open industrial platforms

locked into and limited by whatever a

definition of ‘edge.’ In some cases, we

built on standard operating systems

single technology supplier determines

are talking about a true edge control-

and containerized environments allow

is best for them. This limits their ability

ler with significantly more horsepower

manufacturers to adapt their systems

to use new tools or technologies. With

than the PLC. At other times, the term

as new technologies emerge.”

an open approach, users can choose

describes a bolt-on, non-PLC-invasive

As manufacturing moves rapidly to-

the technologies that best meet their

method for extracting data from the

ward advanced algorithms, closed en-

needs and integrate them using com-

factory floor. One is a heavy industrial

vironments risk becoming data siloes.

mon standards. Such interoperability is

piece of equipment, and the other is a

“This flexibility becomes increasingly

important at the edge, where systems

lightweight data-collection box.”

important as edge computing expands

need to connect across a mix of devices,

The computing power already

beyond traditional automation into

platforms and applications. This makes

present on the factory floor is widely

areas such as AI, machine vision and

the promise of edge hardware, like real-

underestimated, notes Dahlen. “It’s

predictive maintenance,” Budke con-

time analytics and predictive mainte-

hard to comprehend the power in

tinues. “An open architecture allows

nance, more practical to deploy.”

modern PLCs,” he explains. “We tend

deterministic control systems, modular

to think of them as ladder-logic ma-

industrial I/O and high-performance

Compromises and stability

chines, but they are actually powerful

edge computing to work alongside a

Not every manufacturer is ready to

data-processing nodes. Also, most are

wide range of analytics frameworks

embrace a completely open envi-

built with the equivalent of a real-time

and enterprise platforms. Rather than

ronment, leading some suppliers to

operating system. Siemens runtime

locking users into a single ecosys-

develop hybrid options. Bruce Cloutier,

on S7-1200 isn’t exactly Zephyr on an

tem, open platforms allow different

CEO and owner of Integ Process

STM32, but task scheduling and de-

technologies to coexist and evolve over

Group, advocates for a balanced model

terministic timing are present, as are

the lifetime of the machine. For many

where the foundational execution

hazards when interrupts are enabled.”

manufacturers, this approach offers

tier remains under closed lock and

The core of the open-versus-closed

the best balance between reliability,

key (Figure 1). “The combination of a

security and long-term innovation.”

managed, closed OS platform under

an investment, argues Advantech’s

Open industry standards make ad-

our complete control with an open

Budke. “The debate between open

vanced processing claims a physical re-

programming environment allows

and closed edge environments largely

ality rather than a marketing promise,

users to develop and us to support

comes down to long-term flexibility,”

concurs Rockwell’s Garski. “Edge hard-

stable and reliable functionality,” he

he says. “Closed systems can sim-

ware based on open industry standards

reasons. “It also ensures there are no

debate centers on future-proofing

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“If we think about industrial communication protocols as being spoken/written languages, it is much easier to communicate with someone that speaks your native language.” ­—Noah Greene, automation product marketing specialist, Phoenix Contact USA

col converters and simplifies the overall architecture considerably.”

Native integration directly shapes long-term maintenance costs and system performance, explains Emerson’s Sharma. “It is important because there are going to be specific protocols an organization wants to use. Knowing that

underlying performance impacts or

read and translate these disparate

an edge computing solution supports the

unexplained computing activity, as

communication streams, the system

right protocols not only simplifies setup

might be more prevalent in completely

could stutter and stall.

and configuration, but also stream-

open environments. Users can devote

“If we think about industrial com-

lines lifecycle maintenance as teams

their valuable time and effort to creat-

munication protocols as being spoken/

do not need to worry about complica-

ing applications without the burden of

written languages, it is much easier to

tions from middleware solutions when

managing platform details.”

communicate with someone that speaks

making changes or updates,” Sharma

your native language,” explains Phoenix

states. “In addition, protocol selection

would be to balance rapid software

Contact’s Greene. “If a system uses Profi-

has a significant impact on security and

cycles with decades-long machine

net, for example, and the edge controller

performance. OPC UA is the most secure

lifecycles, suggests Yokogawa’s Sekulich.

natively supports Profinet, then connect-

protocol available. MQTT broker makes

“Open edge environments can take

ing it in will be much easier. The data is

passing data an easier and much lower-

advantage of Linux and open-source

going to be formatted and transmitted in

bandwidth process. Forward-thinking

software to stay current with technol-

a way that all nodes can understand. On

organizations want to take advantage of

ogy advances and security updates.

the flip side, if an edge controller natively

these capabilities; therefore, they want

However, without a well-defined update

supports Profinet while the system uses

to know the solutions they put in place

policy, they can introduce operational

EtherNet/IP, then there will most likely

support the protocols they need.”

risks,” he notes. “Closed edge environ-

be a need for a protocol converter or cus-

Standardizing these out-of-the-box

ments provide greater stability, but they

tom software to translate the data from

data formats minimizes custom soft-

can struggle with long-term technology

one protocol to another. This takes time

ware workloads, advises Rockwell’s

obsolescence. This can be addressed by

and experience to get right.”

Garski. “Edge hardware supports a

A similar architectural compromise

maintaining a closed core for control

Broad protocol support is often the

variety of industrial communication

while keeping higher-level applications

ultimate gatekeeper for an edge deploy-

protocols, including OPC UA, message

and data processing open. This approach

ment project, notes Greg Philbrook,

queuing telemetry transport (MQTT)

balances the long lifecycle of industrial

product manager at AutomationDirect.

and REST API, to meet different ap-

machinery with the fast pace of modern

“Protocol support is often the deciding

plication needs. Native support for

software evolution.”

factor in whether an edge device can

these protocols simplifies system

actually connect to the installed base

design and reduces custom develop-

Native protocols

it needs to serve,” he says. “A machine

ment by allowing data to be accessed

An edge controller is only as valuable

on a factory floor might need to com-

and shared in a consistent way across

as the data it can access. On a typi-

municate with Modbus RTU sensors, an

the edge environment. Understand-

cal plant floor, a single machine may

EtherNet/IP PLC from another vendor,

ing what is supported out of the box

contain modern smart sensors, an ar-

an OPC UA server on the SCADA system

helps reduce complexity and sur-

ray of legacy variable frequency drives

and an MQTT broker in the cloud, all

prises down the line,” he says.

