Control Design – October 2024

What is system integration?

SIs use knowledge of engineering, IT and business to automate manufacturing and processes from the plant floor to the enterprise level

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table of contents

Volume 28, No. 5

18 cover story

What is system integration?

SIs use knowledge of engineering, IT and business to automate manufacturing and processes from the plant floor to the enterprise level Jose Rivera, Control System Integrators Association (CSIA)

14 28 machine input

product roundup

How to achieve controlpanel adaptability

Motion makes the difference

Optimize time to market, efficiency and durability in electrical enclosures

Controllers, motors and drives enable actuation

Mike Bacidore, editor in chief

CONTROL DESIGN (USPS 17792, ISSN 1094-3366) is published 6x annually or bi-monthly by Endeavor Business Media, LLC. 201 N. Main Street, Fifth Floor, Fort Atkinson, WI 53538. Periodicals postage paid at Fort Atkinson, WI, and additional mailing offices. POSTMASTER: Send address changes to CONTROL DESIGN, PO Box 3257, Northbrook, IL 60065-3257. SUBSCRIPTIONS: Publisher reserves the right to reject non-qualified subscriptions. Subscription prices: U.S. ($120 per year); Canada/Mexico ($250 per year); All other countries ($250 per year). All subscriptions are payable in U.S. funds.

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ControlDesign.com / October 2024 / 3

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Volume 28, No. 5

table of contents

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

CEO Chris Ferrell President June Griffin COO Patrick Rains CRO Paul Andrews Chief Digital Officer Jacquie Niemiec Chief Administrative and Legal Officer Tracy Kane EVP Group Publisher Tracy Smith VP/Market Leader - Engineering Design & Automation Group Keith Larson

editorial team editor in chief

Mike Bacidore mbacidore@endeavorb2b.com

COLUMNS 7 editor’s page

12 automation basics

60 brands under one umbrella

Lessons in sensing from a sugar mill

Mike Bacidore, editor in chief

Charles Palmer, contributing editor

8

32 real answers

embedded intelligence

Sensing devices protect and serve data Jeremy Pollard, CET

42 live wire

managing editor

Anna Townshend atownshend@endeavorb2b.com digital editor

Madison Ratcliff mratcliff@endeavorb2b.com contributing editor

Rick Rice

How much is too much stacklight?

9

technology trends

How to interface in hazardous areas

What is a panel PC? Joey Stubbs, contributing editor

Rick Rice, contributing editor

rcrice.us@gmail.com contributing editor

Joey Stubbs contributing editor

11 component considerations

contributing editor

How machines stop in emergencies

Charles Palmer

Tobey Strauch, contributing editor

Tobey Strauch tobeylstrauch@gmail.com

charles101143@gmail.com columnist

Jeremy Pollard jpollard@tsuonline.com

design/production production manager

Rita Fitzgerald rfitzgerald@endeavorb2b.com

ad index Altech .................................................................................. 23

icotek ................................................................................... 41

Beckhoff Automation ...................................................... 6

KEB America ...................................................................... 13

Contemporary Controls ................................................. 24

Pepperl+Fuchs ................................................................. 10

DigiKey ................................................................................ 44

SEW-Eurodrive ................................................................... 2

EZ Automation ......................................................... 26-27

Siefert Systems ............................................................... 25

Fuji Electric Corp. of America ..................................... 39

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

ad services manager

Jennifer George jgeorge@endeavorb2b.com art director

Derek Chamberlain

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

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Jeff Mylin jmylin@endeavorb2b.com 847/516-5879 Fax: 630/625-1124 Account Manager

Every effort is made to ensure the accuracy of this index. However, the publisher cannot be held responsible for errors or omissions.

Kurt Belisle kbelisle@endeavorb2b.com 815/549-1034

ControlDesign.com / October 2024 / 5

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editor’s page

Mike Bacidore editor in chief mbacidore@endeavorb2b.com

60 brands under one umbrella IN AUGUST, REGAL REXNORD hosted a group of individu-

“Most of our businesses help to manage or control

als from the industrial press at its downtown Milwaukee

motion,” explained Kevin Zaba, president of the AMC divi-

headquarters to get to know the company and its diverse

sion. “We’re technology-biased as a segment, and we have

portfolio a little better.

deep domain expertise.”

With 250 global sites, 150 of them are manufacturing

“When we first brought Regal and Rexnord together it was

units, and more than 30,000 global associates—9,100 in

exciting, but, as we added the Altra products, we were able

United States; 8,400 in Mexico; 5,200 in Europe—sustain-

to enhance the overall set of offerings, but also from subsys-

ability is a priority for Regal Rexnord. “We’re committed to

tems and powertrains that we’re able to build to meet the

achieving carbon neutrality, scopes 1 and 2, by 2032, with a

needs,” explained Zaba.

12% reduction achieved in 2023,” pledged Scott Curley, senior vice president, sales and marketing, at Regal Rexnord.

Jerry Morton, president, industrial powertrain solutions (IPS), has been in the space for 37 years. “When I started,

Energy efficiency in motors

we had two brands,” he men-

and clutches is a big trend driving

tioned. “Today, we have 41. It’s

investment, but Curley also identified keeping up with regulations, as changes in fuel sources affect turbomachinery. Electrification

The organization’s biggest issue could also be its biggest opportunity.

has been at the forefront of many

Some motion-application customers have been late adoptthe powertrain, integrating that data and those capabilities into a predictive-maintenance model,” said Curley.

Including the completed acquisition of Altra Industrial

three formidable players in the powertrain space.” issue could also be its biggest

“We’ve been doing electric brakes

ers of digitalization. “We’re seeing a lot more integration of

tion. We brought together the

The organization’s biggest

industries for over a decade. for a long time,” noted Curley.

been a tremendous transforma-

opportunity. “Many of our customers see different brands and think they’re all different companies,” said Morton. “Ultimately, we’re trying to get to supplying the entire powertrain.”

IPS products include gearing, couplings, bearings, mechanical drives, clutches and brakes, with 67% of its business in North America. “You see all of those in indus-

Motion in March 2023, 60 brands now fall under Regal

trial powertrains,” noted Morton. Industry verticals for

Rexnord, whose automation and motion control (AMC)

IPS with the most focus include heavy industry, mining,

division includes conveying products, aerospace, seals and

metals, agriculture, food and beverage, commercial HVAC,

bearings, linear motion, precision motors, servo drives and

renewable energy and oil and gas.

controls and power management.

One Regal Rexnord offering that could aid in bringing

About two-thirds of its sales are in the Americas, with

individually branded products under one unified umbrella is

68% directly to original equipment manufacturers (OEMs)

Perceptiv, its cloud-based asset-reliability platform for condi-

and system integrators and the other 32% through distribu-

tion monitoring and predictive maintenance. It’s a single

tors. Factory automation is the largest market segment with

ecosystem for connectable equipment and brands, providing

nearly a third of the business, while aerospace and food and

insights and recommendations based on machine-health

beverage each comprise 20%.

data, explained Morton.

ControlDesign.com / October 2024 / 7

embedded intelligence

Jeremy Pollard jpollard@tsuonline.com

Sensing devices protect and serve data “HONEY, I’M HOME.” This was a normal thing to say in the

The opposite is also true. If someone does not have my

1950s and 1960s by Dad when he came home from work to

fob and tries to open the hatch, they will not be success-

let Mom and the family know that he had returned.

ful. Sensing has two sides—there and not there; pres-

Today is different. My presence is known by simply ap-

ence and absence. It is important in a control narrative to

proaching the house. My Ring camera goes off, my wife’s

determine which one needs to be sensed for the action at

iPad tingles, and my phone lets Google Home know that I am

hand. Sometimes, it is both.

on the premises—presence sensing at its best, and no words are even spoken.

In a project in the 1980s I was using a proximity switch to gauge conveyor speed by counting teeth on the flywheel

Light curtains are used in robot cells to detect people who

of the chain-driven system. I looked at the end of the tooth

try and enter the cell at a time

and then at the absence of the

when they shouldn’t. I used light curtains to protect people who, for some strange reason, would traverse on a conveyor while a pallet wrapper was in operation,

tooth. Knowing the distance of

The cost of adding a sensor can be very insignificant to the cost of the machine and/or process.

so that they didn’t get knocked

the tooth not being there and the time between the teeth being sensed, I determined the speed in lugs/min, which the customer needed for acceptance testing.

out by the whirling arm.

Now, I would use a resolver or

We use various devices to sense things. People, product,

encoder, giving me the speed, which could be converted. A

air quality and pollutants, static location and movement are

variable-frequency drive (VFD) would be employed instead

some of the myriad things that may need to be sensed.

of the hydraulic drive that was being used.

Parts in place—photocell, proximity switch, limit

Sensing comes in many different packages with various

switch—has been implemented for many years. With

connectivity options, such as Bluetooth, Wi-Fi, Ethernet

the advent of programmable logic controllers (PLCs) and

and, of course, ac/dc direct connectivity.

programmable automation controllers (PACs) and control

The real question is why. Why do we need to sense any-

software, wiring in sensing hardware and using that infor-

thing? Safety comes to mind, as well as the process. When

mation for control, feedback, alarming and trending has

we implemented the light curtain for the wrapper it was for

become commonplace.

people and the machine.

Analog sensing is also employed, as 4-20 mA signals for

Sensing is an integral part of any control narrative from

level, speed and the like are used in everyday solutions for

a process and discrete point of view. Water treatment

automated processes and machines. Modern sensors have

systems, making beer, a favorite of mine, an x-y machin-

built-in networking capability to allow for the use of these

ing table and drill platform all are different in function but

devices anywhere on the machine and/or process.

similar in that they all need sensing of product, location and

Radio-frequency identification (RFID) technology is be-

action, such as that valve needs to be closed.

ing implemented in the field. Imagine if your phone could

The cost of adding a sensor can be very insignificant to

connect you to a machine-control system simply by being

the cost of the machine and/or process. The cost of fixing a

in its presence. Well, if the machine can support Bluetooth,

busted system because you failed to sense that all stations

and the mobile app on your phone can talk to that machine,

are home on a dial-table application could be expensive.

then it can. Your presence can be determined by your prox-

Using our common sense will win the day.

imity to the machine. I have a new car whose key fob allows me to actually enter the car without unlocking it with the

JEREMY POLLARD, CET, has been writing about technology and

fob. It senses my proximity and marries my fob to the car so

software issues for many years. Pollard has been involved in

when I touch the door handle the doors unlock.

control system programming and training for more than 25 years.

8 / October 2024 / ControlDesign.com

technology trends

Rick Rice contributing editor rcrice.us@gmail.com

How to interface in hazardous areas THROUGHOUT THE HISTORY of automation, the human-

While this might work for an environment where dry

machine interface (HMI) has evolved from simple lights

goods are produced, it would not stand up to intentional wa-

on a board to sophisticated hardware with computers

ter spray or pressurized materials. By comparison, an HMI

onboard and the possibility of combining the HMI and

with a rating of IP69K means that the device is completely

programmable logic controller (PLC) into the same physi-

dustproof and can withstand washdown at pressures up to

cal package.

1,450 psi for periods of up to 15 minutes at a time and tem-

With sophistication comes the risk of exposure to the environment in which the HMI is installed. Just how do we keep the outside from getting inside?

peratures up to 176 °F. One approach that has gained traction lately is to use a tablet in place of a permanently mounted HMI. Tablets

An HMI does not necessarily

can be charged outside of the

imply a high-resolution screen with complex graphics. Industrial robots, for example, utilize a pendant with an array of buttons on it and a small display to interact

harsh environment and then

The enclosure itself can be positively charged with air or an inert gas.

with the user.

brought into the area for use.

Tablets, much like our smartphones, are designed to withstand environments that other devices could not.

A commercial blender might

There are some rules to follow.

use a pendant that is buttons and lights only. This, too, is

For example, the application on the tablet can only control

an HMI. An operator station for a press might utilize palm

devices that are within eyesight of the operator. This means a

buttons that light up to prompt the user to interact with the

means of locating the device must be made or the application

buttons. Again, this is an HMI.

on the device must be restricted to the immediate vicinity of

Operator hardware is robust these days and current

the wireless access point (WAP) that the device connects with.

designs protect the components when used in a harsh en-

Another means of protecting the HMI is to mount it, as

vironment. For example, 30-mm buttons can be purchased

usual, in an enclosure and then add additional methods of

with a rubber boot that fits over the operating components

protection. For example, if the HMI is used mostly as a visual

that are outside of the enclosure. This reduces the risk of

tool, then a see-through cover could be added to the enclosure

water or other contaminants from getting into the physical

face to go over the HMI. If the operator needs to access the

device and the components that are on the backside—in-

HMI directly, the cover can be unlatched and moved out of the

side the enclosure. The backside components can be totally

way while in use and then latched back into place when done.

encased to prevent contamination.