(VFDs), a third-party safety controller

simultaneously. An edge module that

The edge controller can be viewed

and an upstream supervisory control

natively handles this mix or can be

as the ultimate network unifier, sug-

and data acquisition (SCADA) node.

extended to do so through software

gests Advantech’s Budke. “Industrial

If the edge controller cannot natively

eliminates the need for separate proto-

environments rarely rely on a single

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communication standard. Machines often need to inter-

aly detection is adding an entry-level accelerator card from

act with a mix of legacy equipment, modern automation

Hailo. Training AI models is more resource-hungry and should

systems and enterprise software platforms,” he remarks.

ideally be done on IPC systems that deliver more processing

“For this reason, edge controllers should natively support

power than what is typically available at the edge,” he says.

a broad set of industrial protocols, including fieldbus net-

Daniel Smith, senior product manager for PACSystems

works such as EtherCAT, as well as Ethernet-based proto-

controllers, safety, and motion control at Emerson Ma-

cols and interoperability standards like OPC UA.”

chine Automation Solutions, details the hardware metrics

Native accessibility allows data to transition fluidly

required to sustain concurrent calculations (Figure 2). “The

between execution layers without custom integration

higher number of cores in a CPU, the better it can man-

barriers. “Native protocol support allows controllers to

age parallel processing,” he notes. “The most advanced

communicate directly with sensors, motion systems and

systems also support graphical processing unit (GPU)

PLCs while making machine data available to higher-level

workloads and can be enhanced with specialized physical

systems such as SCADA, MES or cloud platforms,” Budke

AI capabilities to drive a wide range of AI/ML processing

explains. “Equally important is the ability to extend pro-

needs without significantly increasing power consumption

tocol support through software or middleware. This flex-

and temperature. High RAM is critical for advanced ap-

ibility allows the platform to adapt to new communication

plications like machine learning algorithms. Typically, the

standards or integrate with specialized equipment without

more RAM the better, as vision and AI workloads are high

requiring hardware changes. Ultimately, the most effective

consumers of volatile memory.”

edge architectures treat the controller as a convergence point where machine control, industrial data and enterprise systems can interact seamlessly.”

Sizing compute resources When an edge controller moves beyond basic telemetry logging and into localized analytics, vision processing or machine learning, the physical realities of the compute hardware become critical. Inadequate processor cores or insufficient memory can cause high-level applications to freeze or drop frames.

Management and allocation of system resources apply to more than just analytics, vision and AI. But, in this context, vision and AI consume a lot of resources. While the vision system is doing its thing, analytic tasks that might run concurrently will most likely be slower since they must wait for resources to be freed. Large AI models need more RAM. Edge compute tasks will also need RAM. If the AI workload uses most of the RAM available, then edge compute tasks will have to wait until more RAM is freed up.

Phoenix Contact’s Barber notes that over-specifying raw industrial computing hardware can become economically unsustainable, pointing instead to specialized accelerators for on-machine applications: “Of course, adding additional CPU cores, RAM and storage comes with an increased cost.

Manual allocation of resources to tasks and kernel preempting, especially on systems with limited resources, can help keep resources available to the processes when they execute.

A cost-efficient way to support AI tasks like inference/anom-

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engineering

What’s a single-discipline engineer to do?

Artificial intelligence, robotics and additive manufacturing converge into a single stack

by Tom Kelly, Automation Alley

FOR DECADES, AN ENGINEER at a small manufacturer could

Treat the stack as one system

specialize in one discipline and build a successful career

AI, robotics and additive manufacturing are converging

on it. I came out of school as an electrical engineer. I knew

into a new digital stack that could fundamentally reshape

almost nothing about chemical or mechanical engineering,

the traditional automotive supply chain.

and I didn’t need to. That model is breaking.

AI is the brain. It interprets requirements, optimizes

Artificial intelligence (AI), autonomous robotics and

designs and guides decisions that engineers used to

additive manufacturing are converging on the shop floor.

make manually. Robotics is the operator. It executes

Each is advancing on its own steep curve, and all three

physical tasks with increasing autonomy and decreas-

engineering disciplines must increasingly work together in

ing programming overhead.

a single system. An engineer who understands AI but not

Additive is the production mechanism. It turns digital

additive isn’t equipped for what’s coming. The discipline

instructions into physical parts with minimal tooling and

boundaries that defined manufacturing engineering for the

almost no setup time.

past 50 years are dissolving.

The shift this enables is from process-driven to instruction-driven manufacturing. Engineers can define an

What this means for the engineer’s job

outcome and let the system determine the path to it. That

Programmers used to be paid well because they knew how

has direct implications for control system design because

to write code. That career is changing in front of us. The

the control logic has to coordinate across all three layers

programmers who continue to thrive are the ones who have

rather than optimize within one of them.

moved up a level. They’ve gone from writing one program

Stack thinking applies even when the equipment on

a month to managing AI agents that write thousands of

the floor is decades old. TubeCo, a steel tubing manu-

programs a month, and the human role is to verify intent,

facturer in Warren, Michigan, runs machines that in

validate output and orchestrate the result.

some cases predate World War II (Figure 1). With the

Manufacturing engineering is heading the same direc-

help of a state grant, the company added low-cost sen-

tion. Specialization in one discipline will continue to add

sors, data-capture tools and AI-driven analysis to exist-

value, but it’s no longer sufficient on its own. The engineer

ing equipment without replacing any of it.

who can coordinate AI, robotics and additive as one system,

The result was better visibility into processes that had

and who uses AI as a working co-pilot rather than an oc-

been opaque and equipment that now meets the data and

casional tool, will define the next generation of manufac-

traceability requirements of large automotive customers.

turing capability. Everyone in this field will spend part of their week managing AI-based agents the way they used to

Lights-out at low volume

manage human collaborators.