Aside from an all-mechanical device, HMIs do tend to be more fragile in nature. Essentially, they are computers with

The enclosure itself can be positively charged with air or an inert gas to, effectively, push any foreign particles back out any small crevice that might be a point of entry otherwise.

exposed screens that use a touch interface to interact with

Another approach that has merit is the use of a thin cli-

the user. Under normal operating conditions, the hardware

ent. In these situations, the smarts of the HMI are located

might survive operation, but, as most of us know, conditions

remotely, and only the display is mounted in the field. The

are rarely normal.

screen itself can have ratings of IP66 or IP69K, making it an

Hardware manufacturers go to great lengths to protect

excellent choice for this application. Often, the membrane

HMIs from the environment in which they operate. Again,

of the screen can be replaced in the field, and, if there is a

much of this has improved with technology. For example, an

failure, you are only replacing the touchscreen monitor and

HMI originating in the 1980s might have an IP54 rating. This

not the whole system.

means that it would be protected from limited dust ingress and water spray in any direction.

With proper implementation, the HMI can last a very long time. Protecting these devices is very important to the

ControlDesign.com / October 2024 / 9

technology trends

control system design. Manufacturers go to great efforts

various components that make up the control system.

to provide us with a sufficient set of options to make sure

The approach at my place of work is to employ the HMI

that the device suits the need, and we don’t have to put an

as a means of keeping people out of our control cabinets

expensive piece of hardware in our design if we don’t really

whenever possible.

require it for our operating environment.

Happily, in most cases, these various degrees of construc-

To this end, we use graphical representations of most of our in-panel components and super-impose status lights

tion are within a single product line, and an application

right over the appropriate spot on the image. We then use

design can easily be scaled up and down to meet the differ-

soft buttons to pop up information that describes the device

ent physical device characteristics without reinventing our

and what the various lights and patterns mean.

usual operator station design.

The HMI is an essential part of a control system design.

The device provides direct interaction with the controller,

This approach keeps our control enclosures clean and reduces or eliminates the need to open the door to perform basic troubleshooting.

as well as endless capabilities to provide troubleshooting for an operator or line technician.

With the high-resolution graphics, actual photos of

RICK RICE is a controls engineer at Crest Foods

the area of concern can be shown right on the screen

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

with interactive popups to provide further details of the

and packaging company in Ashton, Illinois.

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component considerations

Tobey Strauch contributing editor tobeylstrauch@gmail.com

How machines stop in emergencies IN ANY SAFETY configuration, one must consider how the

activated, the machine decelerates in a controlled manner

machine is going to stop and in which instances. National

to avoid damaging the workpiece or the cutting tool, and

Fire Protection Association (NFPA) 79 is an industrial ma-

then power is cut off.

chine safety regulation and defines stops in categories.

Category 0 is an uncontrolled stop by immediate removal

Automated guided vehicles (AGVs) used in warehouses and manufacturing plants rely on Category 1 stops to ensure

of power to the machine actuators. This requires non-reten-

safety. If an obstacle is detected in the vehicle’s path, the

tive relays. A reset to initial state is required.

AGV will decelerate smoothly before stopping completely,

Category 1 is a controlled stop with power to the machine actuators to achieve a stop and removed power when the

reducing the risk of collisions and damage.

In packaging lines, Category 1 stops are used to prevent

stop is achieved.

damage to both the machinery

Category 2 is a controlled stop with power left available to the machine actuators.

As a machine builder, it might

and the products being packaged.

Would a stop due to fire be a Category 1 stop?

be difficult to discern the differ-

the machine will decelerate before stopping, allowing operators to clear the jam safely.

ences as to when one might do

High-speed printing presses

a full stop, controlled stop, stop with power ready. What is a good reference to follow?

For example, if a jam is detected,

use Category 1 stops to avoid damage to the printing plates and paper.

Emergency stops or conditions are the “darn it” buttons

When an emergency stop is triggered, the press

and require quick stops. This is a Category 1 type stop. Cat-

decelerates in a controlled manner before stopping,

egory 2 would be an instance when a stop requires power to

ensuring that the print quality is maintained and the

remain on a circuit. Hydraulic oil may need to keep circulat-

equipment is protected.

ing for an auxiliary power unit (APU) response, even if a

Cold mills hold high tension with dangerous metal

machine is stopped. E-stops are not Category 2 stops, but a

sheets. When a Category 1 stop is made the tension can be

machine stop can be Category 2.

decreased on a set ramp to allow safe maneuvering of metal

Category 1, quick stops after short amount of time, are

sheeting on a roll. This saves the material and the people. A

used for high inertia machines where an immediate stop

hard depowered stop would leave tension on the sheet and

would harm people or machine, and the safe way to stop is

risk a break and possible equipment damage.

to allow a time to slow down before removing power.

Removing power from the machine in a hard stop, would

Would a stop due to fire be a Category 1 stop? No. That is a Category 0 stop. Why? Fire hazard. Get out now.

require a timed slow down and then removal of power. This

Category 2 stops are like pushing the stop button in

is discerned by the application. Things to consider are time

manual mode but keeping the power on because the drive

to stop, damage in not waiting for a controlled stop, risks be-

should be ready for a “jog” function.

tween controlled stop and depowered stop regarding people.

In automated assembly lines, a Category 1 stop is crucial

In conclusion, there are three types of category stops for machine builders: categories 0, 1 and 2. The most extreme

for safely halting operations. For instance, if a sensor de-

is a hard-stop Category 0. The least extreme is a soft stop,

tects an obstruction or a malfunction, the system initiates

which is Category 2, and Category 2 may not be an emer-

a controlled deceleration of the conveyor belts and robotic

gency stop .

arms before cutting off power.

Computer numerical control (CNC) machines, which are used for precise cutting, milling and drilling, often

Tobey Strauch is an independent principal industrial

employ Category 1 stops. When an emergency stop is

controls engineer.

ControlDesign.com / October 2024 / 11

automation basics

Charles Palmer contributing editor

Lessons in sensing from a sugar mill TECHNOLOGY HAS TRANSFORMED all types of sensors lead-

the signal latched on. This series of electrodes provided the

ing to massive improvements in manufacturing enterprises

4/6/8/10/12/14/16/18/20-mA output to the turbine speed con-

through better quality control and many others.

troller. It proved fully functional and highly efficient.

Having started my instrumentation career in heavy

The second major sensor-related problem was the auto-

industry in the 1960s, when pneumatics was very much the

mated cane tippler system. Small cane-filled rail cars were

core competency, and having moved on through the 4-20

hydraulically pushed into a 270° rotating tippler mecha-

mA analog era, finally ending up in the world of digitaliza-

nism. All position sensors used in the operation to position

tion, I have been extremely blessed to have been able to wit-

the car, lock it in place, rotate it and then unlock and eject

ness these incredible changes in the process industries.

on the rail system were of the simple mechanical type.

I once travelled 300 miles by car

These devices suffered many

to tend to a faulty control valve, for a company who had no instrument staff. All I did was re-attach a positioner feedback arm to the

failures due to the ruggedness

I was faced with an aging factory in dire need of automation.

of the application, in which fulllength sticks of cane, protruding out of the car, came into contact

valve stem, allowing the boiler

with these switches, thereby

feedwater to flow once more. The

damaging them. I found a sim-

time taken to rectify this was less

ple solution, in that I installed

than 10 minutes and the company’s engineering manager

a highly rated series of magnetic switches, extremely

was in total disbelief when my solution solved the problem.

rugged and virtually bullet-proof. Connecting cable was

In 1979, I was offered the position of instrument engi-

permanently connected, thus the ingress of moisture was

neer at a sugar mill.

I was faced with an aging factory in dire need of automa-

prevented. End of problem.

Then there was the not-so-user-friendly system of moni-

tion, and, in the first 13 years I spent there, I systematically

toring the many boiler drum level gauge glasses, whose

installed the latest, at the time, high-tech analog measure-

installation was mandatory under safety regulations.

ment and control instrumentation in the entire factory.

Because these were installed on the boiler drum and four

One of the major challenges was the measurement and

or more floors above the ground, it was not possible to read

control of the multi-stage steam-turbine-driven roller sug-

them continuously. The interim solution was to drop two

ar-cane crushers. The shredded cane was fed into chutes,

long lines down to ground level and mount a second gauge

the levels in which were required to control the speed of

glass within normal visionary contact. The problem here

these turbines. The existing solution was not successful in

was that, with many boilers, not all of these indicators were

that the measurement of the conductivity of the shredded

in direct line of sight of the boiler control room. This meant

cane across the chute to determine its respective height

that the operator still had to leave the control room to verify

in the chute was not reliable and caused much under- and

any suspected problem. The simple answer, by 21st Century

over-feeding. The solution I arrived at was a system of

standards, was to install cameras facing each of the drum-

a solid reference strip, vertically mounted on Perspex,

mounted indicators and provide a desktop computer, where

electrode on the one side of the 84-inch-wide chute, with

the screen was split into four segments, showing each of the

a series of nine button probes, also mounted on Perspex

four boilers. It was very much appreciated in the 1970s.

fitted to the other side of the chute.

This worked to a degree but suffered due to the signals across the chute being interrupted by air pockets in the cane

Charles Palmer is a process control specialist

mass. The ultimate solution was to incorporate positive

and lecturer at Charles Palmer Consulting (CPC).

feedback to the system of logic gates so that, once detected,

Contact him at charles101143@gmail.com.

12 / October 2024 / ControlDesign.com

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machine input

How to achieve control-panel adaptability Optimize time to market, efficiency and durability in electrical enclosures

by Mike Bacidore, editor in chief

MICHAEL BLASS IS design team manager at Concept Systems, a CSIAcertified system integrator headquartered in Albany, Oregon. Mike Moreau is senior electrician at Innovative Automation, a system integrator in

Is NFPA 79 still the go-to standard? What does it tell us about installing electrical equipment properly?

However, the need for NFPA 79 compliance should be evaluated based on the specific requirements of each project, as other standards may be more relevant depending on the application.

Mike Moreau , senior electrician,

CSA C22.2 No. 286 (Industrial Control

How does proper routing ensure cable protection outside the enclosure, and why are bundling and labeling important?

Panels and Assemblies), as well as the

Michael Blass, design team manager,

Canadian Electrical Code (Figure 1).

Concept Systems: One of the

Barrie, Canada, which developed the

Innovative Automation: In

RoboTape platform. Moreau holds

Canada, we follow the CSA

Construction Maintenance 309A RSE

equivalent of the NFPA 79 which is a

and Industrial Electrician 442A elec-

combination of CSA C22.2 No. 301

trical licenses.

(Industrial Electrical Machinery) and

These codes and standards lay out the minimum safety precautions and rules

biggest threats to system reliability is the integrity of the

we must follow to build safe equipment that will not harm or cause injury. We then have a reputable inspection agency, such as the Electrical Safety Authority (ESA) come in and inspect this equipment before supplying it to our customers.

Michael Blass , design team

manager, Concept Systems : NFPA

79 is certainly one of the key standards to consider, but it’s important to recognize that not all control panels require industrial machinery-level compliance.

In cases where NFPA 79 is applicable, it plays a vital role in ensuring that Figure 1: In Canada, Innovative Automation follows the CSA equivalent of the NFPA 79 which is a combination of CSA C22.2 No. 301 (Industrial Electrical Machinery) and CSA C22.2 No. 286 (Industrial Control Panels and Assemblies), as well as the Canadian Electrical Code.

human-machine interactions and elec-

(SOURCE: INNOVATIVE AUTOMATION)

understand and operate the system.

14 / October 2024 / ControlDesign.com

trical safety hardware adhere to a standardized methodology. This consistency is crucial, as it allows both operations and maintenance personnel to easily

Figure 2: Important parts of cable configuration in and out of the cabinet are accurate bundling and clear labeling.

(SOURCE: CONCEPT SYSTEMS)

machine input

interconnect hardware. Sharp edges, burrs and even minor vibrations in machinery can lead to the premature failure of cable and wire insulation.

This is why proper routing and effective strain relief techniques are critical—they help protect the cables from these potential hazards. Equally important is accurate bundling and clear labeling (Figure 2). Proper labeling ensures that if a cable or wire causes issues, it can be quickly identified at both ends, making troubleshooting faster and more efficient. Additionally, it aids in aligning the physical wiring with the design documentation, reducing the risk of errors during maintenance or modifications.

Mike Moreau , senior electrician,

Figure 3: Cable/wire routing is important for different applications, notably reducing the chance of noise and electromagnetic interference (EMI).

(SOURCE: INNOVATIVE AUTOMATION)

Innovative Automation : Cable/

wire routing is important

wiring there are two main types of

While there are various versions

for different applications, equipment

terminations we use, spring clamp

within each category, these two styles

location and inspection bodies who

and screw type. Spring-type connec-

are the foundation of most termina-

will be certifying the equipment and

tions can be a variation of push-in,

tion methods.

cable ratings, as well as separation to

where you simply push the wire into

reduce the chance of noise and

the terminal and it locks in place,

longest history, involves securing the

electromagnetic interference (EMI).

versus having to compress the spring

wire by torquing it to a specific pres-

Depending on all these factors, we do

with a terminal driver to open the

sure to prevent it from loosening over

separate wires and cable of different

mechanism and then insert the wire.

time. This method requires the use of

voltages, such as 480-600 V, three-

Spring-type connections are great for

calibrated torque drivers, adding both

phase power distribution and

applications exposed to vibration

cost and time—not just in the initial

low-voltage communications, such as

where the spring keeps a constant

procurement, but also in the ongo-

Ethernet, Profinet and EtherCAT, and

pressure on the wire. Screw-type

ing maintenance of the tools. While

we will fully separate any ac wiring

terminals use a set screw to compress

screw clamps have been reliable for

from 24 Vdc wiring and communica-

and apply force to the wire to hold it

decades, they can be less efficient and

tion cables in cable tray (Figure 3).

in place; often screw-type terminals

more labor-intensive.

can be used for larger-gauge wires for

Can you explain the different types of termination devices and the best applications for each?

higher current applications.

Screw termination, which has the

In contrast, spring cage technology is becoming increasingly popular due to its ease of use and resilience in

Michael Blass , design team

high-vibration environments. Unlike

manager, Concept Systems: There

screw clamps, spring cage terminals

are several categories of

do not require specific torque, mak-

Mike Moreau , senior electrician,

termination methods for panel wiring,

ing them more straightforward to

Innovative Automation : In regard

but they generally fall into two main

install. A version of this technology,

to panel and enclosure

types: screw clamp and spring cage.

known as push-in terminals, further

ControlDesign.com / October 2024 / 15

machine input

simplifies the process. With push-

cant advantages, such as the ability

in terminals, no special tools are

to accommodate future expansions,

needed—wires of a certain minimum

updates and adaptations to evolving

size can be directly inserted into the

regulations. By planning for these

spring cage, and removal is as simple

contingencies upfront, we ensure that

as pressing a button. The only caveat

the control panels remain robust and

is that push-in terminals require the

adaptable over time.

use of wire end ferrules. However,

Similarly, slightly oversizing

this is often not an issue since many

variable-frequency drives (VFDs) and

customers already mandate the use

servo drives, within reason, provides

of ferrules for all terminations.

crucial benefits. It allows for mo-

Overall, the choice between screw

tor sizing to be finalized later in the

clamp and spring cage methods

design cycle, offering flexibility during

depends on the specific application

development. Additionally, these over-

requirements, including factors like

sized components are better equipped

vibration levels, ease of maintenance

to handle the demands of aging mo-

and the need for specialized tools.

tors that may operate continuously at the higher end of their ampacity

Considering the increasing complexity of machinery and the critical role of control panels, how can you effectively balance the demand for faster time-to-market with the need for robust, longlasting control panels?

range, reducing the risk of premature failure and extending the overall lifespan of the control panel.

By balancing the need for speed with thoughtful design considerations, we can deliver control panels that meet the demands of rapid time-to-market while maintaining the durability and reliability required for long-term performance.

Figure 4: Moving toward devices that communicate with the programmable logic controller (PLC) and other components through varying communication protocols such as Ethernet IP, EtherCAT and Profinet helps to reduce time to market.

(SOURCE: INNOVATIVE AUTOMATION)

Michael Blass , design team

Mike Moreau , senior electrician,

manager, Concept Systems: In

Innovative Automation : Multiple

today’s fast-paced, just-in-

strategies can be used to

logic controller (PLC) and other com-

time manufacturing environment, we

decrease the assembly time and

ponents through varying communi-

achieve success by leveraging

provide robust solutions in a timely

cation protocols such as Ethernet IP,

standard designs that incorporate

manner. Some of these strategies

EtherCAT and Profinet among others

built-in flexibility. One key approach is

may include using spring-type

(Figure 4). This helps reduce the

the inclusion of 20% spare I/O points

terminals that offer quick assembly

time-to-market by not having elec-

and additional space in control panels,

time but provide a durable connec-

tricians hardwire signals between

along with slightly oversized variable-

tion compared to screw-type

both devices in the electrical control

speed motor controllers. This strategy

terminals that take longer to tighten

panel and devices outside the control

reduces the level of detail required

down, as well as require preventive

panel. This also offers a larger range

during the design phase and enables

maintenance to make sure connec-

of control and enables troubleshoot-

the early procurement of long-lead-

tions don’t come loose over time.

ing to be able to pass more informa-

Another strategy we use is to

tion back and forth over a communi-

time components.

The provision of spare I/O points and additional space offers signifi-

16 / October 2024 / ControlDesign.com

move toward more devices that com-

cation protocol, rather than multiple

municate with the programmable

wires between devices.

machine input

What are the most effective methods for standardizing panel design and components while maintaining flexibility to accommodate diverse machine requirements?

impacts, particularly when dealing

gearbox applications, DOL starters do

with one-off turnkey machinery.

not allow for speed adjustments, mak-

However, the diverse requirements of

ing any necessary changes costly in

each application can make this a

terms of both hardware and labor.

complex task. To address this,

While VFDs may initially cost up

standardizing hardware and panel

to three times more than DOL start-

layouts across systems can signifi-

ers, they provide a safeguard against

Mike Moreau , senior electrician,

cantly reduce overall design time,

late-stage speed adjustments, thereby

Innovative Automation: One

allowing for greater focus on creating

protecting the project timeline and

cost-effective method we

adaptable solutions (Figure 5). This

budget. Additionally, using the same

approach not only streamlines the

motor and VFD sizes across various

like to do is to use field-mounted communication-based I/O systems— remote I/O. These systems communicate using protocols such as Ethernet IP, EtherCAT or Profinet, for example, and are flexible with using discrete or analog I/O systems. The other benefit

VFDs offer motor speed adjustability, which is crucial since the exact speed required for a system’s cycle time is often estimated early on.

to these devices is you reduce the number of hardwired signals back to the main PLC and can reduce control panel size. Another advantage to using

design process but also mitigates the

applications simplifies parts selection

remote I/O is the large variation of

impact of changes during both the

and spares management.

hardware configurations.

design cycle and system commission-

The second impact is on installa-

ing. The foundation of this flexibility

tion labor costs. As Ethernet commu-

Michael Blass , design team

lies in building spare capacity

nications become more prevalent in

manager, Concept Systems:

wherever possible.

machinery, the extensive labor hours

Incorporating flexibility into

For instance, even when a func-

traditionally required for I/O wiring

control panel design is essential for

tional safety level of Category 2, Per-

of DOL starters are significantly re-

minimizing budget and schedule

formance Level C, is required, opting

duced. Ethernet connections stream-

for the slight increase in labor and

line the process, reducing complexity

hardware costs to achieve a Category

and saving time.

3, Performance Level D system often

Finally, modern VFDs often include

proves advantageous. This proactive

functional safety-rated safe-torque-off

approach allows for potential hazards

(STO) control. This feature enhances

that could elevate the required safety

motor safety control without the need

level to be addressed later in the de-

for additional contactors and safety

sign or commissioning process, with-

wiring, minimizing hardware within

out disrupting budgets or schedules.

the panel and leaving extra space for

Another effective strategy is substituting VFDs for full-voltage direct-on-

Figure 5: Standardizing hardware and panel layouts across systems can significantly reduce overall design time, allowing for greater focus on creating adaptable solutions.

(SOURCE: CONCEPT SYSTEMS)

potential design changes or future system expansion.

line (DOL) starters. This decision has

By standardizing key components

multiple benefits. First, VFDs offer

while incorporating these flexible strat-

motor speed adjustability, which is

egies, control panel designs can accom-

crucial since the exact speed required

modate diverse machine requirements

for a system’s cycle time is often

without sacrificing efficiency, safety or

estimated early on. In fixed motor and

long-term adaptability.

ControlDesign.com / October 2024 / 17

cover story

by Jose Rivera, Control System Integrators Association (CSIA)

18 / October 2024 / ControlDesign.com

cover story

SIs use knowledge of to automate manufacturing and processes from the plant floor to the enterprise level WHAT IS A system integrator (SI)? Most people have an

SIs represent a diverse community providing a broad

overall understanding about their role providing solu-

spectrum of solutions over many industries. Some suggest

tions by bringing components together into a working

that there isn’t a “typical SI.” To better understand these

system. While there are system integrators in many

solution providers, it is necessary to dive into further detail.

fields, this article restricts the term SIs to those working in industrial automation.

SIs specialize along the following categories:

The CSIA (Control System Integrators Association) pro-

• industry verticals/applications

vides the following definition: “System integrators design

• technology

and implement sophisticated control systems for manufac-

• scope of supply (types of services provided)

turing, process and other industrial facilities. Using their

• geographical presence

knowledge of engineering, information technology and

• company setup.

business, system integrators integrate plant equipment to automate manufacturing and processes from the plant floor

Industry verticals

to the enterprise level. Automation helps manufacturers

When asked to select their top-served end markets, up to

and processors reduce cost, increase production, use less

three, SIs selected food and beverage (50%), water and waste-

energy and lower environmental impact.”

water (29%) and OEM/industrial equipment (23%) (Figure 1).

Sls Cover a Diverse and Broad Spectrum of End Market Most significant served end markets (Select up to 3) Food and beverage (including bottling / canning)

50.00%

Water & wastewater

29.39%

OEM / industrial equipment

23.25%

Packaging and material handling

21.49%

Life sciences

21.49%

Chemicals and petrochemicals

21.49%

Consumer goods / Household products

18.42%

Automotive and tire

17.11%

Power & energy

16.23%

Oil & gas

16.23%

Metals, mining, aggregate, cement

14.47%

Data centers

10.53%

Other (please specify) Building automation

7.46%

Defense / Military

7.02%

Semiconductor & electronics Commercial / Institutional Entertainment 0.00%

5.26% 3.51% 2.63% 10.00%

20.00%

30.00%

40.00%

50.00%

60.00%

Figure 1: SIs selected food and beverage (50%), water and wastewater (29%) and OEM/industrial equipment (23%) as their top-served end markets.

SOURCE: SPRING 2023 CSIA - JP MORGAN SURVEY (253 PARTICIPANTS) NOTE: RESPONDENTS MOSTLY FROM USA.

ControlDesign.com / October 2024 / 19

cover story

System-integrator panelists discuss how they’re using digital tools The digital world returns to CSIA Exchange in Dallas

Digital tools have become important assets in the system integrator’s arsenal.

A variety of products and services are changing the way controls automation is utilized in equipment. At the CSIA Exchange in Dallas, which marked the 30th anniversary of the Control System Integrators Association (CSIA) meeting and conference, Tim Ogden, director, solution provider program, GE Digital, led a diverse group of panelists representing the process/ discrete manufacturing industries, industrial automation and manufacturing execution and operations.

All three panelists— Brian Romano, director of technology development at Arthur G. Russell (AGR), an original equipment manufacturer (OEM) that builds equipment; Renato Leal, founder/CEO, GreyLogix Brasil; and Sam Hoff, president and CEO of system integrator Patti Engineering—were part of a similar panel at the previous year’s CSIA Exchange in New Orleans.

PATTI ENGINEERING At Patti Engineering, digital twins and virtual commissioning have become esteemed components in the toolkit. “We’re doing a lot of work using the Siemens product,” said Hoff. “We do a lot of upgrades.” In fact, Patti Engineering shut down a line and upgraded a system the weekend following CSIA Exchange in Dallas. The upgraded system needed to be up and running on Monday after the weekend upgrade.

Patti Engineering’s use of simulation shortens the time to production start. “You have to build a model,” explained Hoff. “The whole idea is to be able to simulate the code and simulate the system beforehand. Maybe you’re building a new line for General Motors (GM); those parts are very expensive for GM to build. There are certifications on drives that are being done digitally now. It does cost a little more upfront, but you’ll save time in the field.”

Hoff also explained the difference between a simulation and a digital twin.

“You have to feed that real-world data back to make it a digital twin,” he said. “Now you

20 / October 2024 / ControlDesign.com

can feed historical data back to the digital twin. In the old days of delivering a system, you handed them a manual and said, ‘Call me when it breaks.’ That’s not a good way of doing business. We have monthly calls with customers and do service calls. Through analyzing data, you can use the twin for what-if scenarios.”

ARTHUR G. RUSSELL AGR’s Romano has been in automation more than 43 years. “We start off at the proof-ofconcept level,” he explained. “I specialize in connecting the factory floor to the business system. We were doing Industry 4.0 before it was a thing.” Romano identified four steps: • expose the date • collect the data • analyze the data • apply the learning.