True lights-out manufacturing, sometimes called dark-

The fear I hear from engineers at smaller manufactur-

factory production, remains rare. The fully unattended

ers is that they can’t keep up with all of it. Nobody can. The

plants in operation today are concentrated at the top of the

skills that matter now are knowing how to use AI to extend

capital and volume spectrum, in a small number of plants

what you already know and to learn what you don’t.

globally and clustered in industries like semiconductors,

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engineering

PHOTO BY COREY SIMS, AUTOMATION ALLEY

Figure 1: Sensors and a Raspberry Pi dashboard pull real-time uptime, downtime and cycle data from TubeCo’s pre-WWII tubing machines, equipment that previously produced no digital output.

electronics assembly and high-

that simple task with an AI-driven

volume consumer goods. That model

design and queueing system, and you

still works for the largest operators

have continuous low-volume produc-

The example highlights a broader

and isn’t going away.

tion with minimal human oversight.

shift happening across manufactur-

The result is a small-shop version of

ing. Additive manufacturing is not

idea is becoming reachable for the rest

The smaller-scale version of the same

what only the largest operators have

simply a cheaper production method;

of manufacturing. Lights-out behavior

historically been able to build.

it changes how companies approach

at low volume runs on parts of one

At Air & Liquid Systems, the shift to

design, testing and production.

rather than parts of 1 million. Decisions

additive manufacturing started with

that used to require human interven-

a single part (Figure 2). The industrial

tion now happen inside the system.

fluid handling supplier needed a ma-

Why this environment favors faster shops

The mechanical setup is unglamor-

chined coupling that cost more than

Speed is becoming the dominant

ous on purpose. A robot tending a 3D

$100 per unit and had to be sourced

competitive variable in manufactur-

printer is one of the most trivial use

externally. Engineers tested whether

ing, and speed favors smaller organi-

cases in the entire field of robotics. The

the part could be printed in-house and

zations more often than scale does.

robot reaches into the build chamber,

validated it through real-world stress

removes the finished part, clears the

testing. The printed version came in at

legitimate reasons to move slowly.

build plate and starts the next job. Pair

just over a dollar.

They have more to lose. They have

Larger manufacturers have

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engineering

PHOTO COURTESY OF MARKFORGED

Figure 2: A 3D-printed bracket on an Air & Liquid Systems machine. The company now prints parts that previously required ordered plates, drilling, machining and welded assembly, replacing multi-step fabrication with single-operation prints.

first steps aren’t complicated. Bring AI tools into everyday workflows so the team builds fluency.

Identify one process where sensors and data capture would surface what’s currently invisible. Find a small, low-volume part that could be printed rather than machined. Treat each as a learning exercise rather than a transformation program.

without affecting active customer

Where this leaves smaller manufacturers

programs. They have decision layers

All of this means that the future of

the ones whose engineers are willing

and risk-management processes that

automation looks more like a redistri-

to treat the convergence as a single

exist precisely because the conse-

bution of capability toward whoever can

problem rather than three separate

quences of a bad call at scale are

adopt the new stack fastest than a con-

ones. The answer to whether there

severe. None of that is irrational. It

solidation toward the largest players.

is room for the small in the future of

also makes them structurally slow

For engineers and owners at small

legacy systems that can’t be torn out

to adopt new technology, even when

and mid-sized manufacturers, the

The companies that will benefit are

automation is “yes,” but only for those willing to claim it.

the technology is mature.

Smaller manufacturers can experiment. They can put a 3D printer

Tom Kelly has been CEO and executive director at Automation Alley

on the floor next to a CNC and see

in Troy, Michigan, since 2016. Automation Alley is Michigan’s Digital

what gets made. They can deploy

Transformation Insight Center, a nonprofit technology business

sensors on legacy equipment and

association whose mission is to accelerate the growth and global

try AI-based analysis without con-

competitiveness of businesses through Industry 4.0 technologies

vening a steering committee. When

and innovation. Kelly leads the strategic vision, financials and

the underlying technology is chang-

operations of Automation Alley and subsidiaries, including Project

ing every six months, the ability

DIAMOnD and the U.S. Center for Advanced Manufacturing. Kelly launched Project

to iterate quickly compounds. The

DIAMOnD, a $28 million initiative creating the nation’s largest distributed 3D printing

advantage in this environment

network for over 350 small manufacturers, and he elevated Automation Alley to World

goes to the swift rather than to the

Economic Forum status as the U.S. Center for Advanced Manufacturing, positioning

capital-intensive.

Michigan as a global smart manufacturing hub. Under Kelly’s leadership, Automation

Opportunities that were historically

Alley membership expanded from 750 to over 4,000 manufacturers, tech firms,

available only at OEMs are starting to

academics and government partners. Kelly holds a bachelor of science degree in electrical

flow toward smaller shops with the

engineering from Clarkson University and a master of business administration degree

right technical capability.

from University of Michigan. Contact him at kellyt@automationalley.com.

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vision systems

A practical start guide for machine vision 4-part roadmap for implementing automated imaging systems

by David L. Dechow, Arthur G. Russell

MACHINE VISION IS WELL-ESTABLISHED as an essential part

tion success are the same. That said, while acknowledging

of automation. Diverse vision technologies empower ap-

there are technical differences, this discussion will use the

plications in a wide range of use cases, including quality as-

generic machine vision to cover all use cases.

surance, metrology, assembly inspection and vision-guided

Regardless of the exact technologies ultimately deployed

robotics. The capabilities impact many industry sectors,

in any system, there is a widely accepted process that can

reinforcing machine vision’s significance in manufacturing.

help ensure project success. The following quick start steps

Achieving consistent and effective results with automated

can be a practical guide that will help anyone at any level of

imaging solutions though can seem challenging. Fortunately,

machine vision expertise incorporate automated imaging.

for most any application a short list of practical steps, a “quick start guide,” can help ensure that machine vision systems de-

The quick start guide

liver reliable and measurable results in automated processes.