“My mandate when first coming onboard was to put together a data system that would differentiate us as an OEM that would do things others wouldn’t do,” explained Romano, whose vision was to build that system into the equipment, so the customer could just plug into it.

“We also wanted to offer customers a way to bring the old machines into the digital thread,” he recalled. “Some tools we use go back to legacy stuff, like unplugging a photo eye. How can I go to Industry 4.0 if I can’t bring the full legacy suite into the realm?”

Once Arthur G. Russell got its customers onboard, it took a step back and gave remote support.

“There’s a lack of technical help out there because of the silver tsunami and COVID,” said Romano. “I put together a skills matrix.

I have a spreadsheet for every employee in my department. Some are specific to us, but some are not. By being able to look at the skills matrix, I can assign the right person to the right job. Plus, I can do pairing to train new employees with skills.”

GREYLOGIX BRASIL GreyLogix now has an office in Florida, giving the organization three different touchpoints with customers, said Leal. “We

try to make things simpler,” he noted. “We invested in an online virtual tour, so people can go into our facilities and see what we do. We created a platform where you can navigate through the system.”

When GreyLogix calls on customers, it brings a ready-made opportunity for a user to enter the Industry 4.0 world. “We have a YoT box,” explained Leal. “IoT solutions are a fast-track way for customers to get to Industry 4.0. When we go to the customer, we try to remove the barriers to saying no.

When the customer sees the information from his own machine or process, it’s the kind of solution you can charge as a service, so you have recurring revenue.”

Once the customer sees the information via the YoT box and likes the information, Leal said he hasn’t had a customer that returned the contract.

“We believed in this idea,” he explained.

“It’s the kind of venture that doesn’t pay off from the get-go. We spent some hours and money on that. We started investing in that. During the development, we realized we needed a lot of IoT capabilities. Now our IoT team is a mixture of IT and OT guys.

We have more than 100 of these boxes installed. It’s a process.”

cover story

The first two markets are widely distributed geographically providing many SIs with the opportunity to participate.

There are other industries that tend to be more geographically concentrated, like automotive and oil and gas, thus limiting their appeal.

Delivering solutions requires a

Industry

Industry Examples

Typical Control System

Process

Refining, chemical

DCS (distributed control system)

Discrete

Automotive, Packaging

PLC (programmable logic controller), PC (personal computer) based control

Batch

Brewing, Life Sciences

Either

Table 1: Over time the border lines between categories have blurred as systems have become more flexible.

solid understanding of the needs of the clients. It starts with the selection of the industry vertical and

tion of machines understand they

industry and application, other tech-

includes the industry drivers, regula-

tend to go into certain industries.

nologies such as robotics can come

tions, applications and processes. In

into play. The palette is very broad.

addition, most manufacturing and

Technology

process companies have their own

The selection of the industries and/or

standards and preferences that SIs

applications to serve has implications

Services provided by system integrators

must follow.

for the automation technology to de-

Many SIs engage with clients after

ploy. From the perspective of the con-

the project has been specified. The

• Those serving oil and gas, chemi-

trol system, industries can be grouped

services on a typical project include

cals and petrochemicals under-

into process, discrete and batch. Over

the configuration of the control

stand that they work in explosive

time the border lines between these

system to perform the desired tasks,

and poisonous environments where

categories have blurred as the systems

the integration to other systems or

their processes are to operate con-

have become more flexible (Table 1).

applications, procurement of the

tinuously for long periods of time,

SIs servicing brownfield installa-

automation equipment, construc-

ideally until the next scheduled

tions need to master the existing con-

tion of the control panel, installation,

shutdown. This has big implications

trol system, no matter how old they

commissioning and startup.

for the selection, installation and

are. While the approach to SI project

operation of equipment.

management may be replicable, there

• Those serving the life-science

There are many other services provided:

is a learning curve when it comes to

industries understand that their

the specifics of the various control

• operator (client) training

clients deliver products that are

system platforms. SIs need to invest

• s olution design, functional speci-

consumed—ingested or injected—

in the technical competence of their

by individuals. Food and Drug

staff through continuous education.

• electrical design and construction

Administration (FDA) regulations

Practically, this means that SIs select

• mechanical design and construction

play a key role in ensuring product

a finite number of platforms and ven-

• f unctional safety design

safety. Their requirements around

dors that they focus on.

• cost estimation

validation are of paramount

Technology goes beyond the control

fication

• r isk assessment

importance for this industry. SIs

system, and it includes systems like

• engineering staffing services

serving this industry need to mas-

supervisory control and data acquisi-

• remote monitoring of critical assets

ter FDA validation standards.

tion (SCADA) systems, manufacturing execution systems (MES), emergency

Another way SIs may specialize is

/ processes • data management services.

shutdown (ESD) systems and alarm

through their targeted applications.

monitoring systems. Underneath the

Some SIs engage early with their

This approach is not completely

control system are the field devices—

clients, allowing them to design the

divorced from the industry verticals.

actuators like valves and motors—and

solution. At this stage, the client

The SIs that specialize in the automa-

instrumentation. Depending on the

may only have a vague idea of what

ControlDesign.com / October 2024 / 21

cover story

is needed. Other SIs provide services that keep them engaged after project delivery. This may include the upkeep of a virtual twin of the plant or

Delivering Industrial System Integration Independent System Integrator

machine or operator training to help

System Integration

them leverage procured process or machine data.

Geographical presence

Machine Builder

IT SI / Consulting System Integration

System Integration

Historically, end users favored SIs that were geographically close to their sites. There was little expectation that the selected SI would be able to cover

EPC

Automation Equipment Vendor

End User

multiple plants spread over a wide territory. While this may still represent the prevalent mode, some industries,

System Integration

such as automotive and life sciences, have pushed SIs to develop regional and, in some cases, global presences

System Integration

to support their plants.

Certain geographies favor certain

System Integration

industries—Houston for oil and gas, refining, chemical and petrochemi-

Figure 2: Delivery of system integration by different company types.

cal. This will be reflected in the local SIs. On the other hand, other industries like food and beverage and

Independent system integrator: It is

a key part of their deliverables; some

water and wastewater geographically

estimated that there are around 3,000

offer additional services, often elec-

are widely spread, partially explain-

SIs in North America. This number in-

trical construction.

ing the larger participation in these

cludes many independent contractors

segments by SIs.

that operate by themselves or with

the deliverable includes the me-

Machine builder: In this category,

a small support staff. On the other

chanical design and construction.

Company setup

extreme are SI companies that started

The machines in this category tend

The SI company may take differ-

as independent contractors and have

to be highly tailored and sometimes

ent forms. If the focus is on the way

grown to be large, multimillion-dollar

unique—production of one. Frequently

industrial system integration is

companies, some of them with an

there is a group or division in charge

delivered, then the following options,

international presence.

of the deployment of the automation.

which are neither exhaustive nor mutually exclusive, emerge:

According to the Spring 2023

In certain parts of the world with long

CSIA-JP Morgan survey, 52% of the

machine-building traditions, such

represented SI companies had annual

as Germany, Italy and Austria, the

• independent system integrator

revenues below $10 million and 19%

automation and the mechanical parts

• machine builder

had annual revenues under $2 mil-

are viewed as integral. Some machine

• I T SI/consulting

lion. There are a few large indepen-

builders opt to work with an external

• Engineering, procurement and con-

dent system integration companies

SI company for the automation portion.

struction (EPC)

that have grown successfully past the

IT SI/consulting: The trend to-

• automation equipment vendor

$200 million mark. For these compa-

ward digital transformation/smart

• end user (Figure 2).

nies, system integration represents

manufacturing/Industry 4.0—pick

22 / October 2024 / ControlDesign.com

cover story

To gain the expertise to augment their existing internal capabilities, some automation equipment vendors chose to acquire SIs.

your term—has driven the need for solutions that reach from the corporate level down to the factory floor. IT SIs are companies that often provide solutions around consulting and deployment of enterprise resource planning (ERP) software. For the newer solutions, these IT SIs have either

these companies have a division that

expertise to augment their existing

acquired industrial automation Sis,

handles the automation required in

internal capabilities, some automa-

in this context sometimes referred to

the larger projects of the EPC and/or

tion equipment vendors chose to ac-

as operational technology (OT) SIs, or

procures external projects. Some EPCs

quire SIs. This direct approach is re-

partnered with independent ones.

don’t have an internal SI division, and

served for large, strategic accounts.

they work with third-party SIs.

The rest the automation equipment

Engineering, procurement and construction (EPC): These are large

Automation equipment vendor:

service providers that often deliver

The trend toward solutions forced

civil, mechanical and electrical design

many automation equipment ven-

End user: It used to be common for

and construction of large indus-

dors to adapt their strategies and

larger manufacturing and process end

trial plants or installations. Some of

deliver the full solution. To gain the

users to have their own internal sys-

vendors tend to work together with their network of SI partners.

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cover story

tem integration groups within their

best practices guidelines. His global

global leadership roles. Rivera holds an

engineering departments. As competi-

career in the automation industry,

MBA from Kellogg School of Management

tion forced these companies to focus

including Emerson Electric, Schneider

at Northwestern University, and Lic (MS)

on their core capabilities, many chose

Electric and Siemens, has spanned six

and BS degrees in electrical engineering

to eliminate their SI groups. In some

countries, most often with regional or

from the University of Costa Rica.

cases, the employees of the SI groups saw the opportunity to set up their own SIs companies. While some end users still retain their SI capabilities, the trend over the past decades continues to be to outsource the work.

The role of CSIA The Control System Integrators Association was established in 1994 with the

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and improve their companies. Since its founding CSIA has witnessed significant changes in the SI landscape. Through its annual conference, webinars, podcasts and community of peers it helps SIs stay engaged and up to date.

Summary The term SI is frequently used but often in need of additional explanation.

SIs represent a key entity for the delivery of industrial automation solutions.

They are key for their manufacturing

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CEO of the Control System Integrators Association since March 2015, Jose M. Rivera works to help independent system integrators build better companies through the adoption of the association’s

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EZAutomation

A: Innovation is in my blood, in my DNA. It is food for my soul. I don’t think I can live without it. I deal with it every day.

In 1984, General Motors had decided to buy 100 press lines for the stamping plant. In early 1985, I thought of a resolver with built-in electronics using a flexible potting compound. There was nothing like that on the market. I called the chief engineer of General Motors and told him about my idea. Within the next three days, he gave me an order for $10 million worth of resolvers with no physical sample and no prototype ever built. Sometimes innovation at the right time has great rewards. Sometimes necessity is the mother of invention.

In summer of 2004, we got a notice from our marketing partner with mutual exclusivity that they were going to terminate our contract for stocking and selling our EZTouch product line.

We designed and put in stock 10 new product lines including the EZPLC, the EZTouchPLC and EZMarquee. Our survival was at stake.

Q: You’re calling the EZTouch Series 5 HMI your “China killer.” How has the touchscreen interface been redesigned to make it less expen-

26 / October 2024 / ControlDesign.com

sive than those sourced from China, while still delivering the functionality and support that your customers have come to expect?

A: We went to work to reduce our cost of manufacturing further by more efficient design, investing in more automated manufacturing lines and are proud to introduce EZ5. EZ5 has a newer microprocessor. Its memory is a bit smaller. The number of screens are limited to 64. For most customers, 64 is sufficient, but it retains all the other exceptionally innovative features of HMI— online edit, visibility tags, remote monitoring and control over smartphones, real-time datalogging, email and text alerts, on-screen recipe edit, C Level scripting to save PLC code, and screen life of 50,000 hours at 40 °C. Q: The EZTouch miniPLC combines HMI and PLC functions and features in a small form factor. Given the punch it packs, the term “mini” might even be misleading. Can you talk about the amount of innovative technology per cubic inch that OEMs will find in this component?

A: Perhaps it should be called “mega in a mini size.” The reason we called it mini is because this product has its 4-inch screen size with 27 I/O points and it’s only 5 inch by 4 inch, and it is only 1.5 inch deep. That’s the reason we thought of calling it a mini. The website also has a very nice 360° rotational view of the product to view what it looks like overall. Using EZTouchPLC is a prime example of made-in-America innovation costing less than made-in-China.

Inspiration for this product, as usual, came from talking to our customers. They needed a very compact and thin HMI with PLC integrated in it, 27 I/O, that is 12 dc inputs, eight dc outputs, 4 of 5-A one form C relays, two analog in, one analog out, 250 kHz encoder input. All I/O is wired through plug-in terminal blocks with LED indicators.

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These dc outputs are shortcircuit-proof. We even put in numbers on all relay contact outputs, so the customers do not have to put external numbers costing at least $20 plus labor for each number across the contact. Our customers save at least $200 for each PLC. Besides a very low cost of EZTouch miniPLC at $399 for a 4-inch 27 I/O model. Coming back to the PLC, it’s a high-end PLC with lots of function blocks with a unique drag-and-drop feature in its PLC programming.

HMI design, so they do not want the user to have access to the screen designs using our programming software. Yet they still want to be able to upgrade their HMI screen design from time to time.

With the OEM utility, all the OEM has to do is to email an executable file to the user and without any software just connect the programming port to the laptop with the email in it that the executable file is sent over email. EZ5 on any TouchPLC will do the rest.

There’s another feature that came out of a close customer contact.

This is mini 5’s mini Wi-Fi capability, both EZ5 and mini have the opQ: What benefits come with products tion of inserting a tiny Wi-Fi module to the RS-232 port. that are made in America, and how You can program, monitor, edit your EZ will those benefits carry on into file or mini from 50 feet away and sitting on the decades ahead, in light of the a proper workbench instead of climbing changing technological, financial on obstacles like conveyors or suiting up and political climates? to go near the HMI in an environmentally controlled area.

A: If China attacks Taiwan, there I’ll close by telling you another story. will be complete embargo on ChiYou all know about 24 Vdc fans and sonese goods. There are significant lenoid. You know their wattage and dc advantages of design in made-innomimal current. Let’s say it’s a 6-Watt America products. When you are fan with 250 mA nominal current. It closer to your customers and are should be no sweat for dc outputs in the field in their facilities, you rated at 500 mA,right? design better products such as You build your machine but conThe EZ5 “China killer” has maximum EZTouch with patented HMI online stantly see your PLC dc outputs burning out. horsepower per cubic inch. edit, saving thousands of dollars in changing You tried to contact your automation supplier’s screen design on the fly with zero downtime. No other HMI can tech support, but no luck. Frustrated, you just decide to add external do it. This is American innovation on full display; both EZ5 and 5-A solid-state relays, costing $30 in just relay cost, plus labor. miniTouch PLC have it.

You have four outputs that are giving you trouble, so spend anAnother innovative feature we have is the visibility tag. That is, other $200 in cost plus lose precious panel space. On top of all we lay objects on top of each other and make them visible only this, you want the PLC outputs to be shortcircuit-proof. You do not when needed. This is a great space saver on the panels. Another want to have to install fuses and increase the downtime of the mais C Level scripting that cuts down PLC logic; real time data logchine if something burns out. But the 5-A SSR unfortunately is not ging came out of a personal customer visit at an OEM’s facility. shortcircuit-proof. The problem here is a locked rotor current of This customer makes compressors, and some customers of theirs the fan motor, which is 600 mA, and the inrush current of the fan do not maintain the compressor properly and claim warranty. motor is almost 1 A. This is a real-life story. EZautomation came So this OEM wanted to have real-time data-logging, so that, situp with a current module with eight outputs, each one capable of ting in New Jersey, the OEM can show a customer that their mainhandling 1-A locked rotor current and 4-Amp inrush current, fully tenance did not pay attention to a number of alarms resulting in shortcircuit-proof in a 2-by-2-by-1-inch EZ PLC I/O module. This the motor burning up. was done from notice to production in three months.

Another feature that came from a customer visit was OEM utility. Many OEMs want to protect their intellectual property in the For more information, visit osi.ezautomation.net.

ControlDesign.com / October 2024 / 27

product roundup

Motion makes the difference Controllers, motors and drives enable actuation M.G.M Electric IEC motors and brake motors

are two variants each

M.G.M. Electric IEC standard and brake motors are manu-

for the first products in

factured in Italy and are rated for general-purpose and

the series, the AA3123

inverter duty. IEC motors provide the same power out-

and AA3133 electric

put as NEMA motors but

cylinders. The AA3123

have a smaller footprint

has 5,300 N peak force,

and feature a lightweight

1,300 N continuous force and 0.28 m/s maximum speed, as

aluminum construction.

well as 2,650 N peak force, 650 N continuous force and 0.56

IEC standard motors offer

m/s maximum speed. The AA3133 has 12,500 N peak force,

outputs rated up to 5 hp

2,800 N continuous force and 0.12 m/s maximum speed, as

at 1,800 rpm and up to 1

well as 6,000 N peak force, 1,400 N continuous force and

hp at 3,600 rpm. M.G.M.

0.24 m/s maximum speed.

brake motors are available with outputs rated up to 5 hp at

Beckhoff / www.beckhoff.com

1,800 rpm and feature brakes that are direct three-phase ac coils (no dc rectifier required). Replacement brakes are also available. M.G.M. IEC and brake motors start at $144, and all

Festo dc servo drive

motors come with an 18-month warranty.

The Festo CMMT-ST multi-protocol dc servo drives are con-

AutomationDirect / www.automationdirect.com

figurable for EtherNet/IP, EtherCAT, Profinet and Modbus TCP. OEMs can use the Festo Automation Suite configuration tool to log onto the drive and select a protocol from a

KEB America servo motors

dropdown menu. A single drive for

KEB’s DL4 servo motors are designed to deliver high torque

multiple protocols lowers inven-

and precision in a compact design. They are designed

tory overhead and learning

for demanding indus-

curve. The CMMT-ST and ac

trial applications and

version CMMT-AS are available

offer options for cooling,

globally with fast shipping times.

protection and feedback

Festo / www.festo.com

systems. Available in multiple sizes with torque ratings ranging from 11 to

Yaskawa variable speed drive

520 Nm, DL4 servo motors are designed to deliver perfor-

Yaskawa’s GA800 variable speed drive is designed to

mance for a range of large-power machinery.

control traditional and emerging motor technolo-

KEB America / www.kebamerica.com

gies. The GA800 handles applications ranging from simple fans and pumps to test dynamometers requiring pre-

Beckhoff AA3100 series

cise regulation. The GA800 provides

Beckhoff AA3100 series is designed as a drop-in replace-

network communications, embedded

ment for hydraulic or pneumatic actuators. To simplify re-

functional safety and tools featuring

placement, the AA3100 devices leverage an ISO 15552 flange

mobile device connectivity. GA800

size and bolting points on both sides, as well as an external

frame 12 standard drives include 480

thread mount on the shaft end of the spindle to mount ball

V, 700 to 1000 HP.

heads, clamping hooks or other common adapters. There

Yaskawa / www.yaskawa.com

28 / October 2024 / ControlDesign.com

product roundup

Oriental Motor stepper motor

adaptability. Enhanced by MoviSuite software, Movi-C is

The PKP stepper motor series by Oriental Motor offers two

designed to simplify setup and operation.

phase options: two-phase for high torque and low vibration,

SEW-Eurodrive / www.seweurodrive.com

or five-phase for high accuracy and low vibration. Available in motor frame sizes ranging from 20 mm to 85 mm, the PKP series features an enhanced magnetic and structural

Fuji Electric Frenic-Mega

design. Additionally, the torque in the high-speed range

Fuji Electric Frenic-Mega series

can be increased by using high-current motors. Reducing

is designed to offer high-perfor-

the running current supplied to PKP motors maintains the

mance features and functions,

same torque as conventional products

allowing one product family to

while decreasing power con-

cover a broader range of applica-

sumption. By replacing a stan-

tions. Offering expanded power

dard PK series motor with a PKP

ratings and flexible configurations

Series motor, equivalent torque

that support 1/2 hp up to 1,000 hp,

can be achieved, while reducing

the Frenic-Mega is designed for

the motor size.

industrial applications where standardizing on one product

MiSuMi / www.misumiusa.com

across a facility can lead to increased productivity.

Fuji Electric / www.fujielectric.com

Control Techniques ac drive with NFC technology Control Techniques’ Commander S100 series ac drives,

Omron PMAC controller

ranging from 0.18 to 4 kW (0.25 to 5 hp), are designed to

The Omron CK5M EtherCAT modu-

offer versatile performance for various applications. Avail-

lar multi-axis PMAC controller is

able in single-phase and three-phase options, these drives

designed to remove constraints and

support Linear V to F, Square V to F, and

barriers and maximize a machine’s

Resistance Compensation modes.

capabilities, helping to obtain the best

The integration of NFC technology

performance. The CK5M EtherCAT

and the Marshal app are designed

modular multi-axis controller has

to simplify drive commissioning,

motion control capability with its compact design, multi-

cloning and diagnostics, enabling

vendor connectivity and flexible development capability.

seamless configuration and real-

Omron Automation Americas / automation.omron.com

time monitoring.

Galco / www.galco.com

RS 24 Vdc geared motor The 24 Vdc geared motor from RS Pro is designed to deliver

SEW-Eurodrive Movi-C

durable, high-power performance in a variety of industrial

The Movi-C Modular Automation System from SEW-Euro-

applications. It features an iron core, spur gear and 6-mm

drive integrates drive components, control electronics and

straight shaft, delivers 9 rpm and 600 mN/m torque and

software into a single-

measures 110.10 x 38 x 38 mm. It is also RoHS-

source product. This

compliant, equipped with a three-year

system supports applica-

warranty and backed by the RS

tions from conveyors to

Pro seal of approval based on a

robotics, offering scal-

testing, inspection and auditing

able control technolo-

process aligned with demanding

gies and customizable

international standards.

MoviKit modules for

RS / us.rs-online.com

ControlDesign.com / October 2024 / 29

product roundup

ABB CIP safety

making it suitable for

ABB’s CIP Safety FSCS-21 func-

areas with explosive

tion module is compatible with

gases and combustible

its ACS380 (machinery), ACS580

dust. The model also

(general purpose) and ACS880 (in-

features an IP55 rat-

dustrial) series of drives. Certified

ing. The SP4 product

by TUV, this plug-in safety module

line builds on the

is designed to enable seamless

simplicity of ABB’s ac induction motors. These motors are

integration of ABB drives into a CIP Safety network with

compatible with pumps, fans, compressors and conveyors

any CIP Safety PLC. The module features two built-in safety

and are designed for all industries. The cast-iron motors

functions: Safety Torque Off (STO) and Safe Stop 1, time

cover a power range of 25 to 300 hp, and the rolled steel

controlled (SS1-t), which meet machinery safety require-

models are available in ¼ to 20 hp.

ments up to SIL3/Ple. These safety functions require no

ABB Baldor-Reliance / go.abb/motion

special parameterization, software or safety password.

Simply define the safety network number and EtherNet/IP communication settings and start running your application.

Curtiss-Wright Exlar electric valve actuator

Additional features include support for DLR ring networks

Curtiss-Wright’s Exlar Tritex EVA electric valve actuator has

and predefined safety and non-safety add-on instructions

achieved CSA Class 1, Division 2 (C1D2) Hazardous Loca-

for advanced PLC integration.

tion certification. The Tritex EVA is designed to meet the

ABB / www.abb.com

Methane Emissions Reduction Program (MERP) and Quad-O zero-emissions regulations in the oil-and-gas industry.

ABB magnet-free motors

The Tritex EVA is designed

ABB’s synchronous reluctance motor (SynRM) technol-

to be environmentally

ogy is a magnet-free design reaching IE6 hyper-efficiency,

friendly and efficient with

an anticipated efficiency level ABB defines as achieving a

a compact system integrat-

20% reduction in energy

ing a servo drive, motor

losses against comparable

and roller screw actuator to

IE5 motors. Magnet-free

achieve extreme life, speed and accuracy. Combining the ac-

SynRM motors are part of

tuation system with Modbus RTU communications enables

a wide-ranging technol-

producers to have remote operation and monitoring. The

ogy portfolio that also in-

electric Tritex EVA has been under field test throughout 2023.

cludes permanent magnet

Curtiss-Wright / www.curtisswright.com

(PM) and magnet-assisted SynRM (PMaSynRM) motors covering a wide range of application needs. ABB’s magnet-free SynRM motors are an element in ABB’s premium portfolio

IDEC motion assistance

of high-performance motors.

IDEC’s ez-Wheel Assist Wheel Drive (AWD) EW1A series

ABB Motion / www.abb.com

provides electrical motion assistance for industrial manual material-handling equipment. The EW1A system ‘s main drive unit is available with 150 mm

ABB Baldor-Reliance SP4 motor line

or 160 mm resilient polyurethane

The cast-iron totally enclosed fan cooled (TEFC) severe duty

wheels, and the ability to sup-

motor marks the second phase of ABB’s SP4 technology

port a vertical working load up

launch. This model is designed for applications in hazard-

to 400 kg, and to transfer loads

ous environments with certifications for Division 2 and

up to 1,000 kg. A suspension

Class I Groups A, B, C, D, as well as Class II Groups F, and G,

bracket provides an adapt-

30 / October 2024 / ControlDesign.com

product roundup

able way to add the main drive unit to upgrade any equip-

Parvalux system configurator

ment. All models can accept internal batteries, which are

Parvalux by maxon has designed and manufactured a series

recharged with a specific cable and charger. However, for

of modular components that are mixed and matched so that

greater capacity designers can alternately choose to use an

users get a paired system from one manufacturer. In a three-

external battery pack by means of an adapter cable. Batteries

step selection process, designers can purchase a motor that

operate at a nominal 24 Vdc, with capacities ranging from

is built to order using the

3 Ah to 15 Ah, depending on the model. The wheels oper-

company’s online configu-

ate at about 0 to 5 km/hr (0 to 3 mph) in both directions and

rator. Designers need to

are available with adjustable braking modes and an option

focus on voltage, speed

parking brake. The wheels are rated for indoor use, in non-

and torque in every case.

freezing temperatures and up to 40 °C.