The job of bringing together diverse and disparate components and sub-systems and making them function as a

The basics

single unified system is referred to in many disciplines as

Fundamentally, machine vision involves the implementa-

“systems integration.” The phases in the successful integra-

tion of systems in which images are captured—image acqui-

tion of a machine-vision application can be consolidated

sition—and then autonomously processed to obtain specific

into four parts, each with a few easy-to-understand steps.

data—image analysis—and report the results for use in an automation process. It is this capability of extracting actionable information about an automated operation that makes it a significant and valuable technology in the concepts of

These are: • Part 1—Preparation: preliminary analysis and project requirements specification • Part 2—Design: detailed final technical/system

Industry 4.0 and smart factories (Figure 1).

specification

It’s understandable in the tech landscape that there can be confusion between the terms “machine vision” and

• Part 3—Implementation: assembly/build/initial testing • Part 4—Deployment: delivery/installation/startup

“computer vision,” the former often described as using

and acceptance testing.

traditional tools and algorithms, and the latter using ex-

These integration parts/phases and functions might be

clusively deep learning. However, while both have distinct

described in different ways by different experts, but the one

capabilities, the steps to achieve broad practical applica-

constant is that guaranteed success depends on following a

Figure 1: Basic functions of every machine vision system.

Image Acquisition

Image Analysis

Image Integration

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vision systems

defined process (Figure 2). Resist the

Step 2. Specify and document the

to the project requirements and other

temptation to dive right into the fun

performance requirements. Identify

project factors. There should be hands-

stuff—buying components, assem-

functions and operations—inspections,

on evaluation performed in advance

bling the system and trying out tools.

guidance, measurements—that are to

to confirm that the proposed machine

Just like unboxing and assembling

be executed by the targeted automation

vision concept and components will

that new chair for your home office,

along with the detailed related perfor-

be capable of meeting the needs of the

follow the quick start steps to ensure

mance metrics. Prepare a requirements

requirements. The vision system design

a successful implementation.

specification document that states what

will also inform the requirements

the proposed system must accomplish,

and constraints in the design of other

Part 1—Preparation

and a preliminary acceptance criteria

aspects of the system.

Consider the task of building a new

document that details how the system

house. It doesn’t start with ordering

will be tested and validated.

The outcome will be a complete specification of the machine vision

materials and getting out the tools. It

Step 3. Develop a team. It’s impor-

begins with a complete understanding

tant to recognize that integration in any

related automation functions that will

of the expectations and use and de-

discipline is a team activity. In machine

be implemented. In some cases, the

sign requirements. With that informa-

vision the integration team must have

design process will reveal technical

tion it is then possible to competently

skills in optics, lighting, electronics,

or commercial limitations that might

proceed with design and build. In the

controls, programming, mechanical

dictate changes to the requirements

same context, this analysis and prepa-

design and project management and

and overall expectations, and it is

ration phase is critical in machine

perhaps others like robotics, motion

better to uncover these before imple-

vision projects. Here are the key steps.

control, documentation and training. Be

menting the complete application.

system, analysis techniques and

Step 1. Undertake a formal and ex-

sure to keep a clear perspective that the

Step 1. Collect representative sam-

tensive application analysis. Analyze

overall system must enable the vision

ples. Samples will be used for testing and

the needs of the existing operation,

solution. Conceptualizing an automa-

ultimately for development. The samples

process or automation and how it

tion system for a machine vision project

must include all potential failure modes

might benefit from vision. Gather and

with an empty box sketched in that

and part variations in scope for the

document all the details relevant to

says “put vision system here” is a guar-

project as detailed in the application

the targeted application, for example:

anteed path to a difficult integration.

analysis. For certain vision algorithms

• parts/objects related to the proj-

like deep learning, collect representative

ect, sizes, shapes, colors, variations,

Part 2—System Design

images in advance for training; it may

special characteristics, presentation

A preliminary system design is based

require a very large number of images,

on the information gathered during the

and often these are best obtained in an

mation and physical, mechanical or

preparation phase. In this part of the

actual production environment after the

environmental considerations

integration, potential techniques and

vision components are selected.

• incorporation with existing auto-

• commercial issues and limitations.

components will be considered relative

Step 2. Specify and select candidate components for imaging—in general terms, the camera, lens, lights and computer/software—based on the performance requirements collected in Part 1.

Camera: Key metrics for specification include at minimum the required number of pixels or image resolution and the required imaging rate. Image resolution is dictated by the spatial resolution necessary to achieve individual feature

Figure 2: Four phases for machine vision integration success.

detection or measurement precision for

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vision systems

the application and the overall field of view (FOV) needed to cover the objects or parts under inspection.

Note that the image resolution calculated for a targeted FOV might be so large that it is not practical or possible. Add more cameras or take other measures to achieve the necessary resolution.

Lens: This optical component magnifies, or projects, an image the size of the desired FOV onto the camera sensor.

Figure 3: Since lens focal length dictates imaging angle, there are tradeoffs in selecting working distance and focal length relative to a desired FOV.

Use manufacturer or third-party lens calculators to determine the correct fo-

speed of the process, the type and

repeatable and reliable image in the

cal length lens for the specified camera

complexity of the machine vision tools

production environment. This will

(Figure 3). For demanding applications,

that may be implemented and the type

likely require multiple tries with dif-

ensure the optical resolution in line

of interfacing required for an operator

ferent configurations and components

pairs/mm is sufficient for the features

UI and for communication with exter-

to ensure the final design meets the

to be detected. Specialty components

nal automation components.

application needs.

like telecentric lenses might be considered for certain applications.

Illumination: Dedicated lighting is

Certain machine vision systems have

Check the image analysis using

the camera, computing and software in

the selected computing platform and

one package. These are generically called

software with sample parts and the

necessary for all machine-vision appli-

smart cameras. Other systems, which

representative imaging components.

cations. Correct illumination delivers

use separate cameras and comput-

Ensure it can meet the expected

contrast between features of interest

ing components and often customized

capabilities and return to the imaging

and the background to ensure repeat-

analysis code in some cases can be more

design if there are problems.

able and reliable imaging of the desired

flexible and have greater scalability.

features. Experienced vision engineers

Smart cameras are used in a distrib-

Step 4. Prepare the final design, specification and scope of work. The

may have an initial lighting technique

uted imaging architecture where one

final design defines the exact com-

in mind for an application, but in all

device is implemented for one imaging

ponents, functional architecture

cases testing and evaluation with the

purpose. Computer-based systems

and physical layout of the machine

actual parts and specified camera

can be more centralized, in that many

vision system. If a broader automation

and optics is a must to ensure proper

cameras can provide images to be

system is involved, that will of course

performance. Seek out additional infor-

analyzed by one component.

be included but sometimes separate,

mation on lighting techniques from manufacturers and other sources.