Users of the online configurator can fine-tune their selections

IDEC / www.idec.com

using a range of accessories including brakes, encoders, shaft extension kits and controllers.

Portescap slotted flat motors

Parvalux offers a line of motors that includes permanent

The ECF series of brushless

magnet dc motors, brushless dc motors and single-phase or

DC flat slotted motors, with

three-phase ac motors, all of which are available with inline

diameters as small as 20 mm, are

or right-angle gearboxes. The company’s line of ac/dc motors

designed for robotic applications

are available in series-wound or shunt-would versions. Ac-

where space is limited and per-

cessories, such as encoders and brakes can be selected.

formance demands are high. Their

Parvalux / www.parvalux

compact, flat form factor and high-power density ensure higher load capacity without speed loss, while smooth output torque enhances efficiency. Extensive

Schneider Electric variable speed drive

customization options are designed to make the ECF series

Altivar Solar variable speed drive is compatible with a wide

versatile and able to meet a diverse range of needs.

range of pumps and solar arrays. The Altivar Solar ATV320

Portescap / www.portescap.com

drive is designed to be robust, simple to commission and easy to integrate for pumping applications. The drive embeds solar-specific functions to

Bardac loadcell tension controller

address application requirements

The smarty7, fully programmable, four-channel control-

and improve pump performance. Key

ler has selectable inputs for all common types of loadcells

features for the Altivar 320 Solar in-

and is integrated into drive systems to provide accurate

clude intelligent algorithm to detect

load and tension control.

solar panel parameters; dual supply

The basic model dw250-

to change over alternatively from so-

1210, designed and built

lar to grid and vice versa; Ethernet/IP

in the USA, includes drive.

option module to allow Altivar Solar

web Ethernet for interface

drives to be integrated into scalable

to drives and plug-and-play

automation systems; safe pump operation with built-in pro-

interface to savvyPanel

tections like dry pump protection, pump overload, tank-full

touch screens. Diameter compensated winder controls and web splice logic can be added. Multiple

detection, over-voltage and under-voltage fault protection; low operating voltage range, allowing for extended pump-

controllers, drives and touchscreens can be networked

ing hours, early in the morning and late in the evening; and

peer-to-peer over Ethernet for a complete system in one

anti-jam function to enable auto pump cleaning through

homogeneous technology.

forward and reverse movement.

Bardac / www.bardac.com

Schneider Electric / www.se.com

ControlDesign.com / October 2024 / 31

real answers

How much is too much stacklight?

A CONTROL DESIGN reader writes: I’ve seen basic standard stacklight colors on machines for years, but now it seems there are a variety of other colors for various conditions.

Are there any downsides to adding colors or flashing patterns? Do they confuse operators? And what about “smart” stacklights with advanced communication technology? Is it overkill, or are we missing an opportunity by not including them on our machines?

Answers Safety and uptime The evolution of stacklight colors and patterns offers a range of perspectives. To begin, it’s essential to understand the standards relevant to your industry. NFPA 79, Section 10.3.3 and the OMAC PackML guidelines are widely recognized in machine automation and control. However,

(SOURCE: CONCEPT SYSTEMS)

many industries have their own formal and informal standards, so thorough research and alignment with your specific application are critical.

Figure 1: The primary purpose of a stacklight is to draw attention to a specific condition and provide clear guidance on the necessary action.

At Concept Systems, clarity and predictability in automation systems are paramount. The functional design document (FDD) should clearly outline what each stacklight

Some fun and innovative examples of modern stacklight indications go beyond simple machine status and are now

signifies, and this should be reviewed and approved by the

broadcasting analog values such as tank levels and produc-

end customer. During startup and training, it’s crucial to

tion speeds with stack indicators that illuminate from the

thoroughly test the stacklights and ensure operators are

bottom up to show levels. These modern stacklights can also

fully trained on their meanings. Providing robust reference

alternate to show levels vs. multiple light patterns to depict

materials for future training is also vital to eliminate any

various pieces of information with RGB lights to give way

ambiguity regarding what each indicator represents.

more indication possibilities to communicate process status.

The primary purpose of a stacklight is to draw attention to

Interactive use is now becoming more common where lights

a specific condition and provide clear guidance on the neces-

that give operators specific repones to actions by visually

sary action (Figure 1). With advancements in technology, the

responding to inputs such as transitioning an alarm to an

options for visual indicators have never been better. The key

acknowledged or reset state by varying color or brightness.

is to adhere to established standards and meticulously document what each indicator represents and why.

Ultimately, whether these enhancements are considered overkill or a missed opportunity depends on the specific

In modern plants, visual indicators are crucial for

needs of your operation. As the adage goes, “A penny saved

enhancing process visibility, with the ultimate goals

is a penny earned.” Continuous improvement is essential,

of improving safety, maximizing uptime and stream-

and staying ahead means embracing innovations that offer

lining troubleshooting. When used effectively, modern

genuine value.

light indicators enable operators to manage more tasks

SAM CAFFERATA

remotely, relying on visual cues to determine when their

principal engineer / Concept Systems, system integrator in Albany, Oregon

attention is required.

CSIA-certified member of the Control System Integrators Association (CSIA)

32 / October 2024 / ControlDesign.com

real answers

Flexible and smart

as for indication of a certain aspect of the process. There are

When evaluating new technologies, one must ensure that

a few examples I could provide.

the technology adds either efficiency value or utility value that makes your system better than before and competitive.

One of the advantages of multi-colored stacklights is that

Utilizing this light on top of the bowl feeders to indicate the amount of material inside the bowl-feeder system or showing temperature of the boilers along with machine state,

they can provide more specific feedback about the process

or showing the state of the pallet in a palletizing applica-

and not only the state of the machine. For example, beyond

tion, so that the forklift driver moving around the plant can

the three lights, a fourth light with a different color could

determine which palletizing machine needs to be attended

indicate machine issues due to material shortages, or a dif-

first, avoiding unnecessary stoppages of the system due to

ferent color could indicate electrical-maintenance needs or

unavailability of the forklift.

mechanical-maintenance needs.

Having this multi-colored option could help tremendously

Some of these smart lights also offer another feature called run-light mode, in which there is a running segment

with deploying the right resources to handle the situation

and a background segment. Based on the severity of the in-

from the get-go. This also helps with documenting issues and

dication need, the running segment speed can be adjusted,

offers continuous-improvement opportunities.

as well as the color can be defined to indicate process-relat-

Now combining multi-color options with state-of-the art communications technology could offer even more efficiency and utility benefits. The advent of multi-colored LEDs and

ed status. Background segment can be used as indication of the health of the machine or, simply put, as a stacklight.

As an example, the background color green could indicate

communications, such as IO-Link, not only improved the en-

machine is operating fine, but yellow running segment could

ergy efficiency but also added features like making the same

be indication of material flow is slowing down and could be

three-stack-high lights change colors and change styles.

an issue if not addressed soon (Figure 2).

I already explained the benefits of color or blinking,

Additional features of these smart lights, such as chas-

providing added information, now let’s talk about style.

ing light or adjusting colors, intensity of colors, blinking and

We all have used stacklights as one and the only style to

frequency of blinking, all can be adjusted due to IO-Link or

demonstrate the state of the machine. Now with IO-Link

similar communications. IO-Link-based smart lights would

technology, we can change that same stacklight as a level-

also simplify cabling as there is single three-pole cable that

indicator light or a run light.

connects directly into the IO-Link master ports providing

As a level indication, one can map 8-bit or 16-bit status of

flexibility, as well as functionality.

measurement to the smart stacklight, and the light will now

In summary, my suggestion is to evaluate particular

indicate state of that measurement—may it be distance, tem-

applications or situations to see if adding these features

perature, pressure or anything else, for that matter, utilizing

improve plant-floor efficiency or add any utility value before

the same smart light for indication of machine state, as well

selecting these smart lights that offer a lot more than just stacklight functions.

If you already have IO-Link on your automation, it is practically a no-brainer to add smart lights to the system that allows replacing laborious wiring and assembly and further reduces hardware in the control panels.

SHISHIR REGE automation and technology specialist, IIoT, smart manufacturing / Balluff

Let your application and culture be your guide Traditional modular stacklights come in various colors, flashing patterns and rotating effects. Engineers in different departments place orders with purchasing and then wait (SOURCE: BALLUFF)

Figure 2: The background color green could indicate machine is operating fine.

until all parts have arrived before installing them on their machines. But this is where the problems begin:

ControlDesign.com / October 2024 / 33

real answers

• What if one or more color segments are delayed?

want to apply? In which environments will these be used?

• What if engineers working on different machines choose

Your specific application and company culture will likely lead

different color schemes? Will this result in more spare

you in the right direction (Figure 3).

units having to be kept in reserve?

MICHAEL MCCABE

• If a specific flashing pattern is not available, is it okay

product manager / Pepperl+Fuchs

for the engineer to spend extra time programming that pattern into the programmable logic controller (PLC) or

The integrated factory floor

control system?

Flexibility is the name of the game today on the factory floor.

Can there be too many colors? I’m not sure, but as pro-

While the standard five colors are effective and universal,

cesses become more complex, engineers may overload each

what do we do in custom situations? Let’s say you have a pal-

color with different meanings, leading to possible confusion;

let station on a factory floor. You need a pallet moved to the

this also means more training costs. Fewer colors can lead to

next station. One option might be to add another color to the

more stoppages if detailed or specific information cannot be

light stack, like purple, to call the fork truck. With advance-

adequately communicated.

ments in stacklight technology, this is now achievable.

And this is not just a question of too many colors, a signal

Stacklight manufacturers have been redesigning the way

light can come with different modes:

we think of stacklights for a couple of years now. We now see

• t raditional stacklight mode

RGB LEDs, connectivity, buzzers, sirens and even modularity

• autoscale mode—all nine segments are used here, regard-

where you can build your own. All these new advancements

less of whether you select one color, two colors, six colors • filling-level mode —an analog signal indicates the fill percentage • individual mode—each of the nine segments can be con-

mean added flexibility for the factory floor.

Recently, I was on a factory tour where the manufacturer incorporated Microsoft Teams into their design. Using andon stacklights with a pre-programmed keypad, the worker could

trolled individually.

send an automated message through Teams to the floor

Is there too much complexity with newer signal lights?

supervisor while also illuminating a “help needed” light.

The answer is: It depends. How simple do you want ordering

The five standard colors are still necessary, but the added

to be? How much flexibility do you want in the future? How

lights provide flexibility. From calling fork trucks to calling

easy do you want the installation to be? How much informa-

a floor supervisor, the factory floor is more integrated than

tion are you looking to communicate? What branding do you

ever. These new stacklight capabilities are a great tool for any factory floor looking to increase efficiencies and process improvements.

ERIC J. HALVORSON senior marketing technology manager, automation & control / DigiKey

IO-Link-capable signaling columns Some signaling columns can be controlled either via conventional wiring or via IO-Link (Figure 4). In the conventional version, parameters are assigned in advance via a USB interface. The IO-Link-capable signaling columns can be configured at any time, both from the program or from the PG/PC with an active online connection to the CPU. At the same time, the IO-Link-capable signaling columns have all the advantages that come with using IO-Link devices.

Figure 3: How much information are you looking to communicate?

What branding do you want to apply? In which environments will these be used? Your specific application and company culture will likely lead you in the right direction. (SOURCE: PEPPERL+FUCHS)

34 / October 2024 / ControlDesign.com

Adding colors and flashing patterns enhances communication. More colors and patterns can convey specific statuses or alerts, improving clarity and response time. Customizing different colors and patterns can be tailored to specific

real answers

Figure 5: Simplifying the color schemes on stacklights, using universally recognized colors, such as red for stop, green for go and yellow for caution, can reduce confusion, improve safety and ensure that all operators can effectively manage machinery.

(SOURCE: RIPPLE INDUSTRIES)

Figure 4: Some signaling columns can be controlled either via conventional wiring or via IO-Link. (SOURCE: SIEMENS)

processes or machinery, making it easier to identify issues

Simplifying the color schemes on stacklights, using well-

quickly. Operators must be trained to recognize the different

established and universally recognized colors, such as red for

colors and patterns.

stop, green for go and yellow for caution, can reduce confu-

Having a stacklight with advanced communication can

sion, improve safety and ensure that all operators, regard-

provide real-time data and diagnostics, improving overall

less of their color vision capabilities, can effectively manage

efficiency and maintenance. IO-Link allows for remote moni-

machinery (Figure 5).

toring and control, reducing the need for physical presence.