Step 3. Evaluate the proposed system

depending on scope. A vision system

components. The candidate compo-

specification details the way the vi-

nents and software always must be

sion system will execute the proposed

tion of these components drives the

proven relative to the required applica-

tasks, including a more in-depth

overall capability of the system by

tion before committing to a final design

discussion of technical configurations

executing the key functions of image

and specification. In a practical sense,

and an overview of the tools and algo-

acquisition, analysis and data report-

this also might come before providing a

rithms and how they will be used.

ing. Decisions about the computing

customer quote or otherwise commit-

A scope of work (SOW) document

platform and software must consider

ting to the project. As noted, this should

is the ultimate outcome of the design

the scope of the acquisition and analy-

be an iterative/repetitive step done in

phase. The SOW is both a technical

sis to arrive at an architecture that best

parallel with component selection.

and commercial statement of exactly

Computers and software: The selec-

serves the implementation requirements. Key metrics might include the

Validate that the camera, optics and illumination selected will provide a

what the system will do and the exact metrics to which it will perform. Note

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vision systems

that the SOW might not exactly match

Step 1. Create a detailed acceptance

built and configured such that the final

the initial project expectations and

or validation test process document.

system enjoys guaranteed success.

desires. There will always be excep-

Acceptance testing should not be an

It also helps to highlight problems

tions and limitations to initial require-

afterthought introduced at the end of

earlier during build and configuration

ments, and usually these compromis-

a project. Based on the specifications

by revealing discrepancies that might

es need to be resolved commercially.

and scope of work developed in Part 2,

ultimately impact system performance.

Step 2. Prepare a written project plan

an acceptance test document should be

Part 3—Implementation

prepared at the start of project imple-

and task list. Project managers will

Naturally, the systems integration

mentation, or arguably before the start.

agree with how critical this step is. If al-

process will turn from analysis and

The acceptance test procedure be-

ready being used, find one of the several

design to the acquisition of the com-

comes the defining document regard-

good software tools available to help

ponents and materials and assembly,

ing functional and operational criteria

schedule tasks and manage projects.

build, configuration and execution

and metrics that indicate the system

Use one to keep the project on track, but

of the proposed system. This imple-

is working to specification. Project

be sure to also address the details of the

mentation may seem similar to any

engineers and managers must use this

tasks, not just the timelines.

project, yet there still are some critical

document throughout the process to

Step 3. Immediately prototype and

quick steps that will be useful specifi-

ensure that both the machine-vision

begin vision system development. The

cally in machine-vision solutions.

solution and related automation are

most critical implementation mistake made repeatedly is to wait until an automation system, robot, mechanical components and controls are already built to start prototyping and development of the machine vision components and system software. While this step applies broadly to other sub-sys-

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tems, it is critical to immediately start on the machine vision portion of the system as soon as possible.

Physical configuration of the imaging can easily be set up in a test environment using the many sample parts that should already have been collected and following the acceptance test requirements. Perform iterative testing of the vision system and automation throughout.

Step 4. For installation, refine, not design, online. While there are occasions where some imaging, process or

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vision systems

David L. Dechow is principal vision systems engineer at Arthur G. Russell, a machine builder and system integrator with expertise in automated assembly systems. He is an engineer, programmer and technologist with expertise in the integration of machine vision, robotics and automation technologies. Dechow is a recipient of the

ing components—camera, lighting

Association for Advancing Automation (A3) Automated Imaging

optics—within the production envi-

Achievement Award and is a member of A3 Imaging Technology

ronment early in the process to gather

Strategy Board. As an educator within the machine-vision industry, Dechow has

representative production images for

participated in the training of hundreds of engineers as an instructor with the A3 Certified

further off-line testing and program-

Vision Professional program. Contact him at david@daviddechow.com.

ming before final installation.

Part 4—Deployment

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Presuming that is not the case, there still are a couple of quick start steps that will help in this phase.

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Step 2. Follow the validation plan.

As mentioned, the written validation test plan should outline the functional and operational criteria and metrics that indicate the system is working to specification.

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system integration

From plant floor to top floor How Process and Data Automation (PDA) drives integration

by Mike Bacidore, editor in chief

FOUNDED IN 2002, Process and Data Automation (PDA) is

community, says Jeremy Anderson, president of PDA, which

a CSIA-certified member of the Control System Integrators

integrates equipment at all phases of CPG manufacturing

Association (CSIA). With more than 70 employees, almost

from raw material delivery and processing through packag-

half of them electrical engineers, PDA’s world-class team de-

ing and into warehouses (Figure 1). “We routinely integrate

livers innovative digitalization and automation to improve

800-1,000 machines annually,” notes Anderson, who an-

consumer packaged goods (CPG) production for the global

swered several questions about the company he leads.

IMAGE COURTESY OF PROCESS AND DATA AUTOMAITON

Figure 1: Jeremy Anderson (left), president, and Eric Williams, digitalization group manager, Process and Data Automation (PDA), a CSIA-certified member of the Control System Integrators Association (CSIA).

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Highlight some of your most innova-

business revolves around

tive machine integrations, and explain

improving the overall

what makes them unique.

production output for our

Jeremy Anderson, president, Process and

ing the facets of overall

Data Automation: PDA’s most innovative

equipment effectiveness

end clients. By examin-

integrations involve connecting informa-

(OEE)—availability, per-

tion from the plant floor to the top floor

formance and quality—in

by utilizing a thoughtful mixture of op-

each of our solutions, we

erator input and Industry 2.0 and higher

work with our clients to

plant-floor systems to gather informa-

find leverage within their

tion as close to the source as possible

automation to best im-

and then adding contextualization to

prove outcomes (Figure 3).

that information for transport and use

Our core industry is CPG

by Industry 4.0 business systems. What

with specialties in food,

makes our most innovative integrations

beverage and pet care.

unique is the ability to securely deliver this information to both the vendor and

Where do you integrate

the end user in real time. This allows

machines?

both parties deeper collaboration to improve total cost of ownership (Figure 2).