Finally, these signaling columns can be integrated into larger automation systems, providing a more cohesive and intel-

JEROMY PETERSON owner and CEO / Ripple Industries, system integrator in Florence, Arizona member of the Control System Integrators Association (CSIA)

ligent operation.

ROBERT GUAJARDO product manager / Siemens Industry USA

Define your requirements Indicator-light color conditions are somewhat subjective.

The standards agencies have touched a lot of what we do in

Beware of color-blind ambition

automation but have just generically addressed indicator-

Using too many colors on stacklights for machines can

light color coding. Referencing NFPA 79, Section 10.3.3, the

lead to significant issues, particularly in environments

use of color indication is quite open. In layman’s terms,

where quick and accurate interpretation of signals is

NFPA basically repeats the “red bad, green good” with yel-

critical. One of the primary concerns is the potential

low in the middle—more technically, yellow represents a

confusion caused by an excessive variety of colors. When

warning condition. IEC 60073-2002 also addresses indicator

operators are presented with a wide range of colors, it

color coding. You may find our information in our applica-

becomes challenging to quickly distinguish between

tion guide for indicator lights useful.

different states or alerts. This can slow down response

In recent years, multi-color LEDs have become much more

times or even lead to incorrect actions, which can have

flexible to work with for designers. These LEDs have concur-

serious safety implications.

rently become more suitable for use in industrial environ-

Another crucial factor to consider is color blindness. Ap-

ments. This is opening up possibilities for more functionality.

proximately 8% of men and 0.5% of women are affected by

More colors will be visible in industrial environments in the

color vision deficiencies, which can make it difficult for them

same form factors. Logic chips will add functionality and

to differentiate between certain colors. When too many col-

communications capacity.

ors are used on stacklights, individuals with color blindness

So, this expands the application potential of a well-

may struggle to interpret the signals correctly, increasing the

established automation component. This may add a layer of

risk of accidents or machine malfunctions.

complexity or it may increase the net effect in the application

ControlDesign.com / October 2024 / 35

real answers

of more colors, more patterns or more communications. Is

to knowing if the unit is operating correctly. However, the

that good or bad? Yes. It is both.

machine’s maintenance personnel might be better with a

The base use of indicator lights will not change because

multimeter than with a computer when troubleshooting.

they can do more. When operators cross-train on multiple

It’s up to designers to evaluate what’s appropriate for the

machines in a facility that do different things, it is often

user relative to the ongoing ownership of the machine.

a good strategy to keep the visual indication simple and

Let’s examine industrial communications protocols and

generic across equipment—“green good, red bad”—so it’s

then apply them to indicator lights. Industrial communica-

meaning stays coherent from machine to machine.

tions protocols require a large, slow-moving investment by

However, there are instances where the device’s enhanced functionality will increase the net result. Our expe-

the manufacturers developing them.

The protocols don’t always have staying power over

rience with visual-communication products is that the

time. The difficulty for designers is to decide which

best use of enhanced features is for very specific, defined

communications protocol to deploy. It must be techni-

requirements. Here are some examples.

cally suitable for the requirements. And, ideally, it will

Example 1, coil unwinder: Material feeding a long fabrica-

be around until after we retire. When a protocol loses

tion line comes off of a powered unwinder. The state of the

staying power, that can leave a trail of machine longevity

material on the unwinder is well-defined. If there is plenty

issues. Obsolescence is a very serious issue for machine

of material, the operator can tend to other areas of the line,

ownership. Modbus, for example, has longevity built on

such as the cut head area to collect processed parts. If the

a recipe of simple, reliable operation. Manufacturers can

material runs out, the line makes nothing. If it’s low, the

deploy it in products easily across multiple media. IO-Link

operator should start thinking about splicing or queuing up

is younger and is establishing itself. It’s at a different

the next coil. A single segment multi-color indicator is well

point in its lifecycle. EtherCAT and EtherNet I/P quickly

applied here. This is one that has only one color segment

found their place, mostly on the back of improving mo-

that can be any color the process requires. The state of the

tion control. Stacklights could live on any of them if the

coil is an OR condition. If it’s empty, a tangle is detected, or

manufacturers offer those options. So, it’s more a matter

an e-stop violated, then the indicator turns red.

of what the market has made available. We see the main

When the coil is low, it’s yellow, looking for a splice or

reasons for network deployment as reducing wiring,

replacement soon. Green means all good—the line is making

adding flexibility for application specific requirements

money. The operator can see it from up and down the entire

and monitoring performance or status information. It

line for immediate status.

falls on the designer to decide if using a network makes

Example 2, tank level: Tank level can be coarsely dis-

sense over a hardwired deployment. Selecting a network

played visually with an indicator light. There are a few

requires thought about performance for all devices, cost

ways to do this. A five-color segment can be used to dis-

of deployment and longevity of the machine.

play low-low (red), low (yellow), acceptable level (green),

The promises of single-pair Ethernet (SPE) could mud-

high (yellow) and high-high (red) in the sequential seg-

dy the waters further in the not-too-distant future. As a

ments top to bottom. It can also flash all segments red on

media layer, SPE is, to an extent, protocol-agnostic. SPE

a pump-failure condition.

can deploy systems with Profinet, EtherCAT, EtherNet I/P

These are useful, dedicated applications of enhanced features which should be well-received by users who under-

or Modbus TCP/IP, or a mix of them. We are watching its development closely.

stand the visual messaging of the process.

LEE CLORE

Communications is another layer of functionality that

owner and controls designer / Onyx Industries

is expanding on visual communication components like stacklights. We see communications capabilities as quite

Keep traffic moving

useful; however, there are questions about what form that

The versatility of a stacklight allows more machine condi-

will take. Controlling an indicator light over a network

tions to be indicated by adding light modules with differ-

reduces wiring and increases control capacity. Making the

ent colors if required, thus preventing the use of a second

LED current draw data available over a network is useful

visual indication in the machine. In addition, some orga-

36 / October 2024 / ControlDesign.com

real answers

nizations have been recommending the implementation

Align stacklights with alarm tones

of certain color standards in the stacklight to enhance

It is essential to ensure that each color and pattern has a

the comprehension of operators by having a common

distinct and clear meaning and is well-documented with easy

interpretation of the status of the machine—Pack ML

access. Smart stacklights, equipped with advanced commu-

introduced by OMAC—where the light color, function and

nication technologies, such as wireless connectivity (Wi-Fi)

pattern are standardized within the facility to minimize

and various messaging protocols, such as Modbus or message

the risk of operator confusion.

queuing telemetry transport (MQTT), offer significant advan-

It really comes to the application itself. While a standard tower-light arrangement can be enough to inform the

tages for better connectivity and situational awareness.

An application of this can be in a control room with many

operator of the status of a machine, the use of a smart tower

operator consoles. The challenge of managing multiple

light regardless of the communication technology, can bring

alarm priority tones from different operator consoles can be

additional benefits. Most of these devices can be cond to cer-

overwhelming, especially when alarms of varying priorities

tain colors, functions or patterns, minimizing the number of

sound simultaneously. To address this, it is recommended

part numbers to keep in inventory. Another inherent benefit

to use stacklights alongside a common alarm tone.

of the use of a smart stacklight is the wiring reduction,

Each operator console can be fitted with a stacklight that

which will translate to quick plug-and-play installation,

displays the highest priority alarm received at that console

commissioning and troubleshooting of the stacklight itself.

at an instance. A unified tone can alert operators to the

Compared to a standard tower light, a smart tower light

presence of an alarm, while the stacklight indicates which

provides the possibility to gather real-time data, measure-

console requires attention. This system helps quickly iden-

ments and diagnostics that can contribute to minimized

tify the console in need, even if operators are not at their

downtime with proactive maintenance scheduling and

consoles. The operators can then more efficiently navigate

increased productivity. In this case, most of the information

the alarm HMI to identify and address alarms based on its

will be consumed above the operator level.

priority. This approach not only improves response times ALVARO SANCHEZ

global product manager, signaling products / Rockwell Automation

but also reduces the nuisance caused by multiple annunciating alarm sounds from different consoles.

JOHNSON VARGHESE

Safe, efficient and better operations

systems consultant / Yokogawa

By providing immediate visual feedback, tower lights contribute to a safer working environment by providing easy-

Smart stacklight highlights

to-understand information, like changes in machine status

Stacklights, or signal towers, have used a limited color pal-

or emergency situations, even in noisy and busy environ-

ette such as green for regular operation, yellow for caution,

ments. Smart tower lights are gaining popularity for con-

red for emergencies, blue for maintenance and white for

nected systems, processes and machines, as they allow for

specific statuses.

different, more unique setups and quick configuration and

However, implementing an expanded range of colors and

give the user the ability to collect data in different ways.

patterns dramatically enhances the ability of stacklights

These devices have evolved to offer new levels of

to communicate a broader array of conditions and can help

customization, including flashing light patterns, differ-

relieve visual signaling confusion when carefully applied.

ent sounds and pre-recorded messages to help operators

With the right options, stacklights convey more detailed in-

do their jobs better, more efficiently and, most important,

formation about machine statuses, warnings and operational

more safely.

states. By incorporating additional colors and dynamic light-

By customizing these to your machines or to a user’s specific needs, you can ensure that they communicate that critical information where and when needed most, without confusing the operator.

ing effects—such as blinking, flashing or rotating patterns— signals can draw immediate attention to urgent events.

This ability to catch the eye quickly ensures operators can respond more effectively and efficiently to critical situations

PATRICK CASEY offer manager, control & signaling / Schneider Electric

(Figure 6). The added detail and projected urgency enhance overall safety and operational efficiency, making it easier for

ControlDesign.com / October 2024 / 37

real answers

workers to understand and react to the

These advancements ensure that

and controls locations and colors for

the interaction between machines

pushbuttons, operator interfaces and

The introduction of smart stack-

and operators is more straightfor-

signal lights. This standard also gives

lights with advanced communication

ward, more detailed and more effec-

the requirements of whether lights

features marks a significant step for-

tive than ever before. The modern

should be flashing or not.

ward in industrial signaling. Digital

signal tower stands out with its

communications—using an industrial

improved performance, offering more

protocol such as IO-Link—enable a

colors, effects, and individuality.

multitude of signals to be transmit-

Incorporating dynamic lighting pat-

tiating icons of color graphic interface

ted over a single cable and provide

terns further enhances its capabil-

devices shall be color-coded in accor-

easy integration with program-

ity, ensuring that urgent events are

dance with 10.2.2.1 through 10.2.2.6.

mable logic controllers (PLCs) typi-

unmistakably highlighted, ultimately

cally tasked with driving stacklights.

leading to safer and more efficient

what red, green, yellow and other

Modern stacklights offer extensive

industrial operations.

colors shall be used for. Keep in mind

communicated information.

customization options tailored to specific operational needs, including

LENNY FILIPKOWSKI product manager / AutomationDirect

real-time monitoring, security alerts

For instance, NFPA 70:2021—Section10.2.2 Colors states: Pushbutton actuators and action ini-

Preceding this, the standard states

that in some standards, “should be” or “should have” is a recommendation, whereas “shall be” or “shall have” is a

and adaptable signaling modes. This

Stick to the stacklight standards

level of customization, coupled with

The ability to add and modify light col-

the latest LED technology, ensures

ors for signaling has been a challenge

that smart stacklights will continue

for decades. Consider the automotive

play an essential role in improving

arena for a moment before diving

Section A.10.3.3 gives the color order

safety and operational efficiency in

into the commercial and industrial

from top down for stacklights/indi-

industrial settings.

arenas. For example, take a look at the

cating towers.If we are striving for

automobile brake light. How confusing

consistency to minimize confusion,

would it be if we could have any color

then the standards are what we must

for brake lights? What if some automo-

follow. Even the color order in NFPA

tive users installed blue brake lights?

A.10.3.3 can be confusing because

Would it convey the same meaning?

the appendix in the standard is not a

What about the color of turn signals?

requirement but a recommendation.

Even in the red spectrum, from pinks

Did you catch the “should have” in

to oranges to purples, how many varia-

Section A.10.3.3?

(SOURCE: AUTOMATIONDIRECT)

38 / October 2024 / ControlDesign.com

Section and Table 10.3.3 gives the requirements for indicator lights.

In the appendix of NFPA 79:2021,

tions of red have you seen for automo-

We must strive for consistency,

tive brake lights? The answer should

because, in consistency, we find safety.

be no variation in color.