Figure 2: David Koigi, controls engineer, Process and Data Automation (PDA), a CSIA-certified member of the Control System Integrators Association (CSIA).

Jeremy Anderson, president, Process and Data Automation: Most of our

What percentage of your projects are

business is in the continental United

How much time does it typically take

standard machines vs. custom? What

States, but our territory extends

to go from the design stage to installa-

is the focus of custom machines? Do

throughout North America. Recent

tion on a typical machine?

you work with any flagship machine?

non-U.S. countries include Canada, Guatemala and Jamaica.

Jeremy Anderson, president, Process

Jeremy Anderson, president, Process and Data Automation: An average

and Data Automation: The vast major-

What are the important trends affect-

project of five to eight machines will

ity of the projects employ standard

ing the industries you work with and

take us nine months from design to

machines that are individualized to

the types of machines you integrate?

installation.

products being produced. By focusing

Jeremy Anderson, president, Process and

What are your supplier preferences and

on individualizing standard machines,

Data Automation: As all CPG products are

why? How does each component type

our customers benefit from the shared

highly regulated and by design consum-

and/or its technology enhance your

experience and parts of other similar

able, the industry is continually af-

machines? How often do you rely on

machines. The best example of this is

fected by global trends like import/export,

customers to dictate component choice?

our flagship Ingeniq line, the future of

government regulations and evolving

the beverage industry from Krones.

end-user needs. This presents the CPG

Jeremy Anderson, president, Process

producer with challenges, or opportuni-

and Data Automation: For control, it’s

What is your core business? What

ties, for better sourcing of materials or

Rockwell Automation, Siemens and

industries do you work in? What type

emerging markets while maintaining

Modicon, based on end client specifica-

of manufacturers do you work with?

accurate records and meeting the growing

tion. For motion, Rockwell, Yaskawa and

desires of an end customer looking for bet-

Modicon. Siemens and Endress+Hauser

Jeremy Anderson, president, Process

ter innovation and value in the products

are preferred for sensing.For communi-

and Data Automation: At PDA, our core

they introduce into their homes.

cation protocols for data transmission,

the specific needs of the plant and

IMAGE COURTESY OF PROCESS AND DATA AUTOMAITON

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system integration

EtherNet/IP and OPC/UA. We’re also an Inductive Automation Premier Integrator. All components and safety are done to client specification.

How does data enhance your machine chines that use edge computing? Do you integrate remote connectivity to machines? How do the machines you work with use analytics?

Jeremy Anderson, president, Process and Data Automation: Our core offering is enhancing machine functionality by exposing its underlying raw data to upper-level business systems.

This routinely requires edge com-

IMAGE COURTESY OF PROCESS AND DATA AUTOMAITON

integration? Do you integrate ma-

Figure 3: Jason Chludzinski (standing), IT manager, and Mark Silka, MES product lead/plant digitalization, Process and Data Automation (PDA), a CSIA-certified member of the Control System Integrators Association (CSIA).

puting and other means of remote

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connectivity. This can be for use with

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ous third-party systems. The goal is

the end client’s analytic systems, our own packaged solutions or varialways to find the best fit for the client to contextualize and utilize the data to improve their performance.

What is required for typical maintenance on the machines you work with?

How do end users limit downtime?

Jeremy Anderson, president, Process and Data Automation: Smart alarming, such as our Shopfloor Guidance, allows OEMs and end users to define service

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intervals and watchpoints that are indicative of maintenance. By seeing how a machine is trending in critical performance criteria, plants can better plan service to limit downtime.

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Can these components communicate?

How can Beckhoff’s CX9240 embedded PC and Pepperl+Fuchs’ R103 sensor exchange data?

HOW CAN THE Beckhoff CX9240 embedded PC and

like any other signal. From the PLC side it behaves exactly

Pepperl+Fuchs’ R103 sensor communicate?

as expected, so there’s not much that can go wrong.

With IO-Link, there’s a bit more to consider since the sensor

The Beckhoff CX9240 embedded

is coming in through an EtherCAT IO-Link master. Once the

PC is 84 x 100 x 91 millimeters,

IODD is loaded, the device integrates cleanly, but you still need

making it an ultra-compact, DIN

to decide what data belongs in the cyclic mapping. The default

rail-mountable Ethernet control

layouts often include more than you need, so it’s worth narrow-

system. Its ARM Cortex A53 pro-

ing that down to the key values and leaving diagnostics or addi-

cessor offers a 64-bit architecture,

tional data for acyclic access. Parameter setup is usually easiest

higher clock frequency of 1.2 Giga-

to handle once through the IO-Link tool, but it can be managed

Hertz and four cores. Its features

from the controller if needed, with some added logic. Overall,

include two independent 1 Gigabit Ethernet interfaces and

they work well together, and most of the effort is in deciding

2 GigaBytes of LPDDR4 RAM. It supports the DisplayPort

how much data to bring in and how you want to manage it.

interface standard and uses the TwinCAT Runtime for Linux operating system. It has four USB 3.0 interfaces and

Andrew Bollinger, industrial PC prod-

a multi-option interface that can be assigned for M910,

uct manager, Beckhoff USA: Connecting a

EtherCAT, RS-232, RS-485, Profibus or CANopen with a se-

Pepperl+Fuchs R103 photo eye distance sensor

rial port or a fieldbus connection.

to a CX9240 embedded PC is quite simple using an IO-Link communications interface from Beck-

The R103 sensor is the first

hoff. While the embedded PC would serve as an IO-Link

Pepperl+Fuchs component

master, the direct connection to the R103 sensor would

to offer the complete fam-

be handled via one of many different IO-Link interface

ily of photoelectric sensing

options we have as part of our I/O portfolio.

modes all in one housing. It’s

I would recommend using an EL6224 or ED6224 Ether-

compact but offers multiple

CAT terminal as you can wire in the R103 sensor and then

technologies, from thru-beam sensors to distance mea-

directly connect the I/O terminal to the CX9240 embedded

surement, all in a single hybrid housing design, which

PC simply by sliding it onto the right of the device, and

includes an M18 x 1 threaded snout and two M3 holes for

communication is established via a backplane connection.

surface mounting. With an IP69K protection rating, it can

TwinCAT automation software and EtherCAT can automati-

withstand high-pressure washdowns and operate reliably

cally address the R103 sensor along with all other connected

in extreme temperatures from -40 °C to +60 °C.

devices to the network for faster commissioning.

Quinton Potts, controls programmer, Ro-

Tobey Strauch, contributing editor: They get along.

boTape, the robotic tape system by Innova-

The Pepperl+Fuchs R103 can be bought in two con-

tive Automation in Ontario, Canada: Getting a

figurations, one as a discrete sensor and connected

Pepperl+Fuchs R10x or R20x sensor into a Beck-

to an EL1008 card, or as IO-Link and connected to

hoff system is straightforward, and it mainly depends on

an EL6224 master. It features two push-pull outputs and uses

whether you’re using standard I/O or IO-Link. If it’s discrete

an M8, four-pin connector. It can be configured for conven-

or analog, there isn’t much to think about. Wire it into your

tional PNP/NPN operation or connected to an IO-Link master

Beckhoff I/O, map the channel in TwinCAT, and it shows up

for advanced diagnostics and parameterization.

ControlDesign.com / August 2026 / 31

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product roundup

Connections make the machine Terminal blocks and I/O modules offer performance and functionality Beckhoff ED series terminals

KEB America safety system

Beckhoff ED series ter-

safety PLC, safety I/O modules and

minals offer the same

programming software. These

performance, func-

modules have a double-channel

tionality and built-in

design and can be programmed

diagnostics capabilities

through CombiVis studio 6, which

offered by all EtherCAT

streamlines the development and

The KEB system includes the C6

devices. The DIN rail mounted ED series EtherCAT termi-

approval processes. The safety

nals are characterized by a modernized design, tool-free

PLC is a fail safe over EtherCAT

installation via push-in wiring connections and additional

(FSoE) master that works in conjunction with the machine

app-based diagnostics via a scannable product data matrix.

PLC to execute and monitor safety functions. The safety PLC

This systematic advancement of the distributed I/O system

can connect with other FSoE slave modules like safety I/O

is designed to increase signal acquisition efficiency and,

and servo drives that have Safe Motion functionality.

like the original bus terminals and EtherCAT terminals,

KEB America / www.kebamerica.com

sets a standard, achieved with the flexible hardware integration options offered by ED terminals, which help ensure future viability and investment protection.

Beckhoff / www.beckhoff.com

AutomationDirect modules AutomationDirect P1-04TEPS and P2-08TEPS modules

Pepperl+Fuchs intrinsic safety barriers

provide solid-state relay op-

Intrinsic safety

P1-04THMS and Productivity2000 P2-08THMS thermocouple

barriers from

modules feature 16-bit resolutions and inputs that support nu-

Pepperl+Fuchs are

merous thermocouple types. These modules are designed with

designed to limit

input isolation for better accuracy in electrically noisy environ-

tions for the Productivity1000 and Productivity2000 PLC families. The Productivity1000

the energy that is supplied to a circuit and protect hazard-

ments. The P1-12CDRS discrete/relay combo module for the

ous areas from excess energy. In addition to their explosion

Producivty1000 system combines higher current Form A (SPST)

protection function, isolated barriers offer galvanic isolation

relays (5A/point) with eight 24 Vac/Vdc discrete inputs.

to protect measurement and control circuits from signal

AutomationDirect / www.automationdirect.com

distortion and transient surges. These interface modules can also convert, standardize and split measurement and control signals. Whether a single isolator module or large-scale

Dinkle remote I/O module

system integration—application-oriented, K-System features

Dinkle International’s Daudin iO-Grid

include DIN rail mounting, extensive product portfolio for all

Nemo industrial-grade remote I/O mod-

signals, isolated barriers and signal conditioners in the same

ules are available in versions supporting

system, reduced wiring effort, simple expansion and remote

Profinet, EtherCAT, EtherNet/IP, Modbus

fault monitoring via universal power rail and simplified main-

TCP and CC-Link IE Field Basic. Ethernet

tenance due to removable terminals with test sockets.

models include two RJ45 ports with an

Pepperl+Fuchs / www.pepperl-fuchs.com

integrated two-port switch for daisy-

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product roundup

for network connection and pass-through to the next station.

Phoenix Contact terminal block

LED indicators provide status information, and firmware can

Phoenix Contact XT 1.5

be updated via a standard USB Type-C connection. Modules

terminal blocks, part of the

operate throughout a wide ambient temperature range of -10

Push-X series, are available

to +60 °C using 24 Vdc, and they mount to DIN rails with a

with conductor cross-sections from 22 to 14 AWG. The XT 1.5

mechanical and grounding connection. All models are CE and

series includes feed-through, multi-conductor, double-level,

UL certified. Models, all in 24 Vdc sinking or sourcing versions,

PE and PV terminal blocks. The XT 1.5 terminal blocks offer

include 32-channel discrete input, 32-channel discrete output

tool-free wiring of rigid and flexible conductors, even without

and 16-channel discrete input/output.

ferrules, and a factory-pre-tensioned contact spring for conve-

Dinkle / www.dinkle.com

nient plugging. For additional safety, the terminal blocks have

chain expansion, while CC-Link models use terminal blocks

clear identification of the conductor connection with the forceguided actuating element and make an audible click sound

Bihl+Wiedemann safety module

when the spring is released. The XT 1.5 terminal blocks include

Bihl+Wiedemann’s configurable

Phoenix Contact / www.phoenixcontact.com

a nominal current of 15 A and a nominal voltage of 300 V.