Therefore, we must find a solution that

Just like there are automotive stan-

Figure 6: The ability to catch the eye quickly ensures operators can respond more effectively and efficiently to critical situations.

requirement.

resolves every situation. The Interna-

dards that dictate what the standard

tional Electrotechnical Commission

light signals shall be, there are com-

(IEC) standard helps meet this goal.

mercial and industrial standards that

Unlike the NFPA 79, IEC standards are

do the same thing. NFPA 79 is the North

accepted in Europe and other countries

American standard for electrical and

where local standards do not supersede

industrial machinery. This standard of-

the international standards.

fers guidance from sizing and selecting

The international electrical standard

appropriate electrical wires and com-

is IEC 60204-I:2016, and it aligns with

ponents to marking signs. It also covers

NFPA 79 in this case, the general

requirements that include equipment

requirements standard for machine

real answers

safety and electrical equipment of ma-

of deviation management processes,

responds promptly and appropriately

chines. Table 4 in this standard defines

which are crucial for maintaining

to the signals, thereby maintaining

each color along with the appropriate

production flow.

smooth operations.

recommendation (“should have”) for

The ability to customize light signals

RAFA PAREDES

the color order. As system integrators,

to match a site’s unique visual manage-

general manager / Bosch Rexroth

we must strive to adopt the required

ment requirements is a major advan-

colors along with the recommended

tage, as it facilitates quick reactions

Keep your stacklights simple

color order to eliminate confusion in

to deviations and reduces lead times.

There are standard practices which

the event personnel transfers to other

This is particularly effective when

are common to the industry. How-

companies or industries.

the system is linked to an electronic

ever, each organization may have

communication network, such as text

different needs. Adding colors or

messaging or email alerts.

flashing patterns can have both ben-

Smart stacklights with advanced communication technology can be helpful to transmit information about

For this system to be effective, it’s

efits and downsides. Some downsides

production status, maintenance or

critical that operators and the sup-

of adding more colors could include

downtime—for example, from 0 to

port team are thoroughly trained on

increasing the height of the stack-

100%. The color of these stacklights

the significance of the light colors

light when there is not adequate

should be used with respect to the

and the andon process. With proper

room available or reducing visibility

colors indicated by the standards.

training, the risk of confusion is

and line of sight to all of the colors in

Again, one must consider consistency

minimized, ensuring that everyone

the stack. Adding flashing patterns

to eliminate confusion.

KERRY WHITE discrete manufacturing industry leader / Hargrove Controls & Automation system integrator in Mobile, Alabama CSIA-certified member of the Control System Integrators Association (CSIA)

Lean-manufacturing tool Light indicators offer significant benefits for visual management, especially when integrated with andon systems. The use of LED technology provides color flexibility beyond the traditional green, yellow and red signals. This adaptability allows companies to tailor light indicators to their

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Andon is a key component in lean manufacturing, serving as a visual management system that alerts operators and managers to deviations on the production line or within a cell in real time. This immediate notification enables the activation

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real answers

can have downsides, as well, such as confusion due to

Leverage your options

the difficulty of distinguishing between different flashing

Stacklights, also called light towers, range from very basic

patterns. With these downsides being noted, clear docu-

lights to advanced communication devices; they vary in size

mentation and proper training can mitigate any confu-

and function. There are single-tier and up to five- and six-tier

sion to operators, technicians, production managers and

towers, all with different options; some flash or have alarms

manufacturing support staff.

and buzzers, some have programmable colors and patterns.

One thing that is often left out of this discussion is consid-

Depending on your application and specific function needs,

eration of the number of people who are colorblind, which is

you may only need something very basic, but many custom-

about 8% of the male population. That means that the pos-

ers today are looking for all-in-one type products, which

sibility of one out of every 10 employees would find multiple

gives them flexibility in application. Color variations other

colors worthless, or even dangerously confusing. We have

than standard red, yellow and green give additional flexibility

all heard of the KISS acronym—keep it simple, stupid. With

for specific communication, especially in industrial environ-

stacklights, remember KYSS—keep your stacklights simple.

ments where there are other lights and something that will

The Americans With Disabilities Act (ADA) considers color

stand out is needed. Various colors also allow more specific

blindness a disability that you would need to make accom-

and detailed information on machine status or problems.

modations for. Someone with colorblindness would need to

Green usually means things are working, everything is oper-

remember the position of the colors. Having too many colors

ating correctly; yellow may indicate a warning; and red may

in the stack could lengthen reaction time.

indicate an emergency or another type of problem, somewhat

Another consideration is a worker with a seizure disor-

similar to a traffic light. Often there is a need for other colors

der. Would a flashing light trigger a seizure? Do you know

for other situations so you may see blue or white lights. Blue

if any of your workers have a disorder? Are you allowed to

and white can often be used in a safety area, or they can be

ask? My point is that there is more to the colors-and-flash-

used to customize application-specific needs, such as when a

ing-patterns question that goes beyond a simple analysis

machine is off-line or not in use. Flashing colors can be used

and needs to be considered for your particular work envi-

to designate severity of situations; for example, red could

ronment and the litigious times we live in.

indicate a machine issue, but flashing red could indicate an

While “smart” stacklights are clearly the wave of the

emergency or a catastrophic failure of some sort.

future, they require more effort during planning, procur-

Additional colors and functions can be very useful; it’s

ing, initial setup and maintenance. Smart stacklights, with

important to have all workers trained on the meanings of

nearly unlimited options, can allow for maximum custom-

stacklights, regardless of which type is used. This will elimi-

ization and specificity but also decision paralysis and more

nate any confusion.

difficult troubleshooting.

Although these last points represent both pros and

(SOURCE: RS)

cons, the advanced communication technology associated with smart stacklights is most certainly a positive feature which can be leveraged for optimum results. For example, in a scenario where the primary manufacturing support staff or design engineers are not located within line of sight of the equipment, the advanced communication technology can alert those personnel, no matter where they are decreasing the time for resolution and maximizing equipment uptime.

In my opinion, whether smart stacklights are overkill or an opportunity depends on each organization’s needs, as well as the infrastructure to support it.

NEIL BUZZARD global product marketing manager / c3controls

40 / October 2024 / ControlDesign.com

Figure 7: Individuals can see status and colors of light towers remotely, without even being in the facility, if necessary, allowing them to better monitor multiple or large facilities.

real answers

As technology has advanced, so has the communication ability of stacklights. As with most things now there

and ability to track trends, reduce downtime and optimize workflows give factories a competitive edge.

are various options of smart and IIoT-enabled stacklights.

CLIFF ORTMEYER

There are many benefits to these in today’s connected world.

head of solutions / Newark

Remote monitoring is an increasingly needed function. Now, individuals can see status and colors of light towers remotely,

Benefits plus flexibility

without even being in the facility, if necessary, allowing them

The biggest benefit of using a stacklight is its ability to provide

to better monitor multiple or large facilities (Figure 7).

visual indication and status information in industrial environ-

Real-time monitoring is a benefit that goes hand in hand

ments. Smart signal towers offer this benefit plus some added

with remote monitoring; advanced stacklights can provide

flexibility. Not only can you adjust the color display as you

instant feedback. Data collection is another valuable function

wish, but you can also configure the segment size. In case of

of smart stacklights. Data can be monitored and collected

many different colors, some customers might add extra text

over periods of time and stored so it can be analyzed and

displays beside the lamps. On the other hand, with the smart

used for predictive maintenance.

versions, you can still use the standard feature set with seven WILL MORRIS

standard RGB colors. The use of advanced communication

category manager / RS

technologies is a trending topic. It’s important to evaluate which technology makes sense or adds extra value.

Simple and smart

TOBIAS WIENS

The evolution of stacklights from conventional red, yellow

product manager / Balluff

and green to a wider palette of colors and advanced functionality presents both opportunities and challenges for the industrial environment. For example, an unwell-trained operator may misread the color display. Also, an operator with color-vision deficiencies may encounter some problems in distinguishing between some colors, which can lead to safety risks. The stacklight usually flashes to alert the operators about any impending danger. With more colors and flashing signals, there is a good likelihood that operators might become complacent with the alerts that can easily be

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ignored. Too many signals result in information overload, making it harder for workers to prioritize alerts.

Therefore, adopting best practices becomes crucial. It’s important to limit the introduction of new colors and have a standard meaning of the color throughout the facility. Complementing the visual signals, for example, with audible alarm or HMI display, would enhance this kind of messaging. Regular training to make the operators aware of what these signals mean would also reduce confusion and enhance safety.

Smart stacklights offer real-time monitoring, customizable colors, audible alarms and analytics by integrating with IoT systems. They can send data to remote locations, providing alerts on machine conditions, predictive maintenance and performance trends. They enhance troubleshooting, safety and efficiency through detailed machine-health insights. Is it overkill? No. Smart stacklights allow for scalable, data-driven systems that improve operational efficiency. Their flexibility

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Joey Stubbs joey.stubbs@gmail.com

What is a panel PC? BACK WHEN I BEGAN my post-college career as a controls

The robustness of panel PCs also extends to their ability

engineer, I was put on a development team working on a

to handle the physical demands of industrial environments.

new generation of machinery for the fiber optics industry.

They are built to endure harsh conditions such as high

The controls architecture we were using was somewhat

temperatures, humidity and exposure to various chemicals.

dated; okay, even for back then, it was very dated. A sepa-

This ruggedness translates into fewer breakdowns and

rate motion processor, a programmable logic controller

lower maintenance costs, contributing to increased produc-

(PLC) and a human-machine interface (HMI) processor, all

tivity and operational efficiency.

in a Versa module Eurocard (VME) rack talking dynamic

One of the most significant advantages of panel PCs is

data exchange (DDE) protocol so the HMI program could

their lack of moving parts, such as fans and rotating hard

understand and display the

drives. Panel PCs typically use

process parameters on a monochrome monitor with a touchscreen overlay.

Thanks to the evolution of PC processors, now all three of

solid-state drives (SSDs) and

Factory environments are often subject to dust, debris and moisture.

the functions that used to be

passive cooling systems.

Industrial environments often experience extreme temperatures, ranging from freezing cold to intense heat. Panel PCs are de-

separate processors—the mo-

signed to function reliably across

tion processor, the PLC and the HMI processor—can all

a broad temperature range. Many models are engineered to

be software modules or even just one software suite run-

operate effectively in temperatures ranging from -20 °C to

ning on a single powerful central processing unit (CPU)

+60 °C (-4 °F to +140 °F), ensuring their performance remains

inside an industrial PC (IPC). Also, the form factor of that

consistent regardless of external temperature fluctuations.

IPC can be quite a bit different than the desktop or rack versions of days past.

Factory environments are often subject to dust, debris and moisture, all of which can pose significant chal-

In factory automation, this quest for enhanced efficien-

lenges. Panel PCs address these challenges with enhanced

cy, reliability and durability keeps driving the development

ingress protection (IP) ratings, which indicate their resis-

and adoption of new IPC designs. One such advancement is

tance to dust and water.

the panel PC—a combined unit of a PC and a touchscreen

Panel PCs with high IP ratings, such as IP65, IP66 or even

HMI. These devices are increasingly becoming the first

IP67, signify that the devices are protected against dust

choice for controlling automation equipment due to their

ingress and can withstand water jets or even immersion

numerous advantages and increased processing power.

in water. This makes panel PCs highly suitable for environ-

The benefits of using a panel PC as the central industrial

ments where exposure to liquids and particulates is a con-

computer in a factory setting, highlights their robustness,

cern, such as in food processing or chemical manufacturing.

lack of moving parts, wide temperature specifications and improved water and dust resistance.

Panel PCs are renowned for their robust design, which makes them exceptionally suited for the harsh environ-

Additionally, the smooth, sealed surfaces of panel PCs facilitate cleaning. This ease of maintenance is crucial in industries that require frequent sanitization or cleaning to comply with hygiene standards.

ments typical in industrial settings. Their rugged construction often includes reinforced housings and shock-resistant components designed to withstand vibrations, impacts and

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

other mechanical stresses. This durability is crucial for

from the University of South Carolina, was a development

maintaining operational uptime in factories where equip-

engineer in the fiber optics industry and is the former head

ment is subjected to frequent and intense use.

of the EtherCAT Technology group in North America.

42 / October 2024 / ControlDesign.com

Sensing • Control • Motion • Connectivity • Safety • Displays • Design

Get your subscription to Control Design the print magazine for machine builders FREE TO QUALIFIED INDIVIDUALS IN THE UNITED STATES 4 NETWORK S TOPOLOGIE ING: PLC PROGRAMM THEN NOW AND

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l-networking Has industria become so technology that it user-friendly ate and oper ll, insta can ? maintain itself

Written with discrete manufacturing in mind

Who’s

wthaetching henhouse?

Which side are you on?

How integrators share the groove with distributors

Which side are you on?

How distributors share the groove with integrators

J A N U A RY

2023

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HOW DOES ML FEED AI? IS IT INTRINSICALLY SAFE? AGV VS. AMR F E B R U A RY 2 0 2 3

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