ASi-5 safety module offers up to 14 safe inputs and two safe inputs can be configured for al-

Mencom tool-less connector

most any sensor, whether OSSD

The Mencom AXYR series

or floating contacts, either as

supports rigid and stranded

outputs, up to PLe. The safe

standard or antivalent switches. Cyclical diagnostics mean

conductors, prepared (ferrule-

safety diagnostics for each safe signal are included in the

terminated) and unprepared

cyclical data and displayed comprehensively. With ASi-5

wires, within a single contact

Safety, many safe and standard signals can be used under

design. One contact size covers the full cross-sectional range

one address or node number.

supported by the series. Connections are also rewirable. The

Bihl+Wiedemann / www.bihl-wiedemann.de/us/

AXYR contacts are designed to be resistant to mechanical stress and vibrations, a baseline requirement for connectors used in machine-mounted or mobile industrial applications.

Wieland selos DIN rail terminal block

Mencom / www.mencom.com

Wieland’s selos DIN rail to simplify wiring, accelerate

Bristol Instruments universal panel meter

installation and save cabinet

Bristol Instruments’ OM

space. The WTPN Series

403UNI Series of displays/con-

features push-in spring pres-

trollers are configured using a

sure technology. With UL and

setup wizard or configurator

CSA approvals up to 82 A and a wire range from 26 AWG to

software called OM Link where users check-off settings boxes

500 kcmil and application-specific versions for motor, sensor,

or front-panel buttons. Main display is either six digits or four

pluggable, diode, fuse and test terminals, the WTPN Series is

digits plus units. Accuracy is to ±0.05% of f.s. range. The OM

designed to modernize the screw connection with features

402UNI can be set to be a numeric display, numeric and bar

designed for reliability and faster installation. A universal

graph display, controller with relay and/or signal outputs, data

screw head (flat or Phillips), vibration-resistant clamping,

recorder and accumulator by enabling a secondary display on

snap-on ground terminals and push-in jumpers are designed

the device. It also detects error conditions such as a broken

to improve usability and performance.

input signal wire or sensor and alerts the user.

Wieland / www.wieland-americas.com

Bristol Instruments / www.bristolinstruments.com

terminal blocks are designed

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live wire

Joey Stubbs joey.stubbs@gmail.com

Old sensors, new tricks PRESENCE SENSING HAS BEEN part of factory automation

nothing more. By combining sensor output with encoder

for decades. Inductive proximity switches, photoelectric

feedback values or controller timing data, manufacturers

sensors and capacitive sensors remain common throughout

can estimate product spacing, detect accumulation and

manufacturing. In many facilities they detect parts, confirm

identify process instability.

positions and trigger machine sequences with no attention.

If products begin arriving with increasing variability

Rather than replacing established devices, manufacturers

between detections, the root cause may not be production

are beginning to extract more value from already installed

speed but slipping belts, inconsistent feeding or changing

sensors. By leveraging higher-performance controllers, us-

operator interaction. A photoeye becomes an inexpensive

ers are now able to capture timing, compare patterns and

source of process information. Some systems use multiple

convert simple on-off events into

standard photoelectric sensors

useful information.

One practical example is using existing proximity sensors as indicators of machine mechanical condition. An inductive sensor

to approximate functions that

A pneumatic slide that requires longer travel time may suggest seal wear or air leakage.

mounted to detect a home position or confirm carriage move-

historically require basic machine vision.

Detecting leading and trailing edges allows estimation of part length while timing differences between sensors can reveal

ment has traditionally been treated as a binary device.

conveyor speed changes. These methods do not replace

Once the controller sees the signal transition, the machine

dedicated vision systems but often answer operational

advances to the next state. Modern control hardware and

questions at a fraction of the complexity and cost.

higher resolution timing make it possible to observe those transitions and identify trends.

If a conveyor-mounted actuator gradually reaches a sen-

Capacitive sensors are seeing similar repurposing in applications where manufacturers need simple verification rather than detailed inspection. Historically associated with

sor later in the machine cycle over several months, that

level detection and bulk material monitoring, capacitive

timing change may indicate belt wear, coupling looseness or

sensing can also confirm process completion and validate

increasing friction. A pneumatic slide that requires longer

whether material is present where it should be.

travel time may suggest seal wear or air leakage. Index-

Applications include adhesive confirmation, seal pres-

ing tables can reveal growing backlash before positioning

ence, packaging verification and monitoring material build-

problems appear.

up. In many cases the objective is confidence that a process

Evaluating multiple proximity sensors together creates

actually occurred rather than collecting detailed measure-

a timing signature for the process. When those signatures

ments. For manufacturers trying to avoid adding cameras,

begin changing, maintenance teams gain an early warning

capacitive sensors can provide an effective middle ground

that something mechanical is moving outside normal op-

between basic detection and full inspection systems. These

eration. Multiple sensors can also reveal where delay begins

sensors can also support faster changeovers and trouble-

and can help shorten troubleshooting.

shooting. A machine that already includes capacitive sens-

For facilities already practicing vibration analysis, the

ing points may only require software changes.

concept will feel familiar. The goal is to identify operational changes earlier using hardware that already exists.

Photoelectric sensors are also finding a second life be-

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

yond simple presence confirmation. Many production lines

from the University of South Carolina, was a development

already use photoeyes to detect products moving across

engineer in the fiber optics industry and is the former head

conveyors. Traditionally the sensor confirms arrival and

of the EtherCAT Technology group in North America.

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| MX01USA |

Smart. Modular. Cabinet-free.

The MX-System advantage.

Have you taken a serious look at your electrical cabinets lately? Sure, they protect your equipment and have been there right alongside your machines since, well, forever. Maybe you take them for granted, like they just have to be there.

They don’t. Our new MX-System has changed automation and controls system design forever. This flexible, space-saving, and intelligent automation hardware platform can completely replace conventional control cabinets and literally transform your machines. Seriously.

With pluggable modules for all main areas of automation and control such as the controller, I/O, drives, relays and system modules, the MX-System opens up exciting new possibilities for machine builders, system integrators, and end users alike.

Sorry, electrical cabinets, but we think it’s time to retire.

